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Maintenance Information
Safety advice for maintenance

For personal safety reasons, before conducting maintenance interventions,

check that all safety devices are activated and warn the people present in the

workplace that such intervention is underway.
In particular, disconnect the power supply to the machine.
Make sure that the electricity cannot be accidentally restored.
The operator must allow the machine to cool down before carrying out any

intervention to prevent scalds or burns.

Scheduled maintenance chart

Interval

Component

Type of work

Reference

Every 5000 hours

of work

Every 30000

hours of work

Every 10 years of

work

–

–

–

✓

–

–

Radiator - channel

Cleaning

chapter "Cleaning

the radiator and the

channel" on page 354

–

✓

–

Main pump

Replacement

See

chapter "Replac‐

ing the main pump" on

–

✓

–

Cooling fan

Replacement

See

chapter "Replac‐

ing the electric fan" on

–

✓

–

Coolant

Replacement

See

chapter "Replac‐

ing the coolant" on

–

–

✓

EPDM rubber hoses

Replacement

–

Tab. 8-128:

Scheduled maintenance chart

DOK-INDRV*-HXX05******-PR02-EN-P

Bosch Rexroth AG

353/407

Rexroth IndraDrive ML Drive Systems with HMU05

Cables, accessories, additional components

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Summary of Contents for Rexroth HMU05.1N Series

Page 1: ...Rexroth IndraDrive ML Drive Systems with HMU05 Project Planning Manual R911344279 Edition 02 ...

Page 2: ...roth AG 2016 This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be re produced or given to third parties without its consent Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract ...

Page 3: ...ons 26 Firmware 27 1 2 3 About this documentation 28 Purpose 28 Documentations 28 Drive systems system components 28 Firmware 28 Your feedback 29 2 Important directions for use 31 2 1 Appropriate use 31 2 1 1 Introduction 31 2 1 2 Areas of use and application 31 2 2 Inappropriate use 32 3 Safety instructions for electric drives and controls 33 3 1 Definitions of terms 33 3 2 General information 34...

Page 4: ...ors 48 Third party motor encoder requirements 50 Notes on selection and commissioning 51 4 3 3 Cables 52 Motor power cable 52 Encoder cables 52 4 3 4 Leakage capacitances 53 Allowed leakage capacitances 53 HMU05 systems for medium leakage capacitances 53 HMU05 systems with a single supply unit 53 HMU05 systems with supply units connected in parallel 53 HMU05 systems for high leakage capacitances 5...

Page 5: ...as supply unit 95 Overall connection diagram with load contactor 95 Overall connection diagram with a controllable main switch 96 4 6 3 Project planning of control voltage 98 Control voltage for drive systems 98 Sizing the control voltage supply 98 Determining the power requirements 98 Requirements on the 24V power supply unit 100 Installing the 24V supply 101 4 6 4 Mains connection 102 Residual c...

Page 6: ...trical connection 123 6 2 1 Overall connection diagram HMU05 as drive controller 123 6 2 2 Overall connection diagram HMU05 as supply unit 123 Overall connection diagram with load contactor 123 Overall connection diagram with controllable main switch 123 6 2 3 Connection points 124 Arrangement of HMU05 connection points 124 Connection point of equipment grounding conductor 125 L1 L2 L3 mains motor...

Page 7: ... 002 003 157 Motor monitor grounding HAS10 1 002 004 160 Mounting plate for device width 200 mm HAS10 1 002 005 162 Mounting plate for device width 220 mm HAS10 1 002 006 164 8 3 Additional components 166 8 3 1 HNA05 mains connection module 166 HNA05 type code 166 Dimensions 167 Data 169 Connection points 171 Overview 171 Equipment grounding conductor connection point 172 XD1 mains voltage equipme...

Page 8: ...219 N0218 203 HNL05 1R 0182 N0262 204 HNL05 1R 0045 N0327 205 HNL05 1R 0135 N0327 206 HNL05 1R 0054 N0409 207 HNL05 1R 0117 N0409 208 HNL05 1R 0043 N0514 209 HNL05 1R 0130 N0514 210 HNL05 1R 0050 N0652 211 HNL05 1R 0113 N0652 212 HNL05 1R 0040 N0811 213 HNL05 1R 0100 N0811 214 HNL05 1R 0040 N1019 215 HNL05 1R 0094 N1019 216 Data 217 Water cooling 218 Connection 218 Assignment to HMU05 218 8 3 5 HM...

Page 9: ...imensions 250 HLR05 1W 54K0 N05R4 70K0 N04R0 250 Data 251 Installation 252 8 3 9 HLT05 braking unit 255 HLT05 type code 255 Dimensions 256 Data 259 Connection diagram 260 Connection points 263 Overview 263 XE01 equipment grounding conductor connection point 265 XD02 DC bus 267 XD4 braking resistor 271 XD10 24 V supply control voltage 272 XG1 IndraBus 273 XG3 braking resistor overtemperature signal...

Page 10: ...chnical Information 326 Information Concerning Handling and Installation 339 Information for Use 346 Maintenance Information 353 Breakdown Information 355 Information Concerning Replacements 356 Hydraulic diagrams 362 9 Environmental protection and disposal 365 9 1 Environmental protection 365 9 2 Disposal 365 10 Service and support 367 11 Appendix 369 11 1 Switching supply units on and off 369 11...

Page 11: ...n THD 385 11 8 Liquid cooling 387 11 8 1 Sizing liquid cooling 387 Calculation criteria 387 Physical data 387 Flow rate 387 Pressure decrease 388 Sizing aids 389 11 8 2 Sizing example 394 Index 399 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG IX 407 Rexroth IndraDrive ML Drive Systems with HMU05 Table of Contents ...

Page 12: ...Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P X 407 Rexroth IndraDrive ML Drive Systems with HMU05 ...

Page 13: ... 1 1 Overview Rexroth IndraDrive ML Rexroth IndraDrive ML HMU05 Tab 1 1 HMU05 universal inverter of the Rexroth IndraDrive ML product range DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 11 407 Rexroth IndraDrive ML Drive Systems with HMU05 System presentation ...

Page 14: ...onents Tab 1 2 Supply unit drive controller HMV05 HMV05 is the designation for a supply unit consisting of an HNA05 mains connecting module HMU05 universal inverter and CSB02 5 control section with firmware for supply units FWA INDRV PSB HMV05 is not an official product designation and is used solely for documen tation purposes HMS05 HMS05 is the designation for a drive controller consisting of an...

Page 15: ...ishing winches Anchor handling winches Nautical winches Shiplifts Metallurgy Roller conveyors Transfer lifters Others Paper manufacturing pumps rollers Printing machines winding computation cross cutters rollers General automation pumps cranes testing stations Tab 1 3 Target applications DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 13 407 Rexroth IndraDrive ML Drive Systems with HMU05 System present...

Page 16: ...tection of device IP20 degree of protection of connec tions IP00 CSx02 5 control section Control panel with programming module function Scalable signal processing and firmware Multi encoder interface for all standard encoders DC bus connection Analog input 14 bit 10 V Cooling type Liquid cooling Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 14 407 Rexroth IndraDrive ML Drive Systems with HMU05 System...

Page 17: ... basic pow er 1 A 216 180 260 216 324 260 405 324 509 405 645 509 803 645 1009 803 Basic DC bus power 1 kW 144 120 173 144 216 173 270 216 339 270 430 339 535 430 672 535 DC bus overload capacity 1 PDC_max kW 158 180 190 216 238 260 297 324 373 405 473 509 589 645 739 803 Continuous DC bus power PDC_cont kW 145 174 219 273 342 435 540 679 1 x y x basic load for 540 s 10 overload for 60 s y basic l...

Page 18: ...ms Encoder systems with a supply voltage of 5 and 12 V IndraDyn encoder 1Vpp sin cos encoder HIPERFACE 1Vpp sin cos encoder EnDat 2 1 EnDat 2 2 1Vpp sin cos encoder with reference track 5V TTL square wave encoder with reference track SSI Combined encoder for SSI combination of SSI and 1Vpp sin cos encod er Resolver Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 16 407 Rexroth IndraDrive ML Drive Syste...

Page 19: ...ndancy in the case of mains failure HLL DC bus choke HLR Braking resistor HLT Braking unit HMF Motor filter HML Motor choke HMU Universal inverter HNA Mains connection module HNC Mains capacitor HNF Mains filter HNL Choke M Motor Fig 1 3 Rexroth IndraDrive ML drive system DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 17 407 Rexroth IndraDrive ML Drive Systems with HMU05 System presentation ...

Page 20: ... 0350 140 kW 350 A 0170 0250 170 kW 250 A 0170 0430 170 kW 430 A 0220 0300 220 kW 300 A 0220 0510 220 kW 510 A 0270 0370 270 kW 370 A 0270 0660 270 kW 660 A 0340 0820 340 kW 820 A 0400 0600 400 kW 600 A 0430 1040 430 kW 1040 A 0540 0750 540 kW 750 A 0540 1300 540 kW 1300 A 0680 0980 680 kW 980 A 0680 1690 680 kW 1690 A Degree of protection N IP00 Mains connection voltage Nominal DC bus voltage A4 ...

Page 21: ...mains module connection B only possible if parallel op eration P 3 Parallel module connection B or 1 only possible if parallel op eration P 4 DC bus continuous power maximum current 0140 0210 or 0170 0250 or 0220 0300 or 0270 0370 or 0400 0600 or 0540 0750 or 0680 0980 only with cooling type F and mains connection voltage nominal DC bus voltage A5 11 DC bus continuous power maximum current 0140 03...

Page 22: ... Ethernet Interface 1 EC Multi encoder interface Interface 2 NN Not equipped PB PROFIBUS CN CANopen EC Multi encoder interface EM Encoder emulation EP Engineering port Interface 3 safety technology 1 NN Not equipped L3 STO Safe Torque Off S4 Safe Motion S5 Safe Motion SB Safe Motion Bus Interface 4 NN Not equipped EC Multi encoder interface 2 EM Encoder emulation 3 DA Digital analog I O extension ...

Page 23: ... Tab 1 7 CSB02 5 type code Short type designation 1 2 3 4 5 6 7 8 9 1 0 1 2 3 4 5 6 7 8 9 2 0 1 2 3 4 5 6 7 8 9 3 0 1 2 3 4 5 6 7 8 9 4 0 Example C S H 0 2 5 B C C E C E T N N D A N N F W Product CSH Single axis control section ADVANCED Series 02 02 Design 5 For Hxx05 Interface equipment B Extended scope Communication CC sercos III master ET Multi Ethernet Interface 1 EC Multi encoder interface In...

Page 24: ...ipped EC Multi encoder interface 3 EM Encoder emulation 3 DA Digital analog I O extension Other design NN None Firmware FW Firmware must be ordered as a separate subposition NW Without control panel without firmware 1 Only if communication CC 2 The L3 S4 S5 and SB interfaces guarantee both the function and the certification 3 Only if interface 2 ET PB CN or EC Tab 1 8 CSH02 5 type code Bosch Rexro...

Page 25: ...ion Bus L3 Safe Torque Off S4 Safe Motion S5 Safe Motion SB Safe Motion Bus IndraMotion MLD S3 MLD S3 MLD M3 Freely configurable digital in puts outputs incl probe Analog input Control panel With programming module function With slot for microSD memory card Optional I O extension digital analog 1 One additional interface per converter for communication or encoder evaluation 2 If you use PROFIBUS o...

Page 26: ...an only be operated individually Motor temperature sensor brake control HNA05 mains connection module Communication HPC01 1 MN02 Motor mains module for devices that can be connected in par allel individual and parallel operation possible when running multiple HMU05s in parallel HMU05 with this optional card is master Motor temperature sensor brake control HNA05 mains connection module Communicatio...

Page 27: ... tional cards must be discharged beforehand through grounding Such exposed conductive parts include The human body grounding by touching a conductive grounded object Parts and tools place them on a conductive surface Control sections and optional cards may only be stored or shipped in conduc tive packaging Limited number of insertions and removals Risk of damage from frequent installation and remo...

Page 28: ...section HPC01 1 MN02 HPC01 1 P001 Fig 1 4 HMU05 with control section CSx02 5 and optional card HPC01 2 Carefully remove the control section or optional card from the slot 3 Installation is the reverse of removal Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 26 407 Rexroth IndraDrive ML Drive Systems with HMU05 System presentation ...

Page 29: ... 12 Drive firmware Firmware for supply units Assigned device type FWA INDRV PSB 20VRS D5 x NNN NN or higher CSB02 5 control section BASIC Tab 1 13 Supply unit firmware For detailed information see the Functional Description of the firmware used index entry Overview of functions functional packages DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 27 407 Rexroth IndraDrive ML Drive Systems with HMU05 Syst...

Page 30: ...er de en ML Drive Systems with HMU05 Project Planning Manual HXX05 PRxx EN P R911344278 R911344279 Control Sections CBS02 CSE02 CSH02 CDB02 Project Planning Manual CXX02 PRxx EN P R911338961 R911338962 1 In the document typecodes xx is a placeholder for the current edition of the documentation e g PR01 is the first edition of a Project Planning Manual Tab 1 14 Documentations drive systems system c...

Page 31: ...R911338915 R911338916 Rexroth IndraMotion MLD as of MPx 18 Application Manual MLD3 VRS APxx EN P R911338913 R911338914 1 In the document typecodes xx is a placeholder for the current edition of the documentation e g RE02 is the second edition of a Reference Book Tab 1 15 Documentations firmware Your feedback Your experience is important for our improvement processes of products and documentations ...

Page 32: ...Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 30 407 Rexroth IndraDrive ML Drive Systems with HMU05 ...

Page 33: ... modifications Do not decompile software products or alter their source codes Do not install damaged or faulty products or put them into operation Make sure that the products have been installed in the manner descri bed in the relevant documentation 2 1 2 Areas of use and application Drive controllers made by Rexroth are designed to control electric motors and monitor their operation Controlling a...

Page 34: ...A are products of Category C3 with restricted distribution in accordance with IEC 61800 3 The Category C3 comprises EMC limit values for line based and radiated noise emission Components of the Rexroth IndraDrive ML system with a mains input current 400 A are products of Category C4 with restricted distribution in accordance with IEC 61800 3 The Category C4 comprises an EMC plan developed by manuf...

Page 35: ...earing responsibility for the design and manufacture of a product which is placed on the market in the in dividual s or legal entity s name The manufacturer can use finished products finished parts or finished elements or contract out work to subcontractors However the manufacturer must always have overall control and possess the required authority to take responsibility for the product Component ...

Page 36: ...age injury electric shock or even death 3 2 2 Requirements for safe use Read the following instructions before initial commissioning of the compo nents of the electric drive and control system in order to eliminate the risk of injury and or property damage You must follow these safety instructions Rexroth is not liable for damages resulting from failure to observe the safety instructions Read the ...

Page 37: ...the respective application docu mentation The machine or installation manufacturer is responsible for compliance with the limit values as prescribed in the national regulations The technical data connection and installation conditions of the compo nents are specified in the respective application documentations and must be followed at all times National regulations which the user has to comply wit...

Page 38: ...rushing shearing cutting hitting Risk of injury by improper handling of batteries Risk of injury by improper handling of pressurized lines Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 36 407 Rexroth IndraDrive ML Drive Systems with HMU05 Safety instructions for electric drives and controls ...

Page 39: ... disconnect electric components from the mains or from the power supply unit Secure the electric component from reconnec tion With electric components observe the following aspects Always wait 30 minutes after switching off power to allow live capacitors to discharge before accessing an electric component Measure the elec trical voltage of live parts before beginning to work to make sure that the ...

Page 40: ... mm2 X 0 5 mm2 applies to X 50 Tab 3 1 Minimum cross section of the equipment grounding connection 3 3 2 Protective extra low voltage as protection against electric shock Protective extra low voltage is used to allow connecting devices with basic in sulation to extra low voltage circuits On components of an electric drive and control system provided by Rexroth all connections and terminals with vo...

Page 41: ... and control system are installed As a result of the risk assessment the user must provide for monitoring func tions and higher level measures on the installation side for personal safety The safety regulations applicable to the installation or machine must be taken into consideration Unintended machine movements or other malfunctions are possible if safety devices are disabled bypassed or not act...

Page 42: ...tion against electromagnetic and magnetic fields during opera tion and mounting Electromagnetic and magnetic fields Health hazard for persons with active implantable medical devices AIMD such as pacemakers or passive metallic implants Hazards for the above mentioned groups of persons by electromagnetic and magnetic fields in the immediate vicinity of drive controllers and the associated current ca...

Page 43: ...ons of accident prevention Use suitable equipment for mounting and transport Avoid jamming and crushing by appropriate measures Always use suitable tools Use special tools if specified Use lifting equipment and tools in the correct manner Use suitable protective equipment hard hat safety goggles safety shoes safety gloves for example Do not stand under hanging loads Immediately clean up any spille...

Page 44: ...ective equipment safety goggles safety shoes safety gloves for example Immediately clean up any spilled liquids from the floor due to the risk of falling Environmental protection and disposal The agents e g fluids used to operate the product might not be environmentally friendly Dispose of agents harmful to the environment separately from other waste Observe the national regulations of your countr...

Page 45: ...on compliance with this safety instruction minor or moderate in jury could occur NOTICE In case of non compliance with this safety instruction property damage could occur DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 43 407 Rexroth IndraDrive ML Drive Systems with HMU05 Safety instructions for electric drives and controls ...

Page 46: ...Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 44 407 Rexroth IndraDrive ML Drive Systems with HMU05 ...

Page 47: ...MU05 components belong to the Rexroth IndraDrive ML product range and are used as Drive controller HMU05 firmware for drive controllers DC bus voltage 450 800 V DC nominal 750 V DC Supply unit HMU05 HNA05 firmware for supply units Mains connection voltage 3 AC 380 500 V DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 45 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual compone...

Page 48: ...NA Mains connection module HNC Mains capacitor HNF Mains filter HNL Mains choke HPC Plug in module for power section K1 External mains contactor M Motor Fig 4 1 Design of a drive system Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 46 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 49: ...motor Which directives are important In accordance with the legal regulations EU Directive EMC 89 336 EEC and the German EMC laws installations and machines must be designed and built in accordance with the present state of the art of standardization In order to comply with the machine directives regarding electromagnetic compatibility EMC a conformity test must be carried out on the drive sys tem...

Page 50: ... con troller or which position measuring system can be selected for kit motors Third party motor voltage load The voltage load of the insulation system of a motor that occurs in practice is mainly influenced by the following characteristics The output variables of the drive controller used feed the transmission distance Cable parameters depending on cable design and length determine the properties...

Page 51: ...ed di rectly between two motor terminals with an inductance measuring bridge The measurement has to be made for a complete motor wired for normal opera tion but not yet connected One motor terminal remains open For asynchro nous motors the measured value can only be used if the rotor does not have any closed slots Drive controller Minimum required motor inductance mH HMU05 with 3 400 V AC LU V 80 ...

Page 52: ... and protected from being damaged from excess temperature in crease see P 0 0512 Temperature sensor If you want to operate third party motors without a temperature sensor on Rexroth IndraDrive ML drive controllers in exceptional instances you have to determine the thermal time constants of the motor housing P 0 4035 and motor winding P 0 4034 P 0 4037 The firmware can correctly reflect the cooling...

Page 53: ...io Current consumption DC resistance of stator Number of poles Phase shift Using the resolver data check if the supply voltage of the encoder interface and the signal levels of the encoder tracks are sufficient Notes on selection and commissioning Selecting the drive controller in regard to continuous current The drive controller required for the each motor is determined by comparing the motor dat...

Page 54: ...se HMU HNL HNC HNL HNF When connecting multiple HMUs in parallel the allowed leakage capaci tance drops to 450 nF per phase Reason balancing HNF mains filter The overall leakage capacitance for n parallel HMUs is therefore n x 450 nF Encoder cables Encoder Allowed cable length Encoder evaluation in CSx02 control sec tion 75 m Tab 4 4 Cable length Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 52 407 R...

Page 55: ...ems with a single supply unit At a single HMU05 supply unit it is possible to connect cables and motors with a total leakage capacitance of 500 nF The number and operation mode individual or parallel operation of the HMU05 inverters are irrelevant HMU05 systems with supply units connected in parallel For supply units connected in parallel the maximum allowed leakage capaci tance increases by 500 n...

Page 56: ...ci tance Consequently 2 Y capacitor pairs are connected at the DC bus of each inverter Mounting the Y capacitor pairs Mount them as near as possible to the DC bus bars of the inverters Mount the housing directly to the grounded back panel of the control cabinet Make sure the connection is highly conductive Use the shortest possible cables cross section 25 mm2 to connect Y capacitor pairs to L and ...

Page 57: ...s choke and 4 Y capacitor pairs A derating factor of 0 95 applies to the allowed total leakage capacitance The number and operation mode individual or parallel operation of the HMU05 inverters are irrelevant Fig 4 5 HMU05 systems with supply units connected in parallel DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 55 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual componen...

Page 58: ...l DC bus choke HMU05 systems with a central DC bus choke Concerning the tapered cross sections of the DC bus bars please observe the information on DC bus fuses See chapter 11 3 DC bus fuses on page 380 With the drive firmware you can configure an inverter as a module bus mas ter Integrate the relay contact of the module bus master configured as a Bb contact in the power supply control circuit in ...

Page 59: ...bus capacitor unit Dimension the minimum size of the DC bus capacitor unit in accordance with the planned continuous power of the respective drive system 47 μF per kilowatt kW of continuous power Mount Y capacitor pairs close to the HMS HMD drive controllers In the case of multiple drive lines the Y capacitor pairs are distributed propor tionately in accordance with the sum of leakage capacitances...

Page 60: ... HMU05 systems without a central DC bus choke and without an HMU05 inverter Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 58 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 61: ... capacitances HLC DC bus capacitor units have to be installed in the HMS HMD drive lines Dimension the minimum size of the HLC DC bus capacitor unit in accordance with the planned continuous power of the respective drive system 47 μF per kilowatt kW of continuous power Fig 4 8 HMU05 systems with a central DC bus choke DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 59 407 Rexroth IndraDrive ML Drive Sy...

Page 62: ...ons have actually been observed The power dissipation is indicated in the technical data of the individual compo nents as an important input value for calculating the heat levels Ambient and operating conditions Description Symbol Unit Value Conductive dirt contamination Not allowed You can protect the devices against conductive dirt contamination e g by mounting them in control cab inets with a d...

Page 63: ... to hmax an isolating transformer has to be installed at the drive system mains con nection Use above hmax is not allowed hmax_ohne m 2000 hmax m 4000 Simultaneous derating for ambient tempera ture and installation altitude Allowed reduce with factors f and fTa Relative humidity 5 95 Absolute humidity g m3 1 29 Moisture condensation Not allowed Climatic category IEC 60731 3 3 3K3 Allowed pollution...

Page 64: ... fan Requirements for control cabinets with fan Risk of damage by unclean air in the control cabinet NOTICE Operating a control cabinet with a fan but without the corresponding filters can damage the devices or cause malfunction Install filters at the air intake opening of the control cabinet so that un clean air cannot get into the control cabinet Service the filters at regular intervals accordin...

Page 65: ... of cooling devices for liquid cooling Air liquid cooling unit Liquid liquid cooling unit Refrigerating unit Power dissipation in control cabi net Liquid cooled drive components dissipate power in the control cabinet in the form of heat It may be necessary to include the control cabinet in the liquid cooled circuit Cooling devices The cooling device dissipates the sum of all heat output discharged...

Page 66: ...iquid cooling unit Liquid liquid cooling unit Refrigerating unit Temperature control precision of coolant Low 5 K Low 5 K Good 1 K Higher level coolant circuit required No Yes No Ambient air of machine heated up Yes No Yes Recovery of power dissipation possible No Yes No Spatial volume of cooing unit Minor Small Big Depending on ambient temperature Yes No No Tab 4 8 Comparison of cooling devices B...

Page 67: ...in temperature is kept constant the temperature increase from electrical components therefore does not have any effect on the precision of the system Tab 4 9 Uses of cooling devices Cost comparison 1 Air liquid cooling unit 2 Liquid liquid cooling unit 3 Refrigerating unit Fig 4 10 Approximate cost comparison of the cooling devices Cooling device components Overview A liquid cooling system consist...

Page 68: ... required coolant volume Fig 4 12 Required volume of coolant reservoir VCs Coolant volume of cooling system circulating coolant VHe Coolant volume in heat exchanger VFtg Coolant volume in fittings of cooling system VDc Coolant volume in drive components VL Coolant volume in coolant lines Fig 4 13 Coolant circulating in cooling system Coolant pump General information The coolant pump of a cooling d...

Page 69: ... in the working point must be greater than or equal to the flow rate required for the cooling system A Characteristic of coolant pump B Characteristic of cooling system ΔH Delivery height P Working point of coolant pump Q Delivery rate Fig 4 14 Working point of a coolant pump Delivery rate Parallel connection Fig 4 15 Parallel connection of components The delivery rate of the coolant pump QP must ...

Page 70: ...h component referring to a fixed temperature in crease of the coolant water When using different coolants or a different tem perature increase calculate the flow rate accordingly Delivery pressure Required delivery pressure of coolant pump The coolant pump must overcome all pressure decreases on the flow path of the coolant The flow path passes through Heat exchanger Valves and fittings Main distr...

Page 71: ...e ΔpHe Drive components pressure de crease The resulting pressure decrease ΔpDc generally differs from the indicated Δpn because the flow rate is mostly greater than Qmin Calculating pressure decrease See chapter Appendix Liquid cooling Calculation criteria The diagram below shows the relation of pressure decrease and flow rate Δp Pressure decrease Q Flow rate Fig 4 22 Flow diagram Components that...

Page 72: ...ing unit and control cabinet air cooler Data for selection Determining specific cooling capacity PV Power dissipation being discharged in kW P01 Specific cooling capacity in kW K Tamb Ambient temperature in C Tin Inlet temperature of coolant in heat exchanger in C Fig 4 24 Determining specific cooling capacity For economic reasons 50 C should be selected as the maximum outlet tem perature of the d...

Page 73: ...27 Liquid liquid heat exchanger In the liquid liquid heat exchanger two liquids are hydraulically separated and brought to the best possible thermal contact The power dissipation ab sorbed by the coolant is thereby dissipated to the higher level cooling circuit utilities These cooling units are suited for the coolants specified in this documenta tion Depending on the type of material you can use f...

Page 74: ...wer dissipation in kW c1 Specific thermal capacity of coolant in kJ kgK Q1 Flow rate of coolant in l min Fig 4 29 Cooling warmer medium coolant Temperature increase of colder medium utilities ΔT2 Temperature increase of utilities in K ρ2 Density of utilities in kg l PV Power dissipation in kW c2 Specific thermal capacity of utilities in kJ kgK Q2 Flow rate of utilities in l min Fig 4 30 Temperatur...

Page 75: ...s are characterized by their refrigerating capacity For units with an air cooled liquefier the refrigerating capacity depends on the ambient temperature The refrigerating capacity in kW of a refrigerating unit must always be greater than or equal to the total power dissipation to be discharged Determining refrigerating capacity Data for selection PC Refrigerating capacity of refrigerating unit PV ...

Page 76: ...me pressure difference pressure decrease Aspects of application The individual components being cooled Can be cooled with the individually required flow rate high degree of thermal operational safety Have the same temperature level at the coolant inlet steady machine temperature increase All have the same pressure difference between coolant inlet and outlet high degree of hydraulic operational saf...

Page 77: ...ild condensation NOTICE In temperate zones up to 40 C and 70 humidity the inlet temperature of the coolant may be at a maximum 5 K below the temperature in the control cabinet Safest protection against condensation Coolant inlet temperature ambient temperature The temperature of the coolant flowing through liquid cooled drive compo nents generally differs from the temperature of the ambient air De...

Page 78: ...fig ure A Characteristic of water vapor saturation B Maximum temperature of ambient air C Condensation temperature G1 G2 Artificial lines rH Relative humidity T Ambient temperature a Maximum ambient temperature e g 40 C b b1 Intersection point of ambient air temperature and characteristic of water vapor saturation This intersection point characterizes the 100 humidity value b1 c Convert 100 humidi...

Page 79: ...reeze Coolant with antifreeze may only be used for transport and storage of the components see chapter Transport and storage Protection against corrosion For protection against corrosion and chemical stabilization an appropri ate additive must be mixed with the cooling water The required mixing ratio according to manufacturer s data sheet must be complied with and checked Deviations can cause Redu...

Page 80: ...ooling media additives or operating conditions Testing the performance of the coolants used and sizing the liquid coolant system are generally the responsibility of the machine manufacturer Water based coolant Water Antifrogen in a 4 1 ratio e g Rifrost from Rittal Non water based coolant Non water based coolants e g oil are not permitted Sizing liquid cooling The corresponding information for siz...

Page 81: ...only For use on a solidly grounded wye source only Tab 4 11 HMU ambient and operating conditions UL ratings Ambient and operating conditions UL ratings Description Symbol Unit HMU05 1N F0340 0820 N A4 D7 P HMU05 1N F0430 1040 N A4 D7 P HMU05 1N F0540 1300 N A4 D7 P HMU05 1N F0680 1690 N A4 D7 P Planned Short circuit current rating SCCR A rms 85000 Rated input voltage power1 ULN_nenn V DC 450 750 R...

Page 82: ... and operating conditions UL ratings Ambient and operating conditions UL ratings Description Symbol Unit HMU05 1N F0340 0820 N A4 D7 P HMU05 1N F0430 1040 N A4 D7 P HMU05 1N F0540 1300 N A4 D7 P HMU05 1N F0680 1690 N A4 D7 P Planned Short circuit current rating SCCR A rms 85000 Rated input voltage power1 ULN_nenn V 3 x AC 380 500 Mains frequency fLN Hz 50 60 Nominal current ILN A 514 00 652 00 811...

Page 83: ...ne tools which may interact with the controls and drives it cannot be completely ruled out that any reactions with the materials we use might occur For this reason before using the respective material a compatibility test has to be carried out for new lubricants cleaning agents etc and our housings materials DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 81 407 Rexroth IndraDrive ML Drive Systems with...

Page 84: ...imensions HMU05 1N F0140 0350 A Minimum mounting clearance B Boring dimensions Fig 4 35 HMU05 1N F0140 0350 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 82 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 85: ... 0430 A Minimum mounting clearance B Boring dimensions Fig 4 36 HMU05 1N F0170 0430 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 83 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 86: ... 0510 A Minimum mounting clearance B Boring dimensions Fig 4 37 HMU05 1N F0220 0510 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 84 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 87: ... 0660 A Minimum mounting clearance B Boring dimensions Fig 4 38 HMU05 1N F0270 0660 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 85 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 88: ... 0820 A Minimum mounting clearance B Boring dimensions Fig 4 39 HMU05 1N F0340 0820 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 86 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 89: ... 1040 A Minimum mounting clearance B Boring dimensions Fig 4 40 HMU05 1N F0430 1040 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 87 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 90: ... 1300 A Minimum mounting clearance B Boring dimensions Fig 4 41 HMU05 1N F0540 1300 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 88 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 91: ...ss dimensions sound pressure level insulation Data for mass dimensions sound pressure level insulation Description Symbol Unit HMU05 1N F0340 0820 N A4 D7 P HMU05 1N F0430 1040 N A4 D7 P HMU05 1N F0540 1300 N A4 D7 P HMU05 1N F0680 1690 N A4 D7 P Planned Mass m kg 70 00 83 00 103 00 tbd Device height1 H mm 1103 1311 1522 tbd Device depth2 T mm 440 tbd Device width3 B mm 200 220 tbd Insulation resi...

Page 92: ...3500 0 4500 0 Coolant inlet temperature Tin C Less than 60 Required minimum coolant flow for PDiss_cont_F Qmin l min 4 5 7 9 Temperature increase for Qmin and PDiss_cont_F ΔT K Less than 10 Pressure drop for Q min Δp bar 0 4 0 5 Maximum allowed operating pres sure pmax bar 2 00 Coolant channel volume Vch ml 609 667 724 Coolant channel material Aluminum Constant for determining pressure drop KΔp tb...

Page 93: ...let at device Tab 4 17 HMU cooling and power dissipation data Cooling and power dissipation data Description Symbol Unit HMU05 1N F0340 0820 N A4 D7 P HMU05 1N F0430 1040 N A4 D7 P HMU05 1N F0540 1300 N A4 D7 P HMU05 1N F0680 1690 N A4 D7 P Planned Allowed mounting position G1 Allowed switching frequencies1 fs kHz 2 4 8 Power dissipation at Iout_cont 0 A fs fs min 2 PDiss_0A_fs min W 350 400 450 5...

Page 94: ...a_work_red C 0 55 fTa K 2 0 Volumetric capacity of forced cool ing V m3 h Minimum distance on the top of the device5 dtop mm 100 Minimum distance on the bottom of the device6 dbot mm 100 Temperature increase with mini mum distances dbot dtop PBD ΔT K 10 Last modification 2016 06 17 1 Also depending on firmware and control section see parame ter description P 0 0001 Switching frequency of the power...

Page 95: ...te the components in their allowed mounting positions For supply units and drive controllers installed in control cabinets only the mounting position G1 is allowed Mounting position G1 The air that is heated inside the component can flow out of the component in a vertical upward direction The natural convection supports the forced cooling air current This avoids the generation of pockets of heat i...

Page 96: ...Overall connection diagram HMU05 as drive controller Fig 4 43 Connection diagram HMU05 as drive controller Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 94 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 97: ... pictured here instead of the connection with a control lable main switch 1 With multiple contactors connected in parallel connect the N O contacts and N C contacts in series Fig 4 44 Connection diagram with load contactor HMU05 as supply unit DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 95 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 98: ...ontrollable main switch Transient oscillation processes between HNC and mains induc tance can occur when the main switch is turned on Therefore select an appropriate main switch Observe the local regulations regarding EMC and standards Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 96 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 99: ...ct the N O contacts and N C contacts in series Fig 4 45 Connection diagram with controllable main switch HMU05 as supply unit DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 97 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 100: ...wer require ments The total power requirements of the control voltage supply of a drive control ler result from the sum of the following power values Basic device drive controller without connected encoders Optional connection interfaces e g communication additional encoder evaluation Connected encoder systems External loads See the type plate and type code for configuring your drive controller Th...

Page 101: ... with power Table 3 Power requirements of the external loads External load Power requirement 5 V encoder system P IEncoder 5 V 1 75 1 5 12 V encoder system P IEncoder x 12 V x 1 25 1 5 Load at digital output P ILoad x UN3 2 4 Motor holding brake P IBrake x UN3 3 4 1 Iencoder Current consumption of encoder system 2 Iload Current consumption of external load 3 Ibrake Current consumption of motor hol...

Page 102: ...e the continuous current IN3 of all components IN3 PN3 UN3 PN3 power consumption of all components The calculated current IN3 corresponds to the continuous current of the 24 V power supply unit The power consumption is indicated as the maximum value of each compo nent and can occur in individual components In drive systems with several components the occurring power consumption under statistical a...

Page 103: ...th a total cur rent consumption of 40 A in accordance with UL 31 A B Number of devices is limited to y components with a total cur rent consumption of 40 A in accordance with UL 31 A C Third party component e g PLC valve etc 1 Connection to central ground point e g PE earth circuit con nector Fig 4 46 Installing the 24 V supply If you use several 24 V power supply units Output voltages of the 24 V...

Page 104: ...onnection Residual current operated circuit breakers RCD RCCB as additional fusing General information The following designations are used for residual current operated circuit breakers RCCB Residual Current Operated Circuit Breaker RCD Residual Current Operated Device RCM Residual Current Monitoring Device Earth leakage circuit breaker voltage independent Residual current circuit breaker voltage ...

Page 105: ...sures that are taken If measures are taken to improve the electromagnetic compatibility EMC of the installation mains filters shielded lines the leakage current in the ground wire is inevitably increased especially when switching on or in the case of mains unbalance Given these operating conditions residual current operated circuit breakers can trigger without an error having occurred The EMC meas...

Page 106: ... the mains input side connect an isolating transformer between mains connection and power connection of the drive system This reduces the leak age current in the ground wire of the mains that is produced during normal operation which allows the residual current operated circuit breaker to be used Connect the neutral point of the secondary winding of the isolating transformer to the equipment groun...

Page 107: ... TN C mains type T Direct grounding of a point station ground N Exposed conductive parts directly connected to station ground C Neutral conductor and equipment grounding conductor func tions in entire mains combined in a single conductor the PEN conductor Fig 4 50 TN C mains type DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 105 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individ...

Page 108: ...rease in the case of ground fault In case of a ground fault in the IT mains type higher voltages against ground device housing affect the device as opposed to error free operation The ground fault in the IT mains type is only possible temporari ly with the IndraDrive components For operation on the IT mains type the drive system including mains filter and mains choke should be electrically separat...

Page 109: ...elta mains I Isolation of all active parts from ground connection of one phase generally phase V to ground or via an impedance RE T Exposed conductive parts directly grounded independent of grounding of current source station ground Fig 4 53 Mains with grounded outer conductor Notes on project planning The EMC requirements are only observed through specific measures incl special mains filters DOK ...

Page 110: ... connected to the mains and in parallel to a larger HMV05 Each HMU05 has its own mains choke and mains filter Grayed out components optional depending on the applica tion A HMU05 component all components A identical connected to supply mains with mains chokes connected to other compo nents through DC bus B HMU05 component as HMS05 inverter connected to other components through DC bus K1 on off Mai...

Page 111: ...wiring Connect the auxiliary contacts of the mains contactors in series The auxiliary contacts are evaluated by HNA05 Switch on process N O contacts are monitored Switch off process N C contacts are monitored DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 109 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 112: ...lating the mains side phase current The mains side phase current is required for the following cases Selecting mains contactor Determining fuses in the mains connection Determining line cross section Selecting other components in the mains connection mains filter mains choke Operation under rated conditions For data on mains contactor fuses and cross section in operation under rat ed conditions se...

Page 113: ...es of mains V 7 Select mains contactor 8 Determine mains circuit breaker and line cross section See chapter 11 2 Dimensioning the line cross sections and fuses on page 371 Dimensioning the line cross sections and fuses See chapter 11 2 Dimensioning the line cross sections and fuses on page 371 Dimensioning and selecting the mains transformer Mains transformers are always needed when the mains volt...

Page 114: ...0N Mains filter HNL05 1R Preconnected choke HNC05 1N Mains capacitor HNL05 1R Mains choke HMU05 1N Universal inverter Fig 4 56 Mains connection components Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 112 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 115: ... 0135 N0327 0117 N0409 0130 N0514 0113 N0652 0100 N0811 0094 N1019 Preconnected choke HNL05 1R 0045 N0327 0054 N0409 0043 N0514 0050 N0652 0040 N0811 0040 N1019 Mains capacitor HNC05 1N 0050 0075 0100 Mains filter HNF05 1A 500N R0250 500N R0320 500N R0400 500N R0600 500N R1000 500N R1600 Tab 4 22 Mains connection components DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 113 407 Rexroth IndraDrive ML D...

Page 116: ...h as supply units and drive controllers Operation as supply unit uses HNL05 mains chokes to balance parallel oper ation Fig 4 57 Parallel operation of HMU05 to run as supply unit Operation as drive controller uses additional HML05 motor chokes Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 114 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 117: ...hrough the HPC01 1 P001 optional cards ring topology Connection cables to the HPC01 1 P001 op tional cards always have to be run inside the control cabinet Comply with maximum allowed line lengths The power outputs have to be wired symmetrically to ensure the output cur rent of the HMU05s are symmetrically distributed and no HMU05s are over loaded To do this the power outputs are connected to a co...

Page 118: ...vice Lines may not be routed outside the control cabinet Derating 5 Since the output current is not exactly distributed equally even with a sym metrical design the output current is derated Therefore it is impossible to use 100 of the calculated total power Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 116 407 Rexroth IndraDrive ML Drive Systems with HMU05 Combining the individual components ...

Page 119: ... UL File Number enter the file number or under Company Name en ter the company name Bosch Rexroth AG UL standard 61800 5 1 CSA standard Canadian Standard CSA C22 2 No 274 13 Company Name BOSCH REXROTH ELECTRIC DRIVES CON TROLS GMBH Category Name Power Conversion Equipment File numbers Rexroth IndraDrive ML components HMU05 HNA05 HNC05 HNF05 HNL05 HML05 HLL05 HPC01 E134201 Tab 4 24 C UL listing UL ...

Page 120: ...d in China the certification will be checked at customs using the entries in a database Three criteria are typically critical for certifica tion being required 1 Customs tariff number HS code according to CNCA document Appli cation Scope for Compulsory Certification of Products acc first Cata logue 2 Area of application according to CNCA document Application Scope for Compulsory Certification of P...

Page 121: ... standards 5 1 2 Customer testing Risk of damage to the installed Rexroth com ponents by customer side testing of the ma chine or installation NOTICE Before conducting voltage testing or insulation resistance testing for an instal lation or machine in which these components are used Disconnect all connections to the Rexroth components or disconnect the plug in connections to protect the electronic...

Page 122: ...N Documentation Tab 5 2 Contents of delivery HMU05 5 3 Transporting components Ambient and operating conditions for transport Description Symbol Unit Value Temperature range Ta_tran C 25 to 70 Relative humidity 5 to 95 Absolute humidity g m3 1 to 60 Climatic category IEC721 2K3 Condensation Not permitted Icing Not permitted Tab 5 3 Ambient and operating conditions for transport Bosch Rexroth AG DO...

Page 123: ...bus voltage VDC Risk of damage to liquid cooled components from frost NOTICE Before storing fully drain coolant channels or use antifreeze Ambient and operating conditions for storage Description Symbol Unit Value Temperature range Ta_store C 25 to 55 Relative humidity 5 to 95 Absolute humidity g m3 1 to 29 Climatic category IEC721 1K3 Condensation Not permitted Icing Not permitted Tab 5 4 Ambient...

Page 124: ...Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 122 407 Rexroth IndraDrive ML Drive Systems with HMU05 ...

Page 125: ... device width 200 mm HAS10 1 002 005 on page 162 Mounting plate for device width 220 mm HAS10 1 002 006 See chapter Mounting plate for device width 220 mm HAS10 1 002 006 on page 164 6 2 Electrical connection 6 2 1 Overall connection diagram HMU05 as drive controller See chapter 4 6 1 Overall connection diagram HMU05 as drive controller on page 94 6 2 2 Overall connection diagram HMU05 as supply u...

Page 126: ...HPC01 Optional card L1 L2 L3 Mains motor connection L L DC Bus PE Equipment grounding conductor XG1 IndraBus XD10 Control voltage WATER IN OUT Cooling liquid Fig 6 1 HMU05 connection points Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 124 407 Rexroth IndraDrive ML Drive Systems with HMU05 Mounting and installation ...

Page 127: ...ely operate the device with plugged on connectors even if there haven t been any lines con nected to the connectors and with connected equipment grounding conductor Equipment grounding conductor material and cross section Use the same metal e g copper for the equipment grounding conductor as for the outer conductors Make sure the lines for the connections from the device s equip ment grounding con...

Page 128: ... mm2 4 AWG 35 mm2 2 AWG 50 mm2 1 0 AWG 25 mm2 4 AWG 70 mm2 2 0 AWG 35 mm2 2 AWG X mm2 X 0 5 mm2 valid for X 50 Tab 6 2 Minimum cross section of equipment grounding connection L1 L2 L3 mains motor connection Important notes Lethal electric shock by live parts with more than 50 V WARNING Exclusively operate the device with plugged on connectors even if there haven t been any lines con nected to the ...

Page 129: ... or an external motor holding brake controlled directly by the drive controller are not sufficient on their own to guarantee personal safety Personal safety must be achieved using higher level fail safe measures Block off danger zones with safety fences or safety guards Additionally secure vertical axes against falling or dropping after switch ing off the motor power by for example mechanically se...

Page 130: ...4VBr Output for controlling motor hold ing brake 3 0VBr 4 MotTemp Motor temperature evaluation in put 5 MotTemp 6 MotLue Motor fan output 0 10 V 7 MotLue0V Reference to motor fan output 0 V 8 0VEA 0 V supply voltage Spring terminal connector Unit Min Max Connection cable Stranded wire mm2 0 25 1 5 AWG 24 16 Stripped length mm 10 Current carrying capacity XG3 output motor holding brake A 2 Number o...

Page 131: ...orting DC bus availability Cable Unshielded length 3 m Cable designation RKB0036 Shielded length 100 m Cable designation RKB0035 In individual operation that is to say not in combination with other devices of the Hxx05 1 series both IndraBus RBS0025 terminating plugs must have been plugged in Tab 6 6 XG1 IndraBus XD10 24 V supply control voltage Function pin assignment The 24 V supply is applied e...

Page 132: ...rough You may have to connect an other device directly to the 24 V supply and then loop through the control volt age from this device to other devices L L DC bus connection Lethal electric shock from live parts with more than 50 V WARNING Before working on live parts De energize system and secure power switch against unintentional or unauthorized reconnection Make sure voltage has fallen below 50 ...

Page 133: ...aximum current load occurring on the DC bus and the installation method for the connections Risk of damage by reversing the polarity of the DC bus connections L and L NOTICE Make sure the polarity is correct Shield connection Control line shield connection Shield connection for control lines of the control section motor etc whose connectors do not have a shield connection Always connect the shield...

Page 134: ...The motor power cable shield is connected at a separate location in the con trol cabinet and not directly at HMU05 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 132 407 Rexroth IndraDrive ML Drive Systems with HMU05 Mounting and installation ...

Page 135: ... bare metal back panel of the drive controller in conductive form to the mounting surface in the control cabinet To do this use the supplied mounting screws 2 Connect the mounting surface of the control cabinet in conductive form to the equipment grounding system 3 For the ground connection observe the maximum allowed ground re sistance DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 133 407 Rexroth In...

Page 136: ... page 129 HPC01 1 P001 NN Fig 6 4 HPC01 1 P001 NN Cable RKB0038 cable for connecting multiple HPC01 1 P001 NN It is not allowed to run the lines outside the control cabinet Maximum allowed length 1 m between two neighboring devices 8 m between the last and first device Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 134 407 Rexroth IndraDrive ML Drive Systems with HMU05 Mounting and installation ...

Page 137: ...ve components cannot build condensation NOTICE In temperate zones up to 40 C and 70 humidity the inlet temperature of the coolant may be at a maximum 5 K below the temperature in the control cabinet Safest protection against condensation Coolant inlet temperature ambient temperature Condensation protection Refer to the information on condensation protection DOK INDRV HXX05 PR02 EN P Bosch Rexroth ...

Page 138: ...Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 136 407 Rexroth IndraDrive ML Drive Systems with HMU05 ...

Page 139: ...s than 0 01 Rated power consumption control voltage input at UN3 4 PN3 W 65 48 53 46 Last modification 2015 12 03 1 2 3 Observe supply voltage for motor holding brakes 4 See information on Rated power consumption control voltage input at UN3 Tab 7 1 HMU control voltage supply data Rated power consumption control voltage input at UN3 Plus motor holding brake and control section plus safety option C...

Page 140: ... control voltage input at UN3 Tab 7 2 HMU control voltage supply data Rated power consumption control voltage input at UN3 Plus motor holding brake and control section plus safety option Overvoltage Overvoltage greater than 33 V has to be discharged by means of the appropriate electrical equipment of the machine or installation This includes 24V power supply units that reduce incoming overvoltage ...

Page 141: ...f mains choke HNL05 1R 02 19 N0218 HNL05 1R 01 82 N0262 HNL05 1R 01 35 N0327 HNL05 1R 01 17 N0409 Assigned type of mains filter HNF05 1A 50 0N R0250 HNF05 1A 50 0N R0320 HNF05 1A 50 0N R0400 HNF05 1A 50 0N R0600 Nominal current ILN A 218 00 262 00 327 00 409 00 Required wire size in accordance with NFPA 79 and UL 508 A in ternal wiring 4 ALN AWG Project Planning Manual appendix Power factor TPF λL...

Page 142: ...ype of mains choke HNL05 1R 01 30N0514 HNL05 1R 01 13 N0652 HNL05 1R 01 00N0811 HNL05 1R 00 94 N1019 Assigned type of mains filter HNF05 1A 50 0N R0600 HNF05 1A 500N R1000 HNF05 1A 50 0N R1600 Nominal current ILN A 514 00 652 00 811 00 1019 00 Required wire size in accordance with NFPA 79 and UL 508 A in ternal wiring 4 ALN AWG Project Planning Manual appendix Power factor TPF λL at PDC_cont with ...

Page 143: ...nal DC bus capaci tance nom at ULN_nenn 1 CDCext mF 2500 00 Rated power t 10 min at fs 4 kHz ULN_nenn control factor a0 0 8 with mains choke PDC_cont kW 140 00 170 00 220 00 270 00 Maximum allowed DC bus power at ULN_nenn with mains choke PDC_max kW 180 00 216 00 260 00 324 00 Last modification 2016 06 16 1 Use assigned mains choke Tab 7 5 HMU power section data DC bus Power section data DC bus De...

Page 144: ...om at ULN_nenn 1 CDCext mF 2500 00 Rated power t 10 min at fs 4 kHz ULN_nenn control factor a0 0 8 with mains choke PDC_cont kW 340 00 430 00 540 00 tbd Maximum allowed DC bus power at ULN_nenn with mains choke PDC_max kW 405 00 509 00 645 00 tbd Last modification 2015 12 03 1 Use assigned mains choke Tab 7 6 HMU power section data DC bus Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 142 407 Rexroth ...

Page 145: ...fout_8k Hz 0 800 Output frequency threshold for detecting motor standstill4 fout_still Hz 6 Maximum output current when fs 2 kHz Iout_max2 A 357 0 427 0 515 0 660 0 Maximum output current when fs 4 kHz Iout_max4 A 357 0 427 0 515 0 660 0 Maximum output current when fs 8 kHz Iout_max8 A 242 0 362 0 430 0 476 0 Continuous output current when fs 2 kHz Iout_cont2 A 254 0 306 0 392 0 490 0 Continuous o...

Page 146: ...elevant if the halving the PWM frequency in the standstill range function is used see P 0 0045 Control word of current controller Tab 7 7 HMU power section data inverter Power section data inverter Description Symbol Unit HMU05 1N F0340 0820 N A4 D7 P HMU05 1N F0430 1040 N A4 D7 P HMU05 1N F0540 1300 N A4 D7 P HMU05 1N F0680 1690 N A4 D7 P Planned Allowed switching frequencies1 fs kHz 2 4 8 Output...

Page 147: ...fout_still Iout_cont0Hz_2 A 485 0 610 0 650 0 992 0 Continuous output current when fs 4 kHz output frequency fout less than fout_still Iout_cont0Hz_4 A 450 0 493 0 500 0 766 0 Continuous output current when fs 8 kHz output frequency fout less than fout_still Iout_cont0Hz_8 A 298 0 496 0 Last modification 2015 12 03 1 Also depending on firmware and control section see parame ter description P 0 000...

Page 148: ...cy the output current is reduced for thermal protection of the power section The output current is reduced when the electric output frequency has fallen below the threshold to detect motor standstill For the highest possible acceleration the maximum current Imax may not flow for more than 400 mss every 10 minutes Fig 7 1 Current profile during acceleration Bosch Rexroth AG DOK INDRV HXX05 PR02 EN ...

Page 149: ... HLT05 HAS08 Cabinet installation kit mounting kit For mounting an HMU05 HAS10 Blank covers motor monitor grounding mounting plates Tab 8 2 Accessories overview 8 1 3 Additional components Type Additional component HAH01 Heat exchanger HAS04 Y capacitor pair HLL05 DC bus choke HMF05 Motor filter HML05 Motor choke HNA05 Mains connection module HNC05 Mains capacitor HNF05 Mains filter HNL05 Mains ch...

Page 150: ...HLB01 1C 01K0 N06R0 A 007 NNNN 002 HLC01 1C 01M0 A 007 NNNN 002 HLC01 1C 02M4 A 007 NNNN 004 HCS02 1E W0054 004 HCS02 1E W0070 006 HNA05 1 HLT05 1W 105K height leveling depth leveling 200 mm 007 HNA05 1 HLT05 1W 105K height leveling depth leveling 240 mm Other properties NNN None Other design NN None Tab 8 4 HAS03 type code Use Accessories are used to mount HNA05 mains connection modules or HLT05 ...

Page 151: ...t 001 HCS04 2E W0290 002 HCS04 2E W0350 003 HCS04 2E W0420 004 HCS04 2E W0520 005 HCS04 2E W0640 005 HCS04 2E W0790 006 HCS04 2E W1010 006 HCS04 2E W1240 007 HCS04 2E W1540 008 HMU05 Degree of protection P00 IP00 P23 IP23 P54 IP54 NNN Not relevant Other design NN None FL Filter fan GL Separate air flow MH Mounting kit dismounting kit Tab 8 5 HAS08 type code DOK INDRV HXX05 PR02 EN P Bosch Rexroth ...

Page 152: ...g kit 1 Stabilizer bar 2 Supporting bar 3 Stand 4 Stop plate 5 Block and tackle 6 Plate with eyebolt Fig 8 1 HAS08 1 008 NNN_MH mounting kit Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 150 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 153: ...bars on top of control cabinet using 4 M12 2 Fit plate with eyebolt to supporting bar 3 Mount supporting bar to stabilizer bars using 8 M8 4 Align plate with eyebolt and screw it on using 4 M8 5 For heavy devices additionally mount support plates to stabilizer bars using 4 M8 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 151 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additi...

Page 154: ... Stand HAS10 1 002 Mounting plate 2 x M8 Screws to adjust the hight of the stand Fig 8 3 Stand stop plates Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 152 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 155: ... plate using 8 M8 3 Pre assemble stand using M8 and adjust it to device size 1 2 or 3 plates 4 Fit stand to screws of HAS10 1 002 mounting plate and screw it on 5 To adjust screw 2 M8 to bottom plate of stand DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 153 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 156: ...r eyebolt and lift device Fig 8 4 Rear eyebolt Fig 8 5 Device at block and tackle 3 Put edge of device on front stop plate 4 Align equipment grounding conductor connection point with rear stop plate Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 154 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 157: ...inet putting your hand at front of device and lower device using block and tackle 6 Screw on device 7 Disassemble mounting kit DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 155 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 158: ... block and tackle 3 Unscrew device screws 4 Slightly push device into control cabinet putting your hand at front of de vice and lift device using block and tackle Device will tilt outwards over first stop plate 5 Put device down 6 Disassemble mounting kit Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 156 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 159: ... of connectors for increased vibration resistance 002 Fixing clip of connectors and master communication for increased vibration resistance 003 Dummy cover for slide in ducts 1 parallel module 1 motor mains module 1 control section 004 Motor monitor grounding 005 Mounting plate for device width 200 mm 006 Mounting plate for device width 220 mm Other design NN None Tab 8 6 HAS10 type code Blank cov...

Page 160: ...Fig 8 7 Product insert HAS10 1 002 003 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 158 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 161: ...Fig 8 8 Blank covers HAS10 1 002 003 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 159 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 162: ...nitor grounding HAS10 1 002 004 Fig 8 9 Product insert HAS10 1 002 004 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 160 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 163: ...A Tightening torque of screws 1 Nm Fig 8 10 Use HAS10 1 002 004 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 161 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 164: ...or device width 200 mm HAS10 1 002 005 Fig 8 11 Product insert HAS10 1 002 005 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 162 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 165: ...M10 Tightening torque 48 Nm Fig 8 12 Use HAS10 1 002 005 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 163 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 166: ...or device width 220 mm HAS10 1 002 006 Fig 8 13 Product insert HAS10 1 002 006 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 164 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 167: ...M10 Tightening torque 48 Nm Fig 8 14 Use HAS10 1 002 006 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 165 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 168: ...on module Series 05 05 Design 1 1 Application N Standard Cooling type W Air internal Supply system R For regenerative devices only Charging power 02F5 2 5 F example Mains connection voltage A4 3 AC 380 V 15 3 AC 500 V 10 A5 3 AC 380 V 15 3 AC 690 V 10 Degree of protection A IP20 Other design NNNN None Tab 8 7 HNA05 type code Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 166 407 Rexroth IndraDrive ML ...

Page 169: ...imensional drawing M10 Tightening torque 40 Nm Fig 8 15 HNA05 dimensional drawing DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 167 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 170: ...rque 40 Nm Fig 8 16 HNA05 with HAS03 1 007 mounting plate for height leveling and depth leveling to 440 mm depth dimensional drawing Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 168 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 171: ... UN3 V 24 Tolerance of control voltage UN3 20 Input capacitance of control voltage UN3 mF 0 05 Control voltage input current mA 500 Rated mains input voltage Unenn V AC 400 AC 690 Three phase mains input voltage TN S TN C TT mains V AC 380 500 AC 380 690 Mains input voltage tolerance 10 15 Mains frequency Hz 50 60 Maximum allowed mains frequency change Hz s 1 Mains frequency tolerance Hz 2 Rotary ...

Page 172: ... 5 Minimum capacitance at output mF 1 Short circuit current rating SCCR kA rms 85 Tab 8 8 HNA05 ratings Connection diagram See chapter 4 6 2 Overall connection diagram HMU05 as supply unit on page 95 Maximum allowed operating cy cles for charging circuit The exact value depends on the existing DC bus capacitance number and size of HMUs additional capacitance connected Bosch Rexroth AG DOK INDRV HX...

Page 173: ... V XG1 IndraBus XG31 Connection for messages XG32 HNA bus XG33 On off ZKS DC bus short circuit status XG34 Contact for external mains contactor XG40 Acknowledgment messages of mains contactor Fig 8 17 HNA05 connection points DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 171 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 174: ...nductor system in the control cabinet are large enough For outer conductors with a cross section greater than 16 mm you can reduce the cross section of the equipment grounding connection according to the table Equipment grounding conduc tor cross section Cross sectional area A of outer conduc tors Minimum cross sectional area APE of equipment grounding connection A 16 mm A 16 mm A 35 mm 16 35 mm A...

Page 175: ...ction at connector Unit Min Max Tightening torque Nm 0 8 Connection cable Solid wire mm2 0 2 10 Connection cable Stranded wire without ferrule mm2 0 2 6 AWG 24 10 Connection cable Stranded wire with ferrule mm2 0 25 4 Stripped length mm 10 Tab 8 12 Mechanical data Electrical data Unit Min Max Voltage V 630 Current A 41 Tab 8 13 Electrical data DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 173 407 Rex...

Page 176: ...ecure the DC bus connections against being touched View Identifica tion Function L DC bus connection n c n c L DC bus connection Tab 8 14 XD2 DC bus Mechanical data Screw connection at connector Unit Min Max Tightening torque Nm 0 8 Connection cable Solid wire mm2 0 2 10 Connection cable Stranded wire without ferrule mm2 0 2 6 AWG 24 10 Connection cable Stranded wire with ferrule mm2 0 25 4 Stripp...

Page 177: ...ctrical data Unit Min Max Voltage load capacity V UN3 Power consumption W PN3 Current carrying capacity looping through A 40 UL 31 Allowed inductance µH 100 2 twisted single strands 75 m long Tab 8 19 Electrical data Notes on installation Depending on the power consumption of the devices and the current carrying capacity of the connector XD10 check the number of devices through which one line for ...

Page 178: ...ing resistor unit Reporting DC bus availability Cable Unshielded length 3 m Cable designation RKB0036 Shielded length 100 m Cable designation RKB0035 In individual operation that is to say not in combination with other devices of the Hxx05 1 series both IndraBus RBS0025 terminating plugs must have been plugged in Tab 8 20 XG1 IndraBus Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 176 407 Rexroth Indr...

Page 179: ...ontact signals warning states Open with Overtemperature at supply unit 7 8 I Reference potential of supply voltage 0VEA Tab 8 21 XG31 messages Operating HNA05 with HMU05 slave mode does not require XG31 to be connected If the master communication has been deactivated it is necessa ry to connect Bb contact warning contact and reset input Mechanical data Spring terminal connector Unit Min Max Connec...

Page 180: ...protection Short circuit protection Bb and warning contact Digital outputs correspond to IEC 61131 2 Type 1 Switching voltage VDC 30 Continuous current A 1 Switching current A 5 Load current mA 10 Switching cycles 3 105 Tab 8 23 Electrical data Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 178 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 181: ... male Unit Min Max Connection cross section mm2 0 25 0 5 Cable RKB0037 m 0 5 or 0 66 1 Tab 8 24 Function pin assignment properties DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 179 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 182: ...een activa ted Compared to the master communication the input is of higher priority The input can be used for example to loop in an emergency stop circuit or the like 6 O Supply voltage for external ON output ON1 Output 24VEA is used to connect input XG33 7 7 I ON input ON2 Connection for N O contact to switch on the supply unit The input is edge controlled The input is only available if the maste...

Page 183: ...rule mm2 0 25 0 75 Stripped length mm 10 Tab 8 26 Mechanical data Electrical data Unit Min Max Digital Inputs Digital inputs correspond to IEC 61131 2 Type 1 Supply outputs Total output current mA 300 Tab 8 27 Electrical data DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 181 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 184: ...ded wire without ferrule mm2 0 2 2 5 AWG 24 12 Connection cable Stranded wire with ferrule mm2 0 25 2 5 Stripped length mm 10 Tab 8 29 Mechanical data Electrical data Unit Min Max Switching voltage V 5Vac 5Vdc 250Vac 50Vdc Continuous current A 1 Switching current A 5 Load current mA 10 Switching cycles 3 105 Tab 8 30 Electrical data Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 182 407 Rexroth IndraD...

Page 185: ... Mechanical data Spring terminal connector Unit Min Max Connection cable Stranded wire without ferrule mm2 0 2 1 5 AWG 24 16 Connection cable Stranded wire with ferrule mm2 0 25 0 75 Stripped length mm 10 Tab 8 32 Mechanical data Electrical data Unit Min Max Digital inputs Digital inputs correspond to IEC 61131 2 Type 1 Supply outputs Total output current mA 300 Tab 8 33 Electrical data DOK INDRV ...

Page 186: ...A ready no mains voltage Off HNA not ready PF57 Yellow Charging complete DC bus capacitance charged Flashing yellow Charging Off Charging interrupted PF58 Red Error Flashing red Warning Off No error no warning Tab 8 34 LED displays Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 184 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 187: ...ance value 0040 40 μF 0050 50 μF 0070 70 μF 0075 75 μF 0100 100 μF 0125 125 μF 0150 150 μF 0200 200 μF Mains voltage A4 3 x AC 380 V 15 500 V 10 A5 3 x AC 525 V 15 690 V 10 Other design NNNN None Tab 8 35 HNC05 type code Possible combinations Mains volt age Capacitance 0040 0050 0070 0075 0100 0125 0150 0200 A4 A5 Tab 8 36 Possible combinations DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 185 407 Re...

Page 188: ...Dimensions HNC05 1N 0050 Fig 8 19 HNC05 1N 0050 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 186 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 189: ...HNC05 1N 0075 Fig 8 20 HNC05 1N 0075 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 187 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 190: ...HNC05 1N 0100 Fig 8 21 HNC05 1N 0100 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 188 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 191: ...Weight kg 0050 50 60 100 Phases Screw terminal 25 mm2 Tightening torque 4 4 5 Nm Ground Bolt M8x20 IP20 11 6 0075 75 80 100 Phases Screw terminal 25 mm2 Tightening torque 5 Nm Ground Bolt M8x20 IP20 11 6 0100 100 80 150 Phases Screw terminal 25 mm2 Tightening torque 5 Nm Ground Bolt M8x20 IP20 11 6 Tab 8 37 HNC05 1N data Discharge time 20 minutes Assignment to HMU05 See chapter Combining mains fil...

Page 192: ...Extended frequency range in accordance with EMC integration guidelines of the automotive industry for production environment Leakage capacitance 500N 500 nF example Supply system R For regenerative devices only Nominal current 0150 150 A 0180 180 A 0250 250 A 0320 320 A 0400 400 A 0600 600 A 1000 1000 A 1600 1600 A Degree of protection N IP00 Mains connection voltage A4 3 x AC 380 V 15 500 V 10 A5...

Page 193: ...ge A4 A5 Nominal current 0150 0180 0250 0320 0400 0600 1000 1600 EMC area A Tab 8 39 Possible combinations DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 191 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 194: ...Dimensions HNF05 1A 500N R0250 Fig 8 22 HNF05 1A 500N R0250 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 192 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 195: ...HNF05 1A 500N R0320 R0400 Fig 8 23 HNF05 1A 500N R0320 R0400 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 193 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 196: ...HNF05 1A 500N R0600 Fig 8 24 HNF05 1A 500N R0600 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 194 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 197: ...HNF05 1A 500N R1000 Fig 8 25 HNF05 1A 500N R1000 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 195 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 198: ... used as a PE connection to the mounting plate with metallic conduction properties In this case mark the 2 PE connections with the symbol for the equipment grounding conductor connection point The metallic connection to the mount ing plate has to comply with the valid standards Threaded bolt PE Nominal size Tightening torque Nm Tolerance Nm M10 10 0 9 0 11 0 M12 15 5 14 0 17 0 M16 30 27 0 33 0 Tab...

Page 199: ...21 0400 400 53 0600 600 86 52 22 1000 1000 166 33 28 1600 1600 283 22 34 1 With nominal voltage 50 Hz Tab 8 41 HNF05 1A data Assignment to HMU05 See chapter Combining mains filter mains choke preconnected choke and capacitance pack on page 112 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 197 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 200: ...generative devices only Nominal inductance 0040 40 μH 0043 43 μH 0045 45 μH 0050 50 μH 0054 54 μH 0080 80 μH 0094 94 μH 0100 100 μH 0113 113 μH 0117 117 μH 0125 125 μH 0130 130 μH 0135 135 μH 0139 139 μH 0175 175 μH 0182 182 μH 0219 219 μH 0234 234 μH 0346 346 μH 0434 434 μH 0542 542 μH 0649 649 μH 1019 1019 μH Additional option N None Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 198 407 Rexroth Ind...

Page 201: ...238 A 0262 262 A 0327 327 A 0352 352 A 0409 409 A 0471 471 A 0514 514 A 0592 592 A 0652 652 A 0811 811 A 1019 1019 A Degree of protection N IP00 Mains connection voltage A4 3 x AC 380 V 15 500 V 10 A5 3 x AC 525 V 15 690 V 10 Other design NNNF Liquid cooling NNNN None Tab 8 42 HNL05 type code DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 199 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables a...

Page 202: ...409 0514 0652 0811 1019 0327 0409 0514 0652 0811 1019 Nominal inductance 0040 0043 0045 0050 0054 0094 0100 0113 0117 0130 0135 0182 0219 Tab 8 43 Possible combinations mains connection voltage A4 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 200 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 203: ... 0238 0190 0152 0127 0592 0471 0352 0238 0190 0152 Nominal inductance 0032 0040 0054 0080 0100 0125 0139 0175 0234 0346 0434 0542 0649 Tab 8 44 Possible combinations mains connection voltage A5 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 201 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 204: ... frequency 10 Nominal current 11 Number of design specification 12 Nominal inductance 13 Temperature 14 Number and value of additional capacitors 15 Designation of origin 16 Approval number 17 Bar code 39 or 93 18 Serial number 19 Company address Fig 8 27 Type plate Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 202 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional compo...

Page 205: ...Dimensions HNL05 1R 0219 N0218 Fig 8 28 HNL05 1R 0219 N0218 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 203 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 206: ...HNL05 1R 0182 N0262 Fig 8 29 HNL05 1R 0182 N0262 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 204 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 207: ...HNL05 1R 0045 N0327 Fig 8 30 HNL05 1R 0045 N0327 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 205 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 208: ...HNL05 1R 0135 N0327 Fig 8 31 HNL05 1R 0135 N0327 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 206 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 209: ...HNL05 1R 0054 N0409 Fig 8 32 HNL05 1R 0054 N0409 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 207 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 210: ...HNL05 1R 0117 N0409 Fig 8 33 HNL05 1R 0117 N0409 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 208 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 211: ...HNL05 1R 0043 N0514 Fig 8 34 HNL05 1R 0043 N0514 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 209 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 212: ...HNL05 1R 0130 N0514 Fig 8 35 HNL05 1R 0130 N0514 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 210 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 213: ...HNL05 1R 0050 N0652 Fig 8 36 HNL05 1R 0050 N0652 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 211 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 214: ...HNL05 1R 0113 N0652 Fig 8 37 HNL05 1R 0113 N0652 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 212 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 215: ...HNL05 1R 0040 N0811 Fig 8 38 HNL05 1R 0040 N0811 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 213 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 216: ...HNL05 1R 0100 N0811 Fig 8 39 HNL05 1R 0100 N0811 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 214 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 217: ...HNL05 1R 0040 N1019 Fig 8 40 HNL05 1R 0040 N1019 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 215 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 218: ...HNL05 1R 0094 N1019 Fig 8 41 HNL05 1R 0094 N1019 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 216 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 219: ...P00 40 70 0113 N0652 113 652 1500 2700 IP00 40 150 0040 N0811 40 811 620 IP00 40 85 0100 N0811 100 811 1650 3000 IP00 40 180 0040 N1019 40 1019 850 IP00 40 121 0094 N1019 94 1019 1950 3500 IP00 40 225 1 The air water distribution was determined at an ambient tem perature of 30 C and a water inlet temperature of 50 C 2 Up to 55 C with current derating Tab 8 45 HNL05 1R data Temperature monitoring c...

Page 220: ...5 0113 N0652 8 3 4 0 03 0 06 0 10 0100 N0811 8 3 6 0 04 0 07 0 10 0094 N1019 8 4 1 0 04 0 07 0 12 Tab 8 46 Water cooling Connection See chapter 11 4 Aluminum contact points and cupal disks on page 381 Assignment to HMU05 See chapter Combining mains filter mains choke preconnected choke and capacitance pack on page 112 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 218 407 Rexroth IndraDrive ML Drive S...

Page 221: ...choke Series 05 05 Design 1 1 Cooling type type of construction W Air cooling Choke type D dv dt choke Nominal inductance 980U 980 μH example Additional option N None Nominal current 1002 1002 A example Degree of protection N IP00 Rated voltage 500 3 AC 500 V 690 3 AC 690 V Other design NNNN None Tab 8 47 HML05 type code DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 219 407 Rexroth IndraDrive ML Driv...

Page 222: ...021U N0254 N 500 NNNN F0170 0430 D018U N0306 N 500 NNNN F0220 0510 D014U N0392 N 500 NNNN F0270 0660 D009U N0490 N 500 NNNN F0340 0820 D009U N0616 N 500 NNNN F0430 1040 D007U N0771 N 500 NNNN F0540 1300 D006U N1002 N 500 NNNN F0680 1690 D004U N1185 N 500 NNNN Tab 8 48 HML05 HMU05 assignment Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 220 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables acc...

Page 223: ...Dimensions Fig 8 42 HML05 1W D021U N0254 N 500 NNNN dimensions DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 221 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 224: ...Fig 8 43 HML05 1W D018U N0306 N 500 NNNN dimensions Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 222 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 225: ...Fig 8 44 HML05 1W D014U N0392 N 500 NNNN dimensions DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 223 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 226: ...Fig 8 45 HML05 1W D009U N0490 N 500 NNNN dimensions Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 224 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 227: ...Fig 8 46 HML05 1W D009U N0616 N 500 NNNN dimensions DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 225 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 228: ...Fig 8 47 HML05 1W D007U N0771 N 500 NNNN dimensions Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 226 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 229: ...Fig 8 48 HML05 1W D006U N1002 N 500 NNNN dimensions DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 227 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 230: ...Fig 8 49 HML05 1W D004U N1185 N 500 NNNN dimensions Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 228 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 231: ...frequency Nominal current Arms 254 306 392 490 546 632 775 1008 Maximum phase phase capacitance motor cable nF 20 20 20 20 30 30 30 tbd Maximum leakage capacitance nF 120 120 120 120 180 180 180 tbd Working point 3 4 kHz clock frequency 400 Hz rotary field frequency Nominal current Arms 254 306 392 490 546 632 775 1008 Maximum phase phase capacitance motor cable nF 10 10 10 10 30 30 30 tbd Maximum...

Page 232: ...For applications with a high continuous load thermally gauge the motor balancing chokes during commissioning In particular this applies if all pa rameters are not reliably known e g motor inductance in the working point In case of doubt install a forced ventilation or use the next bigger size if the rise of voltage at the motor allows this bigger size has lower inductance Installing a DC bus choke...

Page 233: ...F Liquid cooling W Air cooling Nominal inductance 04M0 4 mH Additional option S Current compensated Nominal current 0202 202 A 0243 243 A 0303 303 A 0380 380 A 0475 475 A 0603 603 A 0720 720 A 0942 942 A Degree of protection N IP00 Nominal DC bus voltage D7 DC 750 V 11 DC 1100 V Leakage capacitance 01U2 1 2 μF Other design NNNN None Tab 8 50 HLL05 type code DOK INDRV HXX05 PR02 EN P Bosch Rexroth ...

Page 234: ... bus current in each drive line The lowest DC bus voltage UDCmin that occurs is always used to determine the DC bus current IDC IDC PDC UDCmin An HLL DC bus choke is always necessary if IndraDrive M HMS01 HMD01 components are connected to the DC bus See chapter Operating HMU05 together with HMS01 HMD01 on page 56 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 232 407 Rexroth IndraDrive ML Drive System...

Page 235: ...Dimensions HLL05 1W 04M0 S0202 Fig 8 50 HLL05 1W 04M0 S0202 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 233 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 236: ...HLL05 1F 04M0 S0202 Fig 8 51 HLL05 1F 04M0 S0202 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 234 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 237: ...HLL05 1F 04M0 S0243 Fig 8 52 HLL05 1F 04M0 S0243 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 235 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 238: ...HLL05 1W 04M0 S0303 Fig 8 53 HLL05 1W 04M0 S0303 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 236 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 239: ...HLL05 1F 04M0 S0303 Fig 8 54 HLL05 1F 04M0 S0303 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 237 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 240: ...HLL05 1F 04M0 S0380 Fig 8 55 HLL05 1F 04M0 S0380 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 238 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 241: ...HLL05 1F 04M0 S0475 Fig 8 56 HLL05 1F 04M0 S0475 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 239 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 242: ...HLL05 1F 04M0 S0603 Fig 8 57 HLL05 1F 04M0 S0603 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 240 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 243: ...HLL05 1F 04M0 S0720 Fig 8 58 HLL05 1F 04M0 S0720 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 241 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 244: ...HLL05 1F 04M0 S0942 Fig 8 59 HLL05 1F 04M0 S0942 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 242 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 245: ...P00 40 33 S0380 4 380 330 580 1 2 IP00 40 36 S0475 4 475 420 760 1 2 IP00 40 86 S0603 4 603 530 940 1 2 IP00 40 98 S0720 4 720 540 960 1 2 IP00 40 110 S0942 4 942 680 1220 1 2 IP00 40 152 1 Maximum ambient temperature 55 C with derating 2 Maximum water inlet temperature 60 C Tab 8 51 HLL05 1F data Temperature monitoring contact Trigger temperatureAuslösetemperatur 160 C N C in one of the windings ...

Page 246: ... 8 0 10 0 18 0 28 S0303 6 1 0 0 12 0 22 0 35 S0380 6 1 1 0 14 0 25 0 40 S0475 6 1 2 0 01 0 03 0 04 S0603 8 1 7 0 02 0 04 0 06 S0720 8 1 9 0 02 0 04 0 06 S0942 8 2 3 0 03 0 05 0 08 Tab 8 52 Water cooling Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 244 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 247: ...F0340 0820 250 kW size F0430 1040 315 kW size F0540 1300 400 kW size F0680 1690 500 kW size DC bus choke HLL05 1F 04M0 S0202 S0243 S0303 S0380 S0475 S0603 S0720 S0942 Tab 8 53 HLL05 HMU05 assignment DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 245 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 248: ...ion DC bus chokes should not be simultaneously connected in paral lel at the input and at the output Use cupal disks for the aluminum contact point connection See chapter 11 4 Aluminum contact points and cupal disks on page 381 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 246 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 249: ...ve accessories Series 04 Capacitor Design 1 1 Capacitor 001 2 470 nF HCS02 x 002 2 470 nF HCS03 x 003 2 2 5 μF HLL05 Other contents NNN None Other design NN None Tab 8 54 HAS04 type code Data Description Unit Value Voltage V AC 500 DC 1200 Capacitance µF 2 5 20 Tab 8 55 Data DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 247 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additio...

Page 250: ...Fig 8 61 Dimensions Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 248 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 251: ... 54K0 54 kW 1 70K0 70 kW 2 Additional option N None Resistance value 04R0 4 0 ohm 2 05R4 5 4 ohm 1 Degree of protection A IP20 Nominal DC bus voltage D7 DC 750 V 1 2 11 DC 1100 V Other design NNNN None 1 54K0 continuous power only with 05R4 resistance value and D7 nominal DC bus voltage 2 70K0 continuous power only with 04R0 resistance value and D7 nominal DC bus voltage Tab 8 56 HLR05 type code D...

Page 252: ...W 54K0 N05R4 70K0 N04R0 Fig 8 62 HLR05 1W 54K0 N05R4 70K0 N04R0 dimensions in mm Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 250 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 253: ...650 VDC duty cycle peak power 120 s max cycle 70 66 820 VDC duty cycle peak power 120 s max cycle 38 41 Maximum energy absorption kWs 6500 8400 Weight kg 145 145 Power connections cross section mm2 25 35 Tab 8 57 HLR05 1W data DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 251 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 254: ...entry of cooling air Ensure unhindered exit of heated air Do not mount below fire alarm sensors Do not mount near flammable materials Cables Length 100 m Keep feeder and return cables in parallel and as close together as pos sible or twist them Place cables away from signal and data lines Place so they are protected against short circuiting and ground faults You can use Rexroth cables HLR05 1W Cab...

Page 255: ...LR terminal 6 35 mm2 2 Stranded wire for HLT terminal connector XD4b connection cross section of HLR terminal 6 35 mm2 3 Stranded wires for HLT terminal connector XG3 connection cross section of HLR terminal 0 25 2 5 mm2 4 Wire not used DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 253 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 256: ...5 Filler strand not used Fig 8 63 Connection point Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 254 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 257: ...ign 1 1 Cooling type type of construction W Air cooling Nominal power 045K 45 kW 1 105K 105 kW 245K 245 kW 1 Degree of protection N IP00 Nominal DC bus voltage D7 DC 750 V 1 11 DC 1100 V Other design NNNN None 1 045K and 245K nominal power only with D7 nominal DC bus voltage Tab 8 59 HLT05 type code DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 255 407 Rexroth IndraDrive ML Drive Systems with HMU05 C...

Page 258: ...de HLT05 1W 045K 105K dimensional drawing A Minimum mounting clearance B Boring dimensions Fig 8 64 HLT05 1W 045K 105K dimensional drawing Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 256 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 259: ...sions M10x25 Tightening torque 40 Nm Fig 8 65 HLT05 1W 045K 105K with mounting plate HAS03 1 007 for height leveling and depth leveling to 440 mm depth dimensional drawing DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 257 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 260: ...ng A Minimum mounting clearance B Boring dimensions Fig 8 66 HLT05 1W 245K dimensional drawing Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 258 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 261: ...d based delay of braking transistor switch on threshold UHLT_On_d V 30 Emergency comparator switch on voltage UNot V 943 2 5 Max input voltage Umax V 980 Continuous current for DC connection points Inom A 100 200 500 Power dissipation full load PDiss_max W 250 400 1000 Power dissipation standby PDiss_min W 20 Rated control voltage input UN3 V 24 20 Control voltage input current IN3 mA 470 630 Shor...

Page 262: ...onnection diagram Fig 8 67 HLT05 1W 045K 105K connection diagram Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 260 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 263: ...Fig 8 68 HLT05 1W 245K connection diagram DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 261 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 264: ...ection points XD02 and XD4 Fig 8 69 Internal wiring of connection points XD02 and XD4 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 262 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 265: ...x05 devices plug in both RBS0025 terminating plugs at XG1 XG3 Braking resistor overtemperature signal contact N C con tact XG31 Signal contact Bb warning and reset input for resetting error messages XG33 DC bus short circuit ZKS function Fig 8 70 HLT05 1W 045K 105K connection points DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 263 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories...

Page 266: ...025 terminating plugs at XG1 XG3 Braking resistor overtemperature signal contact N C contact XG31 Signal contact ready warning and reset input for resetting error messages XG33 DC bus short circuit ZKS function Shield Shield connection on the bottom with HAS02 1 003 accesso ries Fig 8 71 HLT05 1W 245K connection points Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 264 407 Rexroth IndraDrive ML Drive ...

Page 267: ...es for the connections from the device s equip ment grounding conductor to the equipment grounding conductor system in the control cabinet are large enough For outer conductors with a cross section greater than 16 mm you can reduce the cross section of the equipment grounding connection according to the table Equipment grounding conduc tor cross section Cross sectional area A of outer conduc tors ...

Page 268: ...nt grounding system Screw connection Unit Min Max Screw M6x25 Tightening torque Nm 9 5 10 5 Tab 8 62 Equipment grounding conductor connection point Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 266 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 269: ...are used Secure the DC bus connections against being touched HLT05 1W 045K 105K View Connec tion Signal name Function XD02a L Positive pole DC bus voltage XD02b L Negative pole DC bus volt age Tab 8 63 XD02 DC bus Mechanical data Screw connection Unit Min Max Connection cable mm2 85 95 AWG 3 0 4 0 Cable length 1 m 1 Stripped length mm 27 Tightening torque M8 Nm 15 1 Place the HLT05 braking unit cl...

Page 270: ...inal voltage as per UL 1059 V 600 Nominal current as per UL 1059 A 230 Tab 8 65 Electrical data Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 268 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 271: ...e used Secure the DC bus connections against being touched HLT05 1W 245K View Connec tion Signal name Function L L Positive pole DC bus voltage L L Negative pole DC bus volt age Tab 8 66 XD02 DC bus Mechanical data Screw connection Unit Min Max Contact bar mm2 288 Connection cable mm2 2 120 kcmil 2 250 Cable length 1 m 1 Tightening torque M10 Nm 48 1 Place the HLT05 braking unit close to the DC bu...

Page 272: ...inal voltage as per UL 1059 V 600 Nominal current as per UL 1059 A 500 Tab 8 68 Electrical data Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 270 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 273: ... HLT05 1W 245K connection cable mm2 50 AWG 1 0 Stripped length mm 24 Tightening torque M6 Nm 6 Tab 8 70 Mechanical data Electrical data Unit Min Max Nominal voltage as per UL 1059 V 600 Nominal current as per UL 1059 per terminal 1 A 145 1 The rms current Irms should not exceed the nominal current of the terminal connector Irms Pcont Rload Pcont continuous braking power Rload load resistance Tab 8...

Page 274: ...al data Screw connection at connector Unit Min Max Connection cable Solid wire mm2 1 10 Connection cable Stranded wire without ferrule mm2 1 6 AWG 16 10 Connection cable Stranded wire with ferrule mm2 1 4 Stripped length mm 10 Tab 8 73 Mechanical data Electrical data Unit Min Max Voltage V 60 Current A 1 Tab 8 74 Electrical data Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 272 407 Rexroth IndraDrive...

Page 275: ...ing resistor unit Reporting DC bus availability Cable Unshielded length 3 m Cable designation RKB0036 Shielded length 100 m Cable designation RKB0035 In individual operation that is to say not in combination with other devices of the Hxx05 1 series both IndraBus RBS0025 terminating plugs must have been plugged in Tab 8 75 XG1 IndraBus DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 273 407 Rexroth Indr...

Page 276: ...ing resistor signal contact Mechanical data Spring terminal connector Unit Min Max Connection cable Stranded wire without ferrule mm2 0 2 1 5 AWG 24 16 Connection cable Stranded wire with ferrule mm2 0 25 0 75 Stripped length mm 10 Tab 8 77 Mechanical data Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 274 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 277: ...anical data Spring terminal connector Unit Min Max Connection cable Stranded wire without ferrule mm2 0 2 1 5 AWG 24 16 Connection cable Stranded wire with ferrule mm2 0 25 0 75 Stripped length mm 10 Tab 8 79 Mechanical data Electrical data Unit Min Max Digital inputs Digital inputs correspond to IEC 61131 2 Type 1 Switching voltage V 24 6 Output current mA 500 Energy absorption capacity mJ 700 Ov...

Page 278: ... Max Load current mA 10 Switching cycles 3 105 Tab 8 80 Electrical data Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 276 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 279: ...nt The DC bus short circuit function requires a 24 V control voltage In the event of a control voltage failure the DC bus will not dis charge automatically Mechanical data Spring terminal connector Unit Min Max Connection cable Stranded wire without ferrule mm2 0 2 1 5 AWG 24 16 Connection cable Stranded wire with ferrule mm2 0 25 0 75 Stripped length mm 10 Tab 8 82 Mechanical data Electrical data...

Page 280: ...deactivated by default Type DIP 2 pin Fig 8 72 SF1 switch The switch sits underneath a cover The cover can be removed using a screwdriver Function Switch 1 Switch 2 Auto ZKS auto DC bus short circuit activated ON ON ON OFF OFF ON OFF OFF ON Move switch down to the lowermost position OFF Move switch up to the topmost position Sliding force 8 N Tab 8 84 Function Bosch Rexroth AG DOK INDRV HXX05 PR02...

Page 281: ...ly 19 2 V PF56 Green Ready for operation Off Not ready for operation PF57 Yellow Active Off Inactive PF58 Red Error Flashing red Warning Off No error no warning Tab 8 85 HLT05 LED displays DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 279 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 282: ...241 Redundancy module for establishing a redundant power supply 2 40 A input 1 80 A output Tab 8 86 Power supply units redundancy modules Important properties SELV PELV power supply unit1 Overvoltage protection available Overtemperature protection available Exclusively 3 phase operation allowed UL approval E198865 Documentation Product documentations can be found online http www pulspower com inde...

Page 283: ... V ADC 20 continuously 30 4 s 20 continuously 25 4 s 40 continuously 60 4 s Output power 24 V W 480 600 4 s 480 720 4 s 960 1440 4 s Input line fuses Present 2 Present 3 Degree of protection IP20 Weight kg 0 87 0 89 1 5 Dimensions mm W H D 65 124 127 110 124 127 Mounting Top hat rail Wall mounted with optional accessories Tab 8 87 Data DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 281 407 Rexroth Ind...

Page 284: ... bus power supply unit YR40 241 Redundancy module Fig 8 74 24V 20A connection diagram Setting the output voltage QT20 241 25 5 V QTD20 241 24 V Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 282 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 285: ... bus power supply unit YR40 241 Redundancy module YR80 241 Redundancy module Fig 8 75 24V 40A connection diagram Setting the output voltage QT40 241 25 5 V QTD20 241 24 V DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 283 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 286: ...te 0090 90 liter minute 0180 180 liter minute Pressure circuit drive side 015 1 5 bar Other design 0001 Configuration 1 1 Locking cooling power with flow rate circuit drive side and cool ing circuit customer side done Cooling power 008K only available with flow rate circuit drive side 0020 Cooling power 035K only available with flow rate circuit drive side 0090 Cooling power 060K only available wi...

Page 287: ...sure L Customer product code M Week and year of manufacture N Article number P EEEW RAEE marking concerning the obliga tion to dispose of electrical and electronic equip ment separately from household waste Q CE marking of conformity Tab 8 89 Manufacturer s details and machine identification details DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 285 407 Rexroth IndraDrive ML Drive Systems with HMU05 C...

Page 288: ...Declaration of conformity Fig 8 76 Declaration of conformity Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 286 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 289: ...thorised modifications and or repairs missing or inadequate maintenance use of non original spare parts or parts not designed specifically for the model concerned DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 287 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 290: ... may result from the specific activity to be performed Familiarise yourself with the meanings of the symbols on the stickers their shape and colour are important for safety purposes make sure they are al ways legible and always observe the information given Do not tamper with circumvent eliminate or bypass the locking and safety devices failure to comply with this requirement may cause serious ris...

Page 291: ...uits customer side circuit and drive circuit and a heat exchanger The cold liquid provided by the owner flows in the customer side circuit and through the heat exchanger it cools the liquid in the drive circuit The equipment or machine to be cooled is connected to the drive circuit Main parts A Electrical panel B Main pump C Filling pump D Heat exchanger E Expansion tank F Coolant distribution man...

Page 292: ... the drive circuit and conse quently the machine to be cooled The temperature of the fluid in the drive circuit is controlled by the mixing valve of the primary circuit that adjusts the flow of the cold liquid into the heat exchanger Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 290 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 293: ... of the coolant towards the owner s system E Filter it filters the incoming liquid F Mixing valve it automatically varies the flow rate of the coolant in the heat exchanger in order to increase or decrease the tem perature of the fluid in the drive circuit G Actuator it controls the mixing valve in order to shut the cold liquid in the heat exchanger DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 291 4...

Page 294: ... Pressure sensor this measures the differential pressure be tween the intake and the outlet of the machine to be cooled U Check valve this is used to stop the filling pump intake pipe draining Fig 8 78 Operational cycle and component description Guards The owner must fit the machine with suitable guards in conformity with the regulations in force in order to prevent the risk of injury Overpressure...

Page 295: ...Overall dimensions Fig 8 79 Overall dimensions DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 293 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 296: ...mum drive circuit output liquid pressure bar 4 5 Maximum coolant temperature customer side circuit C 50 Minimum coolant temperature customer side circuit C 10 Maximum coolant temperature drive circuit C 70 Minimum coolant temperature drive circuit C 30 Drive circuit coolant monoethyl glycol and demineralised water solution 25 glycol Customer side circuit coolant See tab 8 91 Water quality speci fi...

Page 297: ...10 Mineral oil mg l 0 1 11 Iron Fe mg l 0 5 12 Zinc Zn mg l 0 5 13 Manganese Mn mg l 0 2 14 Phosphor P mg l 1 0 15 Copper Cu mg l 0 2 16 Fluorides F mg l 1 0 17 Nitrates NO3 mg l 10 0 18 Free carbonic acid mg l 8 15 19 Oxygen O mg l 0 2 20 Alkalinity CaCO3 mg l 200 21 Solphate ions SO4 2 mg l 100 22 Cloride ions Cl mg l 50 Tab 8 91 Water quality specification TIU_14_0003 DOK INDRV HXX05 PR02 EN P ...

Page 298: ...e table titled Connect ing the terminals Pos Meaning Terminals 24V 15 Terminals to enable machine via owner s operating terminal ENABLE 6 7 8 9 Machine error signal terminals Closed contact no error 10 11 12 13 Warning signal terminals Closed contact no Warning Tab 8 92 Connecting the terminals Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 296 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables...

Page 299: ... Vac Inter rupting capacity kW Fuse Position 35 90 08 20 FU1 1 1 CC 600 200 Delayed FU2 4 4 FU3 6 3 Tab 8 93 Fuses DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 297 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 300: ... contin ues to rise resulting in machine shutdown E Pressure sensor this detects in real time the differential pressure between the intake pipe and the drive circuit output pipe Through the sensor the drive circuit outlet pipe pressure is kept constant F Check valve this is used to stop the filling pump intake pipe draining Tab 8 94 Processing and protection devices Environmental conditions for op...

Page 301: ...rrect manoeuvres or improp er handling of the load may pose a risk of injury to the operators involved Risk of electric shock maintenance operations or replacement of compo nents may involve a risk of electric shock due to accidental contact with live electrical components Thermal risk contact with hot surfaces can cause burns allow the machine to cool down before any operation DOK INDRV HXX05 PR0...

Page 302: ...works must be carried out in live electrical parts C This indicates that there is the risk of burns due to contact with hot surfaces allow the machine to cool down before any operation D This indicates that there is the risk of electric shock E This shows the fuses technical characteristics F This shows the electrical connec tions of the terminals in the electri cal panel Tab 8 95 Information and ...

Page 303: ...lected means of transport and the destination The parcels can be loaded onto a means of transport directly or in suitable containers if shipped by sea or air or to far off destinations To make transport easier some components are removed and duly protected The figure describes the most common package types their maximum di mensions warning symbols and information affixed to the packages A This sym...

Page 304: ...ld be stored possibly without unpacking it or at least adequately protected in a sheltered place protected from atmospheric agents at a temperature between 20 and 60 C Avoid storing the machine in places where weather conditions could preju dice its good working order Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 302 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional com...

Page 305: ... 1 Unscrew the screws 2 Remove the cover 3 Lift the side walls of the package 4 Remove the locking items and the straps 5 Screw in the eyebolts A 6 Position the bracket B 7 Tighten the screws C 8 Fit the bracket D with the relevant screws DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 303 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 306: ...n movements may injure the people in volved in the operations Remove the machine The packaging material wood propylene etc can be kept for future use or properly disposed of according to the regula tions in force Tab 8 97 Unpacking Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 304 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 307: ...t in the installation area 3 Screw in the self tapping screws A to lock the machine onto the support 4 Lock the machine in the same way on the opposite side 5 Unscrew the eyebolts 6 Position the bracket B 7 Tighten the screws C 8 Screw in the self tapping screws D 9 Fit the bracket E in the same way Tab 8 98 Assembling the machine DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 305 407 Rexroth IndraDri...

Page 308: ...er must install devices to adjust the pressure and discharge in the input pipe of the customer side circuit and in the return pipe of the drive circuit Adjust the pressure in the input and return pipes to the value shown in chapter Specifications on page 294 Use flexible tubes with an internal diameter of not less than 25 mm Use connectors with an internal diameter of not less than 20 mm Tab 8 99 ...

Page 309: ...ator lamp white light indicates that the power supply to the machine is enabled C Key operated two position stay put selector switch this is used to enable service and au tomatic operation modes The key must be kept by the designated staff member and available to the staff responsible for technical servicing D Two position stay put back lit switch red light this is used to switch the filling pump ...

Page 310: ...t 3 Turn the main disconnect switch F to the ON position The indicator lamp G lights up 4 Turn the key selector E to automatic posi tion Machine start up must be performed using the operating terminal of the machine to be cooled via the ENABLE connection see chapter ENABLE UNIT ERROR and UNIT WARNING connections on page 296 Tab 8 101 Starting procedure Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 30...

Page 311: ... of the main pump stops The electrical panel on the machine remains live Remote controlled stopping Remote controlled stopping must be performed using the owner s operating terminal via the ENABLE con nection Operation of the main pump stops The electrical panel on the machine remains live Tab 8 102 Stopping procedure Stopping in emergency conditions To stop the appliance in the event of imminent ...

Page 312: ...CE Do not turn the se lector switch F to automat ic as this could cause dam age to the main pump Open any of the valves in stalled outside the machine on the circuit for the machine to be cooled 11 Turn the main cut off switch G to the ON position The indicator lamp P lights up 12 Turn the selector switch H to activate the filling pump Always keep the fluid in the tank at a sufficient level 13 Clo...

Page 313: ...he valve D If the pressure exceeds 1 5 bar turn off the filling pump and temporarily open the spigot D until the correct pres sure is reached Turn the selector switch H to deactivate the filling pump 17 Close the valve C 18 Remove the pipes from the tank 19 Remove the key from the selector switch F and store in a safe place After one hour of operation check that the pressure is correct and if it i...

Page 314: ... filling pump 5 Open the spigot D and keep open until the fluid is running out of the clear tube L in a steady stream no bubbles and the pressure has reached 1 5 bar 6 NOTICE If the pressure ex ceeds 1 5 bar turn off the fill ing pump and temporarily open the valve D until the correct pressure is reached Turn the selector switch H to deactivate the filling pump 7 Close the valve C 8 Remove the pip...

Page 315: ...r C to Service po sition 4 Close the ball valves A B 5 Unscrew cap D 6 Drain out all the coolant 7 Screw on the cap D NOTICE Do not dump the coolant dis pose of it in accordance with the laws in force Tab 8 105 Customer side circuit drainage procedure DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 313 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 316: ... caps G 9 Drain out all the coolant 10 Close the valve F 11 Screw on the caps G 12 Unscrew the screws H 13 Remove the fixed guard L 14 Unscrew the cap M and allow the liquid to flow out from the main pump 15 Screw on the cap M 16 Put the fixed guard L back in place 17 Tighten the screws H NOTICE Do not dump the coolant dis pose of it in accordance with the laws in force Tab 8 106 Drive circuit dra...

Page 317: ...very 1600 hours of work Every 30000 hours of work Filter Cleaning See chapter Cleaning the customer side cir cuit filter on page 315 Main pump Replacement See chapter Replac ing the main pump on page 319 Coolant Replacement Tab 8 107 Scheduled maintenance chart Cleaning the customer side circuit filter 1 Drain the liquid from the customer side circuit 2 Close the inlet and outlet ball valves A B 3...

Page 318: ...ning Clean the machine with detergents allowed by the legislation in force Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 316 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 319: ...han the machine s rated thermal input Check the 3MV 1 mix ing valve Reduce the thermal output E2014 Warning 4 Outlet fluid tempera ture too high The fluid temperature at the outlet is higher than the set point temperature T_set plus a ΔT defined by parameter P 0 1380 for a given time defined by pa rameter P 0 1381 see IndraDrive programming If necessary change the P 0 1380 and or P 0 1381 paramete...

Page 320: ...sconnect the power supply to the machine Make sure that the electricity cannot be accidentally restored The operator must allow the machine to cool down before carrying out any intervention to prevent scalds or burns Replace worn or damaged parts with original spare parts Replacing the filling pump 1 Close the valve A 2 Cut the power supply cables Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 318 407...

Page 321: ...the removal operations described in re verse order 9 Fill the drive circuit see chapter Procedure to fill the drive circuit on page 310 Tab 8 110 Replacing the filling pump Replacing the main pump 1 Close the valve D 2 Unscrew the screws A 3 Remove the fixed guard B 4 Unscrew cap C DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 319 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories ...

Page 322: ... the mixing valve 1 Unscrew the collars A 2 Remove the valve B and the ac tuator C 3 Remove the gaskets D 4 Unscrew the screws E 5 Separate the valve from the actua tor 6 Join the new valve to the actuator 7 Position the gaskets D Replace the gaskets if damaged or worn 8 Place the valve and actuator in their position 9 Screw in the collars A To fit the new valve carry out the removal operations de...

Page 323: ...onnel with suitable skills for the job When dismantling the machine all components must be collected separately for disposal according to their chemical properties in accordance with the rel evant regulations in force With reference to European Directive RAEE electric and electronic compo nents must be either disposed of in authorized landfill sites or in case of a new purchase the machine complet...

Page 324: ...grams WW0035K 0090 Hydraulic diagram Fig 8 81 WW0035K 0090 Hydraulic diagram Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 322 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 325: ...r 0 6 bar Out 0 10 V CP 1 Main Pump 400 Vac 50 60 Hz CM5 5 LLHE 1 Water Water Heatexchanger TS 1 Temperature Sensor Pt100 Pt100 Converter Out 0 10 V M12 DP 1 24Vdc Pressurization Pump 3MV 1 3 Way Valve Actuator NR 1 One Way Valve Tab 8 114 Designations DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 323 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 326: ...08K 0020 Hydraulic diagram Fig 8 82 WW0008K 0020 Hydraulic diagram Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 324 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 327: ... 0 6 bar Out 0 10 V CP 1 Main Pump 400 Vac 50 60 Hz CM1 4 LLHE 1 Water Water Heatexchanger TS 1 Temperature Sensor Pt100 Pt100 Converter Out 0 10 V M12 DP 1 24 Vdc Pressurization Pump 3MV 1 3 Way Valve Actuator NR 1 One Way Valve Tab 8 115 Designations DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 325 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 328: ...rlying principle of the cooling method is the exchange of heat be tween air and liquid through a heat exchanger The fluid is circulated by a pump inside the radiator and cooled by the air flow generated by an electric fan The machine can be equipped with a heater to increase the temperature of the ingoing liquid Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 326 407 Rexroth IndraDrive ML Drive Systems...

Page 329: ...tric fan C Heat exchanger D Expansion tank E Heater F Main pump G Filling pump Fig 8 83 Main parts DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 327 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 330: ...cle and component description The illustration shows the operating principle Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 328 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 331: ...e of the output liquid D Heat exchanger this is used to lower the temperature of the coolant E Ball valve it opens and closes the flow of the coolant from the owner s system F Ball valve it opens and closes the flow of the coolant towards the owner s system DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 329 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 332: ...sure gauge this is used to detect the liquid pressure in the intake manifold P Valve this is used to open and close the flow to the pressure gauge N Q Valve this is used to open and close the flow from the filling pump R Filling pump it fills the cooling circuit of the owner s equipment S Check valve this is used to stop the filling pump intake pipe draining Fig 8 84 Operational cycle and componen...

Page 333: ...ents inadvertent contact with the fan Fig 8 85 Guards Overpressure devices The owner is required to install a safety device on the return pipe to the ma chine that keeps the system pressure within the maximum limit of 2 bar DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 331 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 334: ...Overall dimensions Fig 8 86 Overall dimensions Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 332 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 335: ... coolant pressure bar 2 Maximum outgoing coolant pressure bar 4 5 Maximum coolant temperature C 70 Minimum coolant temperature C 5 Drive circuit coolant monoethyl glycol and demineralised water solution 25 glycol Degree of protection IP 54 Weight kg 250 Tab 8 116 Machine specification DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 333 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessori...

Page 336: ... table titled Connect ing the terminals Pos Meaning Terminals 24V 15 Terminals to enable machine via owner s operating terminal ENABLE 6 7 8 9 Machine error signal terminals Closed contact no error 10 11 12 13 Warning signal terminals Closed contact no Warning Tab 8 117 Connecting the terminals Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 334 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables...

Page 337: ...Vac Inter rupting capacity kW Fuse Position FU1 1 CC 600 200 Delayed FU2 4 FU3 6 FU4 4 FU5 4 FU6 6 Tab 8 118 Fuses DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 335 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 338: ... an Error temperature continues to rise resulting in machine shutdown E Pressure sensor this detects in real time the differential pressure between the intake pipe and the output pipe Through the sensor the outlet pipe pres sure is kept constant F Check valve this is used to stop the filling pump intake pipe draining Tab 8 119 Processing and protection devices Environmental conditions for operatio...

Page 339: ... has been declared compliant with the national and local regula tions in force Residual risks Risk of crushing when moving the machine incorrect manoeuvres or improp er handling of the load may pose a risk of injury to the operators involved Risk of electric shock maintenance operations or replacement of compo nents may involve a risk of electric shock due to accidental contact with live electrica...

Page 340: ...arc discharg es and electric shocks Wear appropriate personal protec tive equipment D This indicates that there is the risk of burns due to contact with hot surfaces allow the machine to cool down before any operation E This indicates that there is the risk of electric shock F Indicates risk of electric shock and that no works must be carried out in live electrical parts G This shows the fuses tec...

Page 341: ...ption each package must be inspected to verify the integrity and the exact quantity of its contents in case of damaged or missing items con tact the importer or the manufacturer directly to discuss the procedure to be adopted Package description The type of packing is chosen according to the selected means of transport and the destination The parcels can be loaded onto a means of transport directl...

Page 342: ...e fragile D This symbol indicates that the package must be kept away from direct sunlight and heat sources to avoid exposing its content to exces sively high temperatures E This symbol indicates the overall weight of the package F The plate shows the procedure for lifting the package Tab 8 121 Package description Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 340 407 Rexroth IndraDrive ML Drive System...

Page 343: ...ld be stored possibly without unpacking it or at least adequately protected in a sheltered place protected from atmospheric agents at a temperature between 20 and 60 C Avoid storing the machine in places where weather conditions could preju dice its good working order DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 341 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional com...

Page 344: ...ly The figure shows how to unpack the machine properly Proceed as outlined below 1 Unscrew the screws 2 Remove the cover 3 Lift the side walls of the package Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 342 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 345: ...ever perfectly barycentric sudden movements may injure the people involved in the operations The packaging material wood propy lene etc can be kept for future use or properly disposed of according to the reg ulations in force Tab 8 122 Unpacking DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 343 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 346: ...ons required by regulations and laws in force The area must be adequately ventilated and illuminated in accordance with the relevant workplace health and safety reg ulations Make sure to leave enough space around the installation area so that interventions can be carried out under safe conditions Tab 8 123 Installation area Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 344 407 Rexroth IndraDrive ML D...

Page 347: ...ses L1 L2 L3 and the earth wire to the relevant ter minals inside the electrical panel Hose connections The owner must install a pressure regulating device on the return pipe Adjust the pressure in the input and return pipes to the value shown in chapter Specifications on page 333 Use flexible tubes with an internal diameter of not less than 25 mm Use connectors with an internal diameter of not le...

Page 348: ...is enabled C Key operated two position stay put selector switch this is used to enable and disable main pump operation The key must be kept by the designated staff member and available to the staff responsible for technical servicing D Two position stay put back lit switch red light this is used to switch the filling pump on and off E Signal light yellow this shows automatic shut down of the heate...

Page 349: ... ON po sition The indicator lamp B lights up 3 Turn the key selector C to automatic posi tion Machine start up must be performed using the operating terminal of the machine to be cooled via the ENABLE connection see chapter ENABLE UNIT ERROR and UNIT WARNING connections on page 334 Tab 8 126 Starting procedure DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 347 407 Rexroth IndraDrive ML Drive Systems w...

Page 350: ...d stopping Remote controlled stopping must be performed using the owner s operating terminal via the ENABLE connection Operation of the main pump stops The electrical panel on the machine remains live Automatic stop The machine stops automatically if the circuit pressure drops below 0 2 bar and the fluid temperature goes above the preset upper limit see parameter P 0 1382 Tab 8 127 Stopping proced...

Page 351: ...Open the valve M 6 Open the valve L 7 Open the valve H 8 Turn the key operated selector switch C to OFF to prevent unexpec ted activation of the main pump 9 Make sure that the remote controlled ENABLE function is activated 10 NOTICE Do not turn the selector switch C to ON as this could cause damage to the main pump Open any of the valves installed outside the machine on the circuit for the machine...

Page 352: ...ector switch C to facilitate circuit bleeding and pressurisation Make sure that the key operated switch is set to ON If it is hard for the system to get up to pressure close the valve M If the pressure exceeds 1 5 bar turn off the filling pump and temporarily open the valve M until the correct pressure is reached Turn the selector switch D to deactivate the filling pump 17 Close the spigot M when ...

Page 353: ...ector switch D to activate the filling pump 5 Open the spigot M and keep open until the fluid is running out of the clear tube N in a steady stream no bubbles and the pressure has reached 1 5 bar 6 NOTICE If the pressure exceeds 1 5 bar turn off the filling pump and temporarily open the valve M until the correct pressure is reached Close the valve M 7 Turn the selector switch D to deactivate the f...

Page 354: ...sition 4 Turn the main cut off switch A to the OFF position 5 The signal light B will switch off 6 Close the ball valves F G 7 Open the valve H 8 Unscrew caps L 9 Drain out all the coolant 10 Close the valve H 11 Screw on the caps L NOTICE Do not dump the coolant dispose of it in accordance with the laws in force Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 352 407 Rexroth IndraDrive ML Drive System...

Page 355: ...scalds or burns Scheduled maintenance chart Interval Component Type of work Reference Every 5000 hours of work Every 30000 hours of work Every 10 years of work Radiator channel Cleaning See chapter Cleaning the radiator and the channel on page 354 Main pump Replacement See chapter Replac ing the main pump on page 358 Cooling fan Replacement See chapter Replac ing the electric fan on page 360 Coola...

Page 356: ...core of the radiator D using compressed air 6 Vacuum away the dirt in the channel again 7 Place the electric fan unit in position 8 Tighten the screws A Tab 8 129 Cleaning the radiator and the channel Machine cleaning Clean the machine with detergents allowed by the legislation in force Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 354 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accesso...

Page 357: ...ary change the P 0 1380 and or P 0 1381 parameters F2011 Error 1 Low pressure alarm The circuit pressure is below 0 2 bar Pressurise the circuit to 1 5 bar F2012 Error 2 High temperature alarm The fluid temperature is above the maximum al lowed temperature limit see parameter P 0 1382 If necessary change the P 0 1382 parame ter Clean the radiator Reduce the level of thermal output to be dissipated...

Page 358: ...ervention is underway In particular disconnect the power supply to the machine Make sure that the electricity cannot be accidentally restored The operator must allow the machine to cool down before carrying out any intervention to prevent scalds or burns Replace worn or damaged parts with original spare parts Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 356 407 Rexroth IndraDrive ML Drive Systems wi...

Page 359: ...move the strap C 7 Extract the hose D 8 Repeat the same operations to re move the other flexible tube 9 Unscrew the screws E 10 Remove the pump 11 Install the new pump To fit the new pump carry out the removal operations described in re verse order Tab 8 131 Replacing the filling pump DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 357 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessori...

Page 360: ...achine from the power supply source 2 Unscrew the screws A 3 Remove the fixed guard B 4 Close the valve C Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 358 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 361: ...11 Remove the pump 12 Install the new pump To fit the new pump carry out the removal operations described in re verse order NOTICE The spare pump is sup plied with the fittings mounted Do not unscrew the fittings as this could cause liquid leakage Tab 8 132 Replacing the main pump DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 359 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories a...

Page 362: ...uses descrip tion on page 335 Replacing the coolant Drain out the machine s hydraulic circuit see chapter Procedure to empty the hydraulic circuit on page 352 Fill the hydraulic circuit see chapter Procedure to fill the hydraulic circuit on page 349 Scrapping and disposal Scrapping operations must be handled by specialised personnel with suitable skills for the job When dismantling the machine all...

Page 363: ...working life to the appropriate collection structures failure to comply shall lead to penalties foreseen by the regulations in force DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 361 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 364: ...grams WA0035K 0090 Hydraulic diagram Fig 8 91 WA0035K 0090 Hydraulic diagram Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 362 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories additional components ...

Page 365: ... Vac 50 60 Hz 3P IP55 TS 1 Temperature Sensor Pt100 Pt100 Converter Out 0 10 V M12 DP 1 24Vdc Pressurization Pump PS 1 Diff Pressure Sensor 0 6 bar Out 0 10 V ALHE 1 Air Water Heatexchanger DT 1 Drain Tank 2L PI 1 Pressure Indicator 0 4 bar NR 1 One Way valve Tab 8 134 Designations DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 363 407 Rexroth IndraDrive ML Drive Systems with HMU05 Cables accessories ...

Page 366: ...Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 364 407 Rexroth IndraDrive ML Drive Systems with HMU05 ...

Page 367: ...s free domicile to the following address Bosch Rexroth AG Electric Drives and Controls Buergermeister Dr Nebel Strasse 2 97816 Lohr am Main Germany Packaging The packaging materials consist of cardboard wood and polystyrene These materials can be recycled anywhere without any problem For ecological reasons please refrain from returning the empty packages to us Batteries and accumulators Batteries ...

Page 368: ...e of plastics can contain flame retardants These plastic parts are labeled according to EN ISO 1043 They have to be recycled separately or disposed of according to the valid legal requirements Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 366 407 Rexroth IndraDrive ML Drive Systems with HMU05 Environmental protection and disposal ...

Page 369: ...Additional information on service repair e g delivery addresses and training can be found on our internet sites Service worldwide Outside Germany please contact your local service office first For hotline numbers refer to the sales office addresses on the internet Preparing information To be able to help you more quickly and efficiently please have the following information ready Detailed descript...

Page 370: ...Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 368 407 Rexroth IndraDrive ML Drive Systems with HMU05 ...

Page 371: ...age inductance of the mains transformer t1 Time depends on whether the supply unit is connected to a control unit via the communication and on how fast this control unit is booting up t2 Time can be set by the user Take the time into account which is required for run up of all devices connected to IndraBus This time depends on the control unit or the machine t3 Switch on pulse t4 HNA charges the D...

Page 372: ...ss starts You can make sure this order is observed by appropriate switch elements e g by a control cabinet main switch with leading auxiliary contact For this purpose connect the auxiliary contact in series with mains OFF t1 Time depends on device mains contactor off delay OFF re lates to the hardware input Fig 11 2 Signal sequences when switching off Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 370...

Page 373: ...2 4 In Current carrying capacity table row select the value that is immedi ately above the value determined in the first step 5 In Fuse table row read corresponding fuse 6 In Cross section A table row read corresponding required cross section International except for USA Canada installation type B1 Country of use international except for USA Canada Fuse IN A Current carrying ca pacity 0 87 IZ 40 A...

Page 374: ...3 300 Tab 11 1 Line cross sections and fuses B1 according to EN 60204 1 2006 Table 6 for 150mm and more DIN IEC 60364 5 52 2004 Table B 52 4 International except for USA Canada installation type B2 Country of use international except for USA Canada Fuse IN A Current carrying ca pacity 0 87 IZ 40 A Cross section A mm2 Installation type B2 1 2 3 2 1 6 0 75 4 3 3 0 75 6 5 0 0 75 10 8 5 0 75 16 10 1 1...

Page 375: ... 100 272 22 3 70 125 327 03 3 95 160 376 36 3 120 160 411 08 3 150 200 465 89 3 185 200 542 62 3 240 250 619 35 3 300 Tab 11 2 Line cross sections and fuses B2 according to EN 60204 1 2006 Table 6 for 150mm and more DIN IEC 60364 5 52 2004 Table B 52 4 International except for USA Canada installation type E Country of use international except for USA Canada Fuse IN A Current carrying ca pacity 0 8...

Page 376: ...316 68 185 425 374 10 240 500 432 39 300 160 272 83 2 x 70 200 331 30 2 x 95 250 384 19 2 x 120 250 444 05 2 x 150 315 506 69 2 x 185 400 598 56 2 x 240 400 691 82 2 x 300 160 358 09 3 x 70 200 434 83 3 x 95 200 504 25 3 x 120 250 582 81 3 x 150 250 665 03 3 x 185 315 785 61 3 x 240 400 908 02 3 x 300 Tab 11 3 Line cross sections and fuses E according to EN 60204 1 2006 Ta ble 6 for 150mm and more...

Page 377: ... 4 AWG 110 100 3 AWG 125 115 2 AWG 150 130 1 AWG 175 150 1 0 AWG 200 175 2 0 AWG 225 200 3 0 AWG 250 230 4 0 AWG 300 255 250 kcmil 300 285 300 kcmil 350 310 350 kcmil 350 335 400 kcmil 400 380 500 kcmil 450 420 600 kcmil 600 460 700 kcmil 600 475 750 kcmil 600 490 800 kcmil 600 520 900 kcmil 800 545 1000 kcmil 800 590 1250 kcmil 800 625 1500 kcmil 800 650 1750 kcmil DOK INDRV HXX05 PR02 EN P Bosch...

Page 378: ...l 600 920 2 700 kcmil 600 950 2 750 kcmil 600 980 2 800 kcmil 800 1040 2 900 kcmil 800 1090 2 1000 kcmil 200 450 3 1 0 AWG 225 525 3 2 0 AWG 250 600 3 3 0 AWG 300 690 3 4 0 AWG 300 765 3 250 kcmil 350 855 3 300 kcmil 350 930 3 350 kcmil 400 1005 3 400 kcmil 450 1140 3 500 kcmil 200 600 4 1 0 AWG 225 700 4 2 0 AWG 250 800 4 3 0 AWG 300 920 4 4 0 AWG 300 1020 4 250 kcmil 350 1140 4 300 kcmil 350 124...

Page 379: ... 52 e g multi core line routed in cable duct E in accordance with EN 60204 1 e g multi core line routed on open cable tray In accordance with NFPA 79 external wiring UL508A internal wiring NEC NFPA 70 1 cable with 3 conductors 1 neutral conductor and 1 equip ment grounding conductor Routed in pipe on the wall Internal wiring Routing inside of control cabinet or inside of devi ces External wiring R...

Page 380: ...12 5 5 a 0 88 0 94 1 00 1 1 1 18 1 32 1 52 Tab 11 5 Ambient temperature correction factor in accordance with EN 60204 1 2006 and NFPA 79 2007 Correction factor for bundling lines installation methods B2 and E and cir cuits installation method B11 Number of lines 1 2 3 4 5 Correction factor according to EN 60204 1 2006 table D 2 1 1 25 1 43 1 54 1 67 Correction factor according to NFPA 79 2007 tabl...

Page 381: ...tallation pipes and in installation channels to be opened C Cables or lines on walls E Cables or lines on open cable trays Fig 11 3 Installation methods compare IEC 60364 5 52 VDE0298 7 EN 60204 1 DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 379 407 Rexroth IndraDrive ML Drive Systems with HMU05 Appendix ...

Page 382: ...IndraDrive C M series drive components sizes between 110 and 350 A can be connected with a maximum DC bus cable length of 2 m without DC bus fuses For drive components lower than 110 A or a DC bus cable length over 2 m DC bus fuses should be installed Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 380 407 Rexroth IndraDrive ML Drive Systems with HMU05 Appendix ...

Page 383: ...posite made of copper Cu and aluminum Al Use cupal disks whenever contact is established between the aluminum con tact point and any material other than aluminium Clean both sides of the cupal disks with abrasive fleece before connecting them and then grease the cupal disks with a thin layer of contact grease If the connection is opened after operation abrade and grease the connec tions and the cu...

Page 384: ...ical stress Always hold the aluminum contact point and ring terminal in place when tight ening the screw connection Screw Tightening torque Nm M4 1 9 M5 3 7 M6 6 3 M8 15 M10 30 M12 52 Tab 11 7 Tightening torque Protection against corrosion To protect the connection against corrosion apply a thin layer of anticorro sive paste contact grease to the connection Suitable anticorrosive paste acid and al...

Page 385: ... of leakage capacitance Cab_Mg Total value of motor leakage capacitance Cab_Kg Total value of cable leakage capacitance Fig 11 5 Total leakage capacitance The total capacitance Cab_Mg is the sum of the capacitances of the individual motors See motor documentation for these capacitances Cab motor Leakage capacitance of a motor Fig 11 6 Total leakage capacitance of motor CY_K typ Capacitance per uni...

Page 386: ...e Power core cross section Leakage capacitance mm2 CY_K_typ nF m INK0653 1 0 0 6 INK0650 1 5 0 8 INK0602 2 5 0 7 INK0603 4 0 0 8 INK0604 6 0 0 8 INK0605 10 0 1 0 INK0606 16 0 1 2 INK0607 25 0 1 1 INK0667 35 0 1 2 INK0668 50 0 1 3 Last modification 2007 11 08 Tab 11 8 INK technical data excerpt Excerpt of data sheet on bulk cables Type Power core cross section Leakage capacitance CY_K_typ mm2 nF m ...

Page 387: ... 2 0 785 4 867 Nominal load HMU05 1 F0170 400 4 2 1 262 5 157 Peak load HMU05 1 F0170 500 4 2 3 786 3 455 Partial load 50 HMU05 1 F0170 500 4 2 0 453 4 150 Nominal load HMU05 1 F0170 500 4 2 2 135 4 564 Peak load HMU05 1 F0220 400 4 2 3 189 4 224 Partial load 50 HMU05 1 F0220 400 4 2 2 247 1 646 Nominal load HMU05 1 F0220 400 4 2 2 244 2 482 Peak load HMU05 1 F0220 500 4 2 4 871 3 620 Partial load...

Page 388: ...4 2 3 781 3 925 Nominal load HMU05 1 F0430 400 4 2 3 440 3 948 Peak load HMU05 1 F0430 500 4 2 4 911 3 338 Partial load 50 HMU05 1 F0430 500 4 2 3 887 3 789 Nominal load HMU05 1 F0430 500 4 2 3 772 3 892 Peak load HMU05 1 F0540 400 4 2 3 175 3 334 Partial load 50 HMU05 1 F0540 400 4 2 2 344 3 784 Nominal load HMU05 1 F0540 400 4 2 2 080 3 869 Peak load HMU05 1 F0540 500 4 2 3 352 3 121 Partial loa...

Page 389: ...e Q indicates how much coolant volume ΔV per time interval Δt flows through the compo nent Q Flow rate in l min ΔV Coolant volume in l Δt Time interval in minutes in which ΔV flows Fig 11 9 Flow rate Calculating the required flow rate If the power dissipation PV and the coolant are known the required flow rate Q can be calculated with a selected coolant temperature increase ΔT The required flow ra...

Page 390: ...onent Flow diagram Δp Pressure decrease ΔpQmin Pressure decrease for Qmin Q Flow rate Qmin Min required flow rate see technical data for each component Fig 11 11 Flow diagram All other parts of the cooling system through which the coolant flows tubes valves etc also cause pressure decreases Calculating pressure decrease The pressure decrease Δp in liquid cooled drive components is indicated in the...

Page 391: ... based on a cooling system with four motors con nected in parallel 1 Liquid cooled motor 2 Main distributor of cooling liquid 3 Cooling device cooling or refrigerating unit 4 Heat dissipation 5 Higher level cooling medium Fig 11 13 Arrangement with liquid cooled motors DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 389 407 Rexroth IndraDrive ML Drive Systems with HMU05 Appendix ...

Page 392: ...r level cooling medium Q Flow rate Δp Pressure decrease Ftg fittings Dc drive components Chk choke L line P coolant pump He heat exchanger ΔPv Power dissipation of a drive component being discharged Fig 11 14 Liquid cooling circuit diagram for four liquid cooled drive components Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 390 407 Rexroth IndraDrive ML Drive Systems with HMU05 Appendix ...

Page 393: ...ce Air liquid cooling unit P01 kW K Liquid liquid cooling unit P01 kW K Refrigerating unit PRefrig kW Make installation plan Components determine interconnection series parallel Lines determine lengths and diameters Size coolant pump Fluidic data of cooling system branches Parallel connection of branches Series connection of branches Pressure decrease in overall system Working point of pump ΔH m Q...

Page 394: ...ion Flow rate Qchn l min Pressure decreases Coolant line Length ln m Added length ladd m Ø d mm ΔpL Δl for Qch hPa m ΔpLn hPa Drive component Δpchn hPa Additional component ΔpAdd hPa Total pressure de crease Without choker valve ΔpBn hPa Only with parallel con nection With choker valve 1 ΔpBn hPa Parallel connection of branches no Total pressure de crease Δpb hPa Bosch Rexroth AG DOK INDRV HXX05 P...

Page 395: ... for Qch hPa m ΔpL hPa Heat exchanger ΔpHe hPa Fittings ΔpFtg hPa Additional component ΔpAdd hPa Overall cooling system ΔpCs hPa Working point of coolant pump Required delivery height ΔH m Required delivery rate QP l min 1 The required coolant flow Qchn is set with the choker valve in the cooling system branch 2 The coolant flow Qchn is set according to the pressure decrease over the cooling syste...

Page 396: ...nts Form Gathering technical data for temperature increase 10 K Drive com ponent Pv kW Coolant Pv kW Air Q l min Δp hPa ΔT C V l HMU05 1N F0540 7 5 1 2 15 8 1 3 10 xxx HMU05 1N F0340 4 5 1 9 0 6 xxx HMU05 1N F0140 2 5 0 5 4 5 0 4 xxx HNL05 1R 4 1 8 10 1 5 xxx HNA05 1 0 15 ΣPvCl 18 5 kW ΣPvAir 4 65 kW ΣVch xxx Tab 11 14 Gathering technical data Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 394 407 Rex...

Page 397: ...the cooling device The absorbed thermal energy should be dissipated into the ambient air with an air liquid cooling unit The cooling liquid must dissipate 18 5 kW of heat output into the ambient air The maximum expected air temperature is 35 C Specific cooling capacity PV 18 5 kW sum of power dissipations from technical data of drive com ponents Tin 60 C max coolant inlet temperature into cooling ...

Page 398: ...rged Fig 11 16 Liquid cooling circuit diagram Sizing the coolant pump Fluidic data of cooling system branches Cooling system branch 1 2 3 4 Drive component Type designation Flow rate Qchn l min Pressure decreases Coolant line Length ln m Added length ladd m Diameter d mm ΔpL Δl for Qch hPa m ΔpLn hPa Drive component Δpchn hPa Additional component ΔpAdd hPa Total pressure decrease Without choker va...

Page 399: ...xchanger ΔpHe hPa Fittings ΔpFtg hPa Additional component ΔpAdd hPa Overall cooling system ΔpCs hPa Working point of coolant pump Required delivery height ΔH m Required delivery rate QP l min 1 The required coolant flow Qchn is set with the choker valve in the cooling system branch 2 The coolant flow Qchn is set according to the pressure decrease over the cooling system branches Δpb Tab 11 15 Sizi...

Page 400: ...ive components VL line lengths x flow cross section VDist as indicated by the distributor manufacturer Conclusion The data determined for the cooling device can be retained in the procedure diagram This data can be used to contact the supplier of the cooling device Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 398 407 Rexroth IndraDrive ML Drive Systems with HMU05 Appendix ...

Page 401: ... 384 Encoder cables selection table 52 Leakage capacitance 384 Overview 147 Shield connection 131 Calculations Leakage capacitance 383 Liquid cooling 387 Mains side phase current 110 Phase current 110 Capacitance Power cables 384 CCC China Compulsory Certification 118 CE label 117 Certifications 117 Characteristic Fuses 377 China Compulsory Certification CCC 118 Compatibility With foreign matters ...

Page 402: ...ng 114 CSB02 5 BASIC 23 Type code 20 CSH02 5 ADVANCED 23 Type code 20 CSx02 5 Functional equipment 23 Cupal disks Aluminum contact points 381 D Data Ambient conditions 60 HLL05 243 HLR05 251 HLT05 259 HML05 229 HMU05 control voltage 137 HMU05 cooling 90 HMU05 DC bus 141 HMU05 dimensional drawing 82 HMU05 dimensions 82 HMU05 distances 90 HMU05 housing dimensions 89 HMU05 insulation 89 HMU05 inverte...

Page 403: ...ts 346 Electrical connection 345 ENABLE UNIT ERROR and UNIT WARNING connections 334 Fuses description 335 General description of the machine 326 Handling and installation safety recom mendations 339 Handling and lifting the packed unit 341 Hose connections 345 Hydraulic diagram 362 Hydraulic diagram WA0035K 0090 362 Information and safety signs 338 Information for Use 346 Machine specification 333...

Page 404: ... 250 Installation 252 Type code 249 HLT05 Braking unit 255 Connection diagram 260 Connection points 263 Data 259 Dimensional drawing 256 Dimensions 256 Display elements 279 LEDs 279 Type code 255 HML05 Assignment 220 Data 229 Dimensional drawing 221 Dimensions 221 Type code 219 HMS05 Drive controller 12 HMU05 Assigning additional components 112 Brief description 45 Connection points overview 124 C...

Page 405: ...6 L L L DC bus 130 L1 L2 L3 Mains motor connection 126 Leakage capacitance Calculating 383 Determining 383 HMU05 systems for high leakage capaci tances 54 HMU05 systems for medium leakage ca pacitances 53 Power cables 384 Leakage currents Cause 103 Line Correction factor 378 Cross sections dimensioning 371 Fuses dimensioning 371 Liquid cooling Calculation criteria 387 Condensation protection 75 Co...

Page 406: ...arallel operation Power extension 114 PELV 38 Performance features HMU05 15 PF55 PF56 PF57 PF58 LEDs HLT05 279 LEDs HNA05 184 Phase current Calculating 110 Power extension Parallel operation 114 Power supply unit 24 V 280 24V 20A connection diagram 282 24V 40A connection diagram 283 Data 281 Pressure decrease Calculation 388 Production processes 365 Project planning Electrical project planning 94 ...

Page 407: ...evice 120 HNL 202 U UL File numbers 117 Listing 117 Ratings HMU05 79 Ungrounded mains 106 Use Appropriate use 31 Inappropriate use 32 V Voltage testing 119 W WA0035K 0090 Hydraulic diagram 362 WATER IN OUT Cooling liquid connection 135 WW0008K 0020 Hydraulic diagram 324 WW0035K 0090 Hydraulic diagram 322 X XD1 Mains voltage equipment grounding con ductor 173 XD02 DC bus 267 XD2 DC bus 174 XD4 Brak...

Page 408: ...Mains contactor acknowledgment mes sages 183 Y Y capacitor pair HAS04 1 003 247 Bosch Rexroth AG DOK INDRV HXX05 PR02 EN P 406 407 Rexroth IndraDrive ML Drive Systems with HMU05 Index ...

Page 409: ...Notes DOK INDRV HXX05 PR02 EN P Bosch Rexroth AG 407 407 Rexroth IndraDrive ML Drive Systems with HMU05 ...

Page 410: ... Electric Drives and Controls P O Box 13 57 97803 Lohr Germany Bgm Dr Nebel Str 2 97816 Lohr Germany Phone 49 9352 18 0 Fax 49 9352 18 8400 www boschrexroth com electrics R911344279 R911344279 DOK INDRV HXX05 PR02 EN P ...

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