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Bosch Rexroth IndraDrive Mi KCU02, Project Planning Manual

The Bosch Rexroth IndraDrive Mi KCU02 is a state-of-the-art industrial drive controller. Unlock its full potential with the comprehensive Instruction Manual, available for free download on our website. This manual provides detailed guidance and insights to ensure smooth operation and maximum efficiency. Get yours now at manualshive.com!

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1.1.2 

Features

KSM02 motor-integrated servo drive

*

Power is supplied to the drives via HMV or HCS (alternative

power supply: KMV); HMS, HMD: optional

Fig. 1-1:

IndraDrive Mi with KSM02 – Features

2/407

System presentation

 IndraDrive Mi Drive Systems with KCU02, KSM02,

KMS02/03, KMV03, KNK03, KLC03

Bosch Rexroth AG R911335703_Edition 04

Summary of Contents for Rexroth IndraDrive Mi KCU02

Page 1: ...IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Project Planning Manual R911335703 Edition 04 ...

Page 2: ...l as in the event of applications for industrial property rights 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 All rights are reserved with respect to the content of this documentation and the availability of the product Editorial Department Engineering Drives JoGo...

Page 3: ...e 13 1 3 1 Introduction 13 1 3 2 KSM02 motor integrated servo drive 14 KSM02 type code 14 1 3 3 KMS02 near motor servo drive 17 KMS02 type code 17 1 3 4 KMS03 near motor servo drive 19 KMS03 type code 19 1 3 5 KCU02 drive connection box 20 KCU02 2 type code 20 1 3 6 KMV03 supply unit 21 KMV03 type code 21 1 3 7 KNK03 mains filter 22 KNK03 type code 22 1 3 8 KLC03 DC bus capacitor unit 23 KLC03 typ...

Page 4: ... Protection against pressurized systems 43 3 4 Explanation of signal words and the Safety alert symbol 44 4 General data and specifications 45 4 1 Acceptance tests and approvals 45 4 2 Transport and storage 47 4 2 1 Transporting the components 47 4 2 2 Storing the components 47 4 3 Installation conditions 50 4 3 1 Ambient and operating conditions 50 4 3 2 Control cabinet design and cooling 56 4 3 ...

Page 5: ... KLC03 1N B04M7 dimensional drawing thermal interface 102 5 6 3 KLC03 1N A04M7 dimensional drawing natural convection 103 5 6 4 KLC03 1N W04M7 dimensional drawing forced cooling 104 5 7 KNK03 mains filter 105 5 7 1 KNK03 data sheet 105 5 7 2 KNK03 1A NR B Ixxxx dimensional drawing thermal interface 106 5 7 3 KNK03 1A NR Axxxx dimensional drawing natural convection 107 5 7 4 KNK03 1A NR Wxxxx dimen...

Page 6: ...2 Multi Ethernet 146 6 2 4 X49 L3 Safe Torque Off 148 Data 148 Pin Assignment Function 148 6 2 5 X50 E Stop Input 149 6 2 6 X52 Status Messages 150 6 2 7 X53 Control Voltage Output 151 6 2 8 X54 DC Bus Equipment Grounding Conductor Output KSM02 KMS02 152 6 2 9 DC Bus Connection L L 153 6 2 10 Control Voltage Supply 24V 0V 156 6 3 KSM02 connection points 158 6 3 1 Positions of the connection points...

Page 7: ...digital inputs outputs 197 6 5 8 X103 1 X103 2 hybrid cable connection point 197 6 5 9 X107 programming module 197 6 5 10 X108 X109 communication output coupling 197 6 5 11 X118 X119 external communication 197 6 5 12 X141 safety technology 197 6 5 13 Second equipment grounding conductor connection point 197 6 6 KMV03 connection points 198 6 6 1 Positions of the connection points 198 6 6 2 X37 X38 ...

Page 8: ...y HMV01 HMV02 HCS01 HCS02 or HCS03 217 Supply units 217 7 1 4 Power supply by HCS01 218 7 1 5 Power supply by KMV03 and KNK03 218 KMV03 supply unit KNK03 mains filter 218 7 1 6 Control voltage power requirement 42 V 219 7 1 7 KCU02 drive connection box 220 General information 220 Control voltage supply 220 Power supply to KSM KMS KCU 222 7 1 8 KLC03 DC bus capacitor unit 226 Application notes 226 ...

Page 9: ... 254 7 3 5 Mechanically attaching driving elements 255 General information 255 Redundant bearings 255 Gearbox attachment 256 Coupling attachment 256 Bevel gear pinions or skew bevel driving pinions 256 8 Identification 259 8 1 Scope of supply 259 8 1 1 KCU02 259 8 1 2 KSM02 KMS02 259 8 1 3 KMS03 260 8 1 4 KMV03 260 8 1 5 KNK03 260 8 1 6 KLC03 260 8 2 Identifying and checking the delivered componen...

Page 10: ...277 9 1 2 System overview 278 Available connection points 278 9 1 3 Cold plate 279 9 2 KSM 280 9 2 1 Required Steps to Follow 280 Preparations for Mounting 280 Mounting KSM 280 9 2 2 Mechanical Interfaces 281 Flange Mounting 281 9 2 3 Practical tips 281 9 3 KMS 282 9 3 1 Required steps to follow 282 Preparations for mounting 282 Mounting KMS 282 9 4 KCU02 283 9 4 1 Mounting depths 283 9 4 2 Touch ...

Page 11: ...8 10 9 HAS05 1 023 HCS01 adapter 310 10 10 HAS05 1 024 passive 42 V supply unit 316 10 10 1 View 316 10 10 2 Purpose 316 10 10 3 Properties 317 10 10 4 Dimensions 318 10 10 5 Connection 319 X37 319 X103 1 X103 2 hybrid cable connection point 319 10 11 HAS10 mechanical mounting parts 320 10 11 1 Type code 320 10 11 2 Use 321 10 11 3 Scope of supply 322 10 12 RKB0021 Multi Ethernet cable 325 10 13 R...

Page 12: ...e 347 LED H25 displays 348 LED H26 displays 349 11 3 4 Diagnostic messages via parameters 354 11 3 5 Firmware functions 354 Easy startup mode 354 Analog outputs 355 Oscilloscope function 355 Patch function 355 Monitoring function 355 Logbook function 355 11 4 Service functions troubleshooting 356 11 4 1 General information 356 11 4 2 Replacing fuses F4 and F5 357 11 4 3 Deactivating and Dismountin...

Page 13: ...igital inputs 369 14 1 1 Digital inputs type A standard 369 14 1 2 Digital inputs safety technology L options 369 14 1 3 Digital inputs safety technology S options 370 14 2 Digital outputs 371 14 2 1 Digital outputs safety technology L options 371 14 2 2 Digital outputs safety technology S options 372 14 3 Two piece connection cover 374 14 4 Sizing mains filters drive system 375 Index 395 IndraDri...

Page 14: ...XII IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 15: ...onnect the servo drives to HMV supply units or HCS converters KMV03 supply unit Component used to supply servo drives KNK03 mains filter with integrated mains choke Mains connection component for KMV03 supply units KLC03 DC bus capacitor unit Component used to buffer the DC bus voltage Components of the IndraDrive Mi product range allow a drive system to be designed without a control cabinet Suppl...

Page 16: ...upplied to the drives via HMV or HCS alternative power supply KMV HMS HMD optional Fig 1 1 IndraDrive Mi with KSM02 Features 2 407 System presentation IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 17: ... the drives via HMV or HCS alternative power supply KMV HMS HMD optional Fig 1 2 IndraDrive Mi with KMS02 Features IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 3 407 System presentation R911335703_Edition 04 Bosch Rexroth AG ...

Page 18: ...unit Degree of protection IP65 Integrated overload protection Cooling types natural convection forced cooling with fan cold plate mounting KMS03 near motor servo drive Degree of protection IP65 With heat sink KMS03 1B A With thermal interface for cold plate mounting KMS03 1B B MultiEncoder interface Hiperface Endat 2 1 2 2 SSI Safety 4 Wire 1 Vpp 4 digital inputs and outputs two thereof can be use...

Page 19: ...without connector is named REH0800 hybrid cable incl communication or REH0803 hybrid cable without communication devices with external communication ES option use separate cables for communication Tab 1 1 IndraDrive Mi with KMS03 Features Cooling types Thermal interface cold plate insulated mounting Forced cooling Natural convection Tab 1 2 Cooling types example KMV03 IndraDrive Mi Drive Systems w...

Page 20: ...depends on the following factors DC bus power power requirement of control voltage Y capacitance and leakage capacitance of axes cable lengths The module bus always limits the maximum number to 30 Tab 1 3 Maximum number of drives per drive line 6 407 System presentation IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 21: ...er KMV03 supply unit KLC03 DC bus capacitor unit KMS03 near motor servo drive on page 4 KNK03 mains filter Mains filters reduce radio interference and mains pollution chapter KNK03 mains filter KMV03 supply unit KLC03 DC bus capacitor unit KMS03 near motor servo drive on page 4 KLC03 DC bus capacitor unit DC bus capacitor units buffer energy in the DC bus of the drive system chapter KNK03 mains fi...

Page 22: ...id cable without connector is named REH0800 hybrid cable incl communication or REH0803 hybrid cable without communication chapter 5 9 RKH hybrid cable on page 114 1 2 2 Series See section Type code KCU02 drive connection box KSM02 motor integrated servo drive KMS02 near motor servo drive KMS03 near motor servo drive KMV03 supply unit KNK03 mains filter KLC03 DC bus capacitor unit 8 407 System pres...

Page 23: ...s the system structure Possible supply units Rexroth IndraDrive HMV01 1E R or HMV02 1R supply unit Rexroth IndraDrive HCS02 1E or HCS03 1E converter Rexroth IndraDrive converter HCS01 1E W0054 HAS05 1 023 Rexroth IndraDrive KMV03 1R supply unit The IndraDrive Mi drive system in the figure below contains KSM motor integrated servo drives This system structure also applies to IndraDrive Mi drive sys...

Page 24: ...ve KMS02 near motor servo drive and motor MSK Servo motor optional RHS Terminal connector RKB0021 Ethernet cable of variable length RKB0013 Ethernet cable of defined length max 0 55 m RKG Encoder cable optional RKH Hybrid cable RKL Motor cable optional X14 Mains synchronization only with regenerative HMVs X103 1 Connection of RKH hybrid cable at first KSM02 Fig 1 3 IndraDrive Mi drive system with ...

Page 25: ...01 fig 9 8 IndraDrive Mi system with HCS01 1E W0054 on page 293 HCS02 fig 9 5 IndraDrive Mi drive system with HCS02 on page 290 HCS03 fig 9 6 IndraDrive Mi drive system with HCS03 on page 291 KMV03 fig 9 9 IndraDrive Mi drive system with KNK03 KMV03 KMS03 on page 294 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 11 407 System presentation R911335703_Edition 04 Bosch Rexro...

Page 26: ...ed functional restrictions as compared to drive controllers with separate control sections Safety technology not all safety functions available No analog inputs or outputs No digital and analog I O extensions No additional encoder evaluations or encoder emulations 12 407 System presentation IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition ...

Page 27: ...mation For product selection and purchase order take the following aspects into account Observe detailed information and instructions in chapter 5 Technical data of the components on page 61 and chapter 7 Notes on project planning on page 217 Before placing a purchase order have our sales representative check whether individual options are available The figure illustrates the basic structure of th...

Page 28: ...ing 42 61 Winding 61 Cooling type N Natural convection Encoder S1 Optical encoder Hiperface single turn 128 signal periods S3 Capacitive encoder Hiperface single turn 16 signal periods M1 Optical encoder Hiperface multi turn absolute 128 signal periods M3 Capacitive encoder Hiperface multi turn absolute 16 signal periods Electrical connection H Connector hybrid Shaft G Plain shaft with shaft seali...

Page 29: ... Safe Motion with SBC Supply voltage D7 DC 750 V Other design AE ATEX version external master communication Multi Ethernet 2 M12 AN ATEX version AT ATEX version Multi Ethernet output coupling 2 M12 ES External master communication Multi Ethernet 2 M12 NN None TO Multi Ethernet output coupling 2 M12 Firmware FW Firmware has to be ordered as a separate subposition Tab 1 5 KSM02 type code Size Length...

Page 30: ...1 061 071 076 Tab 1 7 Other design Encoder Safety option NN L3 S3 SD S1 M1 S3 M3 Tab 1 8 Safety option 16 407 System presentation IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 31: ... type A Natural convection exterior heat sink Maximum current 018 18 A Degree of protection P IP65 Nominal DC bus voltage D7 DC 750 V Master communication ET Multi Ethernet Encoder interface ENH Encoder Hiperface NNN Without 3 4 ENA Encoder ACURO link 3 Safety option L3 Safe Torque Off STO S3 Safe Motion without SBC 1 3 SD Safe Motion 1 NN Without IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02...

Page 32: ...ngular connector motor and encoder connection Multi Ethernet output coupling 2 M12 2 WE Angular connector motor and encoder connection external master communication Multi Ethernet 2 M12 2 Firmware FW Firmware has to be ordered as a separate subposition 1 Only if encoder interface ENH ENA 2 Only if encoder interface ENH 3 Only if other design WN WT WE 4 Only if safety option L3 NN Tab 1 9 KMS02 typ...

Page 33: ...036 36 A Degree of protection P IP65 Nominal DC bus voltage D7 DC 750 V Master communication ET Multi Ethernet Encoder interface END Encoder Hiperface and digital encoder Safety option L3 Safe Torque Off STO SD Safe Motion NN Without Other design ES External master communication Multi Ethernet 2 M12 NN Without TO Multi Ethernet output coupling 2 M12 Firmware FW Firmware is required to operate the ...

Page 34: ...n Master communication input ET Multi Ethernet Master communication output ET Multi Ethernet DC fuse 025 Nominal current 25 A Interface NN None Control panel N Without Other design NN None Firmware NW Without firmware Tab 1 11 Type code KCU02 2 KCU02 2 vs KCU02 1 KCU02 2 is fully downward compatible with version KCU02 1 and completely replaces this type 20 407 System presentation IndraDrive Mi Dri...

Page 35: ...ced cooling exterior heat sink mounted fan Rated power 0007 7 5 kW 1 01K5 1 5 kW 2 05K0 5 kW 3 06K0 6 kW 4 Degree of protection P IP65 Nominal DC bus voltage D7 DC 750 V Master communication ET Multi Ethernet Other design NNNN None Firmware FW Firmware is required to operate the device 1 Rated power 0007 only with cooling type B 2 Rated power 01K5 only with cooling type I 3 Rated power 05K0 only w...

Page 36: ...terface cold plate mounting I Thermal interface insulated mounting W Forced cooling exterior heat sink mounted fan Nominal current 0002 2 3 A 1 0008 8 1 A 3 0010 9 5 A 4 0012 12 A 2 Degree of protection P IP65 Leakage capacitance U226 226 nF Mains connection voltage A4 3 AC 380 V 10 3 AC 500 V 10 Other design NNNN None 1 Nominal current 0002 with cooling type I only 2 Nominal current 0012 with coo...

Page 37: ...ne Cooling type A Natural convection exterior heat sink B Thermal interface cold plate mounting W Forced cooling exterior heat sink mounted fan Nominal capacitance 04M7 4 7 mF Degree of protection P IP65 Nominal DC bus voltage D7 DC 750 V Other design NNNN None Tab 1 14 KLC03 type code 1 3 9 Firmware Type code see Functional Description of firmware IndraDrive Mi Drive Systems with KCU02 KSM02 KMS0...

Page 38: ...ntroller Included Safe Motion safety option Updated type code Revised E Stop function Revised sizing of hybrid cable length and control voltage power consumption Included information on locking pins at connectors and connection points of hybrid cables Included conductor colors of hybrid cable for connection points X52 X53 and X54 Included internal design of digital inputs outputs X37 X38 24 407 Sy...

Page 39: ...ication HAS05 1 018 019 020 accessories Hybrid cable without communication lines REH0803 Drive systems with HCS01 1E W0054 supply unit Modified contents KSM02 type code KMS02 type code Allowed maximum number of KCU02 KMS02 KSM02 devices per drive line increased from 20 to 30 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 25 407 System presentation R911335703_Edition 04 Bos...

Page 40: ...awing fig 5 12 KSM02 1B 041C dimensions ATEX design on page 74 HAS05 1 021 Hybrid joint HAS05 1 023 HCS01 adapter HAS05 1 024 Passive 42 V supply unit RKH09xx Hybrid cable with circular connector RH2 030 Hybrid cable KMS02 MS2N Sizing mains filters for drive systems with IndraDrive Mi C M Cs System type plate for modules of configured variants Two piece connection cover for KMV03 KNK03 KLC03 KMS03...

Page 41: ...B01 CSH01 CDB01 Project Planning Manual CSH PRxx EN P 295012 Drive Controllers Control Sections CSE02 CSB02 CDB02 CSH02 Project Planning Manual Cxx02 PRxx EN P 338962 Additional Components and Accessories Project Planning Manual ADDCOMP PRxx EN P 306140 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 M...

Page 42: ...l number R911 Rexroth Connection Cables IndraDrive and IndraDyn Selection Data CONNEC CABLE INDRV CAxx EN P 322949 1 In the document typecodes xx is a placeholder for the current edition of the documentation e g CA02 is the second edition of the Selection Data documentation Tab 1 19 Documentations overview Firmware Title Type of documentation Document typecode1 DOK INDRV Material number R911 Indra...

Page 43: ...RNxx EN P 331588 IndraDrive MPx 16 to MPx 21 and PSB Parameters Reference Book GEN1 PARA RExx EN P 328651 IndraDrive MPx 16 to MPx 21 and PSB Diagnostics Reference Book GEN1 DIAG RExx EN P 326738 Rexroth IndraDrive Integrated Safety Technology Safe Torque Off as of MPx 16 Application Manual SI3 VRS APxx EN P 332634 IndraDrive Integrated Safety Technology Safe Motion as of MPx 18 Application Manual...

Page 44: ...e IndraMotion MLD as of MPx 18 Application Manual MLD3 VRS APxx EN P 338914 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 20 Documentations firmware 30 407 System presentation IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 45: ...ntation or have suggestions for changes please send your feedback to the following address Bosch Rexroth AG Dept DC AE EPI5 Bürgermeister Dr Nebel Str 2 97816 Lohr am Main Germany Email dokusupport boschrexroth de IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 31 407 System presentation R911335703_Edition 04 Bosch Rexroth AG ...

Page 46: ...32 407 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 47: ...modifications It is not permitted to 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 as described in the relevant documentation 2 1 2 Areas of use and application Drive controllers by Rexroth are designed to control electric motors and monitor their operation Controlling and...

Page 48: ...llers outside of the operating conditions technical data and specifications described in this documentation Drive controllers must not be used if they are exposed to operating conditions that do not meet the specified ambient conditions This includes for example operation under water under extreme temperature fluctuations or extreme maximum temperatures Furthermore Drive controllers may not be use...

Page 49: ...bles Installation An installation consists of several devices or systems interconnected for a defined purpose and on a defined site which however are not intended to be placed on the market as a single functional unit Machine A machine is the entirety of interconnected parts or units at least one of which is movable Thus a machine consists of the appropriate machine drive elements as well as contr...

Page 50: ...r the safe operation of the components If the component is resold rented and or passed on to others in any other form these safety instructions must be delivered with the component in the official language of the user s country Improper use of these components failure to follow the safety instructions in this document or tampering with the product including disabling of safety devices could result...

Page 51: ...easures modifications and complements Commissioning of the delivered components is only allowed once it is sure that the machine or installation in which the components are installed complies with the national regulations safety specifications and standards of the application Operation is only allowed if the national EMC regulations for the application are met The instructions for installation in ...

Page 52: ...e High electrical voltage Danger to life risk of injury by electric shock or serious injury Only qualified persons are allowed to operate maintain and or repair the components of the electric drive and control system Follow the general installation and safety regulations when working on power installations Before switching on the equipment grounding conductor must have been permanently connected t...

Page 53: ...nts of the electric drive and control system permanently to the main power supply at all times The leakage current is greater than 3 5 mA Establish an equipment grounding connection with a minimum cross section according to the table below With an outer conductor cross section smaller than 10 mm2 8 AWG the alternative connection of two equipment grounding conductors is allowed each having the same...

Page 54: ...pment is switched on or even after an unspecified time of trouble free operation The monitoring functions in the components of the electric drive and control system will normally be sufficient to avoid malfunction in the connected drives Regarding personal safety especially the danger of injury and or property damage this alone cannot be relied upon to ensure complete safety Until the integrated m...

Page 55: ...uarantee personal safety Disconnect electrical power to the components of the electric drive and control system using the master switch and secure them from reconnection lock out for Maintenance and repair work Cleaning of equipment Long periods of discontinued equipment use Prevent the operation of high frequency remote control and radio equipment near components of the electric drive and control...

Page 56: ...hot surfaces For certain applications and in accordance with the respective safety regulations the manufacturer of the machine or installation must take measures to avoid injuries caused by burns in the final application These measures can be for example Warnings at the machine or installation guards shieldings or barriers or safety instructions in the application documentation 3 3 6 Protection du...

Page 57: ...tially supplied with externally fed pressurized media such as compressed air hydraulics oil cooling liquids and cooling lubricants Improper handling of the connected supply systems supply lines or connections can cause injuries or property damage Risk of injury by improper handling of pressurized lines Do not attempt to disconnect open or cut pressurized lines risk of explosion Observe the respect...

Page 58: ...es the signal words DANGER WARNING and CAUTION is used to alert the reader to personal injury hazards DANGER In case of non compliance with this safety instruction death or serious injury will occur WARNING In case of non compliance with this safety instruction death or serious injury could occur CAUTION In case of non compliance with this safety instruction minor or moderate injury could occur NO...

Page 59: ...tories Inc Proof of certification can be found online Enter the terms UL and databases in a search engine to get to the relevant UL web page With the file number you will find the proof of certification UL ratings When using the component in the scope of CSA UL observe the UL ratings for each component Only the following components have been approved in the scope of CSA UL for supplying KSM and KM...

Page 60: ...rvo and Stepper Motors Component File numbers MSK MSM motors E335445 Tab 4 3 C UR listing UL wiring material ready made Rexroth cables In the scope of CSA UL use copper 60 75 C only class 6 or equivalent only Allowed pollution degree Comply with the allowed pollution degree of the components see Ambient and operating conditions CCC China Compulsory Certifica tion The CCC mark is a compulsory certi...

Page 61: ... operating conditions for transport Description Symbol Unit Value Temperature range Ta_tran C 20 70 Relative humidity 5 95 Absolute humidity g m3 1 60 Climatic category IEC 721 2K3 Moisture condensation Not allowed Icing Not allowed Tab 4 4 Ambient and operating conditions for transport 4 2 2 Storing the components Risk of damage to the KCU drive connection box from long term storage NOTICE The KC...

Page 62: ...n on commissioning to preserve proper functioning irrespective of the storage time which may be longer than the warranty period of our products However this does not involve any additional warranty claims Motors Storage time months Measures for commissioning 1 12 60 Visual inspection of all parts to be damage free Resurface the holding brake Check the electric contacts to verify that they are free...

Page 63: ...ion Visually inspect the cable jacket Do not use the cable if you detect any abnormalities squeezed or kinked spots color deviations Tab 4 7 Measure before commissioning cables and connectors that have been stored over a prolonged period of time IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 49 407 General data and specifications R911335703_Edition 04 Bosch Rexroth AG ...

Page 64: ...T KCU HLC HNF Description Symbol Unit Value Conductive dirt contamination Not allowed Protect the devices against conductive dirt contamination by mounting them in control cabinets with the degree of protection IP54 in accordance with IEC529 Degree of protection of the device IEC529 IP20 Use within scope of CSA UL For use in NFPA 79 Applications only Temperature during storage See chapter 4 2 2 St...

Page 65: ...ormance data with the product f FTa Relative humidity 5 95 Absolute humidity g m3 1 29 Climatic category IEC 60721 3 3 3K3 Allowed pollution degree EN 50178 2 Resistance to chemically active substances IEC 60721 3 3 Class 3C1 Vibration sine amplitude peak peak at 10 57 Hz 1 mm 0 15 Vibration sine acceleration at 57 150 Hz 1 g 1 Overvoltage category III according to IEC 60664 1 1 According to EN 60...

Page 66: ...d power is reduced to PDC_cont_red PDC_cont FTa PDC_cont 1 50 40 0 03 PDC_cont 0 7 Operation at ambient temperatures outside of Ta_work and Ta_work_red is not allowed Ta_work_red C 40 55 fTa K 3 Derating vs installation altitude At an installation altitude h hnenn the available performance data are reduced by the factor f2 3 At an installation altitude in the range hmax_ohne to hmax an isolating t...

Page 67: ...g conditions KMS KMV KNK KLC Description Symbol Unit Value Degree of protection IEC 60529 IP65 Use within scope of CSA UL For use in NFPA 79 Applications only Temperature during storage See chapter 4 2 2 Storing the components on page 47 Temperature during transport See chapter 4 2 1 Transporting the components on page 47 Allowed mounting position Definition of mounting positions See chapter Mount...

Page 68: ...is not allowed hmax_ohne m 2000 hmax m 4000 Simultaneous derating for ambient temperature and installation altitude Allowed reduce performance data with the product of factors f and FTa f FTa Relative humidity 5 95 Absolute humidity g m3 1 29 Climatic category IEC721 3K4 Allowed pollution degree IEC 60664 1 3 only with connectors plugged in Maximum concentration of corrosive gases According to deg...

Page 69: ... 60721 3 3 Tab 4 10 Ambient and operating conditions KMS KMV KNK KLC IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 55 407 General data and specifications R911335703_Edition 04 Bosch Rexroth AG ...

Page 70: ...trol 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 unclean air cannot get into the control cabinet Service the filters at regular intervals according to the dust loading in t...

Page 71: ...ough the filter at the air intake opening The control cabinet fan behind the air intake opening conveys the air into the control cabinet and generates overpressure in the control cabinet The overpressure prevents unclean air from getting into the control cabinet through possibly existing leaky points leaky cable ducts damaged seals etc IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KN...

Page 72: ...positions are specified with G1 G2 G3 G4 or G5 in the technical data of the components Mounting position Description G1 Normal mounting position The air heated inside the component can flow unimpeded vertically upward In the case of components with integrated fans the natural convection supports the forced cooling air current 1 Mounting surface 2 Outgoing heated air 3 Component 4 Fan within the co...

Page 73: ...ing to the state of the art technology As it is impossible to follow the continuing development of all materials e g lubricants in machine 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 c...

Page 74: ...nt w The amplitudes of the alternating component on UN3 must be within the specified voltage range Maximum allowed overvoltage UN3max V 33 max 1 ms Tab 4 15 Control voltage Overvoltage Overvoltage greater than 33 V has to be discharged by the appropriate electrical equipment of the machine or installation This includes 24V power supply units that reduce incoming overvoltage to the allowed value Ov...

Page 75: ...ion control voltage input at UN3 UL PN3 W Power with which the power supply unit is loaded for 24V supply Power section data Rated power t 10 min PLN_nenn W Power consumption from the DC bus L L at the point of maximum power PML Power dissipation at continuous current and continuous DC bus power respectively UL PDiss_cont W Occurring power dissipation at PLN_nenn Rated input voltage power UL 3 ULN...

Page 76: ...rces bearing stress or electrical DC bus voltage causes Insulation class according to DIN EN 60034 1 Insulation class Data of optional holding brake Holding torque M4 Nm Transmittable holding torque Clamping delay t1 ms ON delay when clamping Release delay t2 ms Release delay Brake mass mBr kg Add mass of holding brake to mass of motor Holding brake inertia Jrot kg m2 Add holding brake inertia to ...

Page 77: ... methods of EN 60034 1 The specified characteristics correspond to operation modes S1 or S3 P Load PV Electric losses Θ Temperature Θmax Highest temperature motor housing t Time TC Duty cycle ΔtP Operating time with constant load ΔtV Idle time Fig 5 1 Operation modes according to EN 60034 1 1998 Duty cycle Operation mode S3 intermittent duty is supplemented by specification of the duty cycle ED Th...

Page 78: ...tic S1 Continuous operation characteristic of the motor according to EN 60034 1 1998 natural convection S3 Intermittent duty characteristic with 25 ED of the motor ac cording to EN 60034 1 1998 and max duty cycle 1 min 1 Mmax controlled supply DC 750 V 2 3 4 Mmax uncontrolled supply 3 AC 400 V the voltage drop on the supply line has not been taken into account Fig 5 4 Sample characteristic 64 407 ...

Page 79: ...conditions according to UL50 50E Type 4X Indoor use only Mass mmot kg 5 6 9 6 14 1 14 6 Average sound pressure level accuracy class 2 at PDC_cont 1 LP dB A Less than 75 Control voltage data Rated control voltage input2 UN3 V DC 30 42 Rated power consumption control voltage input at UN3 3 PN3 W 17 5 Power section data Rated power t 10 min PLN_nenn W 470 895 765 1320 1285 1200 Power dissipation at c...

Page 80: ...arative value at 1 m dis tance out of cabinet 2 Observe supply voltage for motor holding brake 3 See information on Rated power consumption control voltage input at UN3 4 Plus dissipation of braking resistor and control section 5 Mains input L1 L2 L3 for HMV and HCS only For use on a solidly grounded wye source only 6 Also depending on firmware and control section see parame ter description P 0 00...

Page 81: ... 0 Ambient temperature range for operation with nominal data Ta_work C 0 40 Degree of protection according to IEC 60529 IP IP65 Ambient conditions according to UL50 50E Type 4X Indoor use only Mass mmot kg 5 9 10 1 15 2 15 7 Average sound pressure level accuracy class 2 at PDC_cont 1 LP dB A 75 Control voltage data Rated control voltage input2 UN3 V DC 30 42 Rated power consumption control voltage...

Page 82: ... delay t1 ms 25 30 Maximum release delay t2 ms 35 40 50 Holding brake mass mBr kg Holding brake inertia Jbr kg m2 0 000023 0 0 0000590 0 0001610 Latest amendment 2017 01 24 1 According to DIN EN ISO 11205 comparative value at 1 m dis tance out of cabinet HCS types in L design load depend ent 2 Observe supply voltage for motor holding brake 3 See information on Rated power consumption control volta...

Page 83: ...luding motor holding brake plus power consumption of externally connected inputs outputs plus safety option IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 69 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 84: ...ig 5 5 KSM02 1B 041C 42 characteristics S1 S3 Characteristics apply to a PWM frequency of 4 kHz 1 Mmax controlled supply 1 3 AC 400 V 2 3 4 Mmax uncontrolled supply 2 3 AC 480 V 3 3 AC 440 V 4 3 AC 400 V Fig 5 6 KSM02 1B 061C 35 characteristics 70 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 85: ...B 061C 61 characteristics S1 S3 Characteristics apply to a PWM frequency of 4 kHz 1 Mmax controlled supply 1 3 AC 400 V 2 3 4 Mmax uncontrolled supply 2 3 AC 480 V 3 3 AC 440 V 4 3 AC 400 V Fig 5 8 KSM02 1B 071C 24 characteristics IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 71 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 86: ... 071C 35 characteristics S1 S3 Characteristics apply to a PWM frequency of 4 kHz 1 Mmax controlled supply 1 3 AC 400 V 2 3 4 Mmax uncontrolled supply 2 3 AC 480 V 3 3 AC 440 V 4 3 AC 400 V Fig 5 10 KSM02 1B 076C 35 characteristics 72 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 87: ...connectors More mounting clearance is required to install the HAS10 accessory with a screwdriver The exact dimension of the mounting clearance is not specified since the required mounting clearance depends on the length of the screwdriver used Fig 5 11 KSM02 1B 041C dimensions IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 73 407 Technical data of the components R911335703...

Page 88: ...ance is required to install the HAS10 accessory with a screwdriver The exact dimension of the mounting clearance is not specified since the required mounting clearance depends on the length of the screwdriver used Fig 5 12 KSM02 1B 041C dimensions ATEX design 74 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_...

Page 89: ... clearance is required to install the HAS10 accessory with a screwdriver The exact dimension of the mounting clearance is not specified since the required mounting clearance depends on the length of the screwdriver used Fig 5 13 KSM02 1B 061C dimensions IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 75 407 Technical data of the components R911335703_Edition 04 Bosch Rexrot...

Page 90: ... clearance is required to install the HAS10 accessory with a screwdriver The exact dimension of the mounting clearance is not specified since the required mounting clearance depends on the length of the screwdriver used Fig 5 14 KSM02 1B 071C dimensions 76 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Editio...

Page 91: ... clearance is required to install the HAS10 accessory with a screwdriver The exact dimension of the mounting clearance is not specified since the required mounting clearance depends on the length of the screwdriver used Fig 5 15 KSM02 1B 076C dimensions IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 77 407 Technical data of the components R911335703_Edition 04 Bosch Rexrot...

Page 92: ...t shaft end and cen tering hole Motors with keyway have been balanced with the complete key The machine element to be driven has to be balanced without a key Shaft end cylindrical acc to DIN 748 Teil 3 ed 07 75 IEC 60072 1 Centering hole according to DIN 332 Teil 2 ed 05 83 Type Corresponding key according to DIN 6885 A is not part of the scope of supply of the motors Centering hole according to D...

Page 93: ...ings Radial force Fradial Fig 5 16 KSM02 1B 041 Allowed radial force shaft and bearing load Fig 5 17 KSM02 1B 061 Allowed radial force shaft and bearing load Fig 5 18 KSM02 1B 071 Allowed radial force shaft and bearing load IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 79 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 94: ...al Type Maximum allowed axial force in N KSM02 1B 041 20 KSM02 1B 061 20 KSM02 1B 071 40 KSM02 1B 076 40 Tab 5 6 Allowed axial force 80 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 95: ...SCCR A rms 42000 Rated input voltage power3 ULN_nenn V DC 540 750 Capacitance in DC bus CDC mF 0 02 Capacitance against housing9 CY nF 118 100 Rated input current ILN A 7 3 Allowed switching frequencies4 fs kHz 4 8 Maximum bypass current A Bypass max 25 A Power dissipation at continuous current and continuous DC bus power respectively5 PDiss_cont W 50 00 Power section data output Output voltage fu...

Page 96: ...control voltage input at UN3 3 Mains input L1 L2 L3 for HMV and HCS only For use on a solidly grounded wye source only 4 Also depending on firmware and control section see parame ter description P 0 0001 Switching frequency of the power output stage see P 0 4058 Amplifier type data for supply units the switching frequency is 4 2 kHz 5 Plus dissipation of braking resistor and control section 6 7 Gu...

Page 97: ...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 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 83 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 98: ...More mounting clearance is required to install the HAS10 accessory with a screwdriver The exact dimension of the mounting clearance is not specified since the required mounting clearance depends on the length of the screwdriver used B Boring dimensions Fig 5 20 Dimensions 84 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth A...

Page 99: ...iver The exact dimension of the mounting clearance is not specified since the required mounting clearance depends on the length of the screwdriver used B Boring dimensions Fig 5 21 Dimensions with angular connector for motor and encoder connec tion IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 85 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 100: ... connection to an HMV supply unit or HCS converter with 42V control voltage with integrated fuses protects the RKH hybrid cable against electric overload allows the higher level control unit to communicate with the KSM motor integrated servo drives and KMS near motor servo drives 86 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch R...

Page 101: ... approx 0 3 Power dissipation at continuous current and continuous DC bus power respectively PDiss_cont W 90 Insulation resistance at 500 V DC Ris Mohm 50 Average sound pressure level accuracy class 2 at PDC_cont 4 LP dB A 70 Control voltage data input Control voltage input5 UN3 V DC 24 20 Rated power consumption control voltage input at UN3 PN3 W 675 Max inrush current at 24 V supply IEIN3_max A ...

Page 102: ...DC bus power at ULN_nenn PDC_max kW 42 0 53 3 Latest amendment 2017 01 20 1 2 3 See fig Air intake and air outlet at device 4 According to DIN EN ISO 11205 comparative value at 1 m dis tance out of cabinet 5 Observe supply voltage for motor holding brake Tab 5 8 KCU Technical data Property damage due to temperatures higher than 105 C NOTICE Comply with specified minimum distances A Air intake B Ai...

Page 103: ...ensional drawing A Minimum mounting clearance Fig 5 23 Dimensions IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 89 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 104: ...A rms 42000 Rated input voltage power1 ULN_nenn V 3 AC 380 500 Rated input current ILN A 8 1 12 0 2 3 9 5 Output voltage Uout V DC 750 Output current Iout A 6 7 10 0 2 0 8 0 Latest amendment 2019 08 08 1 Mains input L1 L2 L3 For use on a solidly grounded wye source only Tab 5 9 KMV Ambient and operating conditions UL ratings 90 407 Technical data of the components IndraDrive Mi Drive Systems with ...

Page 105: ...ermal interface A Minimum mounting clearance B Boring dimensions Fig 5 24 KMV03 1R B Ixxxx thermal interface dimensions IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 91 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 106: ... A Minimum mounting clearance B Boring dimensions Fig 5 25 KMV03 1R Axxxx natural convection dimensions 92 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 107: ... A Minimum mounting clearance B Boring dimensions Fig 5 26 KMV03 1R Wxxxx forced cooling dimensions IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 93 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 108: ...esistance at 500 V DC Ris Mohm 50 Capacitance against housing5 CY nF 150 200 Average sound pressure level accuracy class 2 at PDC_cont 4 LP dB A 50 60 Latest amendment 2019 08 08 1 2 3 Housing dimension see also related dimensional drawing 4 According to DIN EN ISO 11205 comparative value at 1 m dis tance 5 150 nF L against ground 200 nF L against ground Tab 5 10 KMV Data for mass dimensions sound...

Page 109: ... Power dissipation at continuous current and continuous DC bus power respectively1 PDiss_cont W 390 00 500 00 220 00 430 00 Power consumption control voltage input at UN3 2 PN3 W 18 Temperature increase with minimum distances dbot dtop PBD ΔT K Latest amendment 2019 08 08 1 Plus dissipation of braking resistor and control section 2 See information on Rated power consumption control voltage input a...

Page 110: ...h current at 24 V supply IEIN3_max A 10 00 Pulse width of IEIN3 tEIN3Lade ms 1000 Input capacitance CN3 mF 11 00 Rated power consumption control voltage input at UN3 PN3 W 18 Latest amendment 2019 08 08 1 2 3 Observe supply voltage for motor holding brake Tab 5 12 KMV Control voltage supply data 96 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK...

Page 111: ...nce of mains supply mains phase inductance 3 Lmin µH 50 Assigned mains filter with integrated mains choke KNK03 1A NR A0008 P U226 A4 NNNN KNK03 1A NR B0012 P U226 A4 NNNN KNK03 1A NR I0002 P U226 A4 NNNN KNK03 1A NR W0010 P U226 A4 NNNN Minimum short circuit power of the mains for failure free operation Sk_min MVA 1 5 Inrush current IL_trans_max _on A 8 1 13 Maximum allowed ON OFF cycles per minu...

Page 112: ...e ULN Use a transformer with grounded neutral point do not use autotransformers 3 Otherwise use HNL mains choke 4 Observe allowed number of switch on processes without ex ternal capacitors at the DC bus 5 Copper wire PVC insulation conductor temperature 90 C Ta 40 C in accordance with NFPA 79 chapter 12 and UL 508A chapter 28 Tab 5 13 KMV Mains voltage supply data 98 407 Technical data of the comp...

Page 113: ...vs mains input voltage ULN ULN_nenn V PDC_cont Maximum allowed DC bus power at ULN_nenn with mains choke PDC_max kW 15 00 Monitoring value maximum DC bus voltage switch off threshold UDC_limit_m ax V 900 Monitoring value minimum DC bus voltage undervoltage threshold UDC_limit_mi n V 500 Allowed external DC bus capacitance nom at ULN_nenn 2 CDCext mF 9 40 Charging time for maximum external DC bus c...

Page 114: ... resistance RDC_Bleede r ohm 60 Braking resistor switch on threshold independent of mains voltage1 UR_DC_On_f V 820 Regenerative power to be absorbed WR_max kWs 7 50 Cooling of integrated braking resistor Heat sink Base plate Coldplate Heat sink Latest amendment 2019 08 08 1 Factory setting Tab 5 15 KMV Integrated braking resistor data 100 407 Technical data of the components IndraDrive Mi Drive S...

Page 115: ...citance CDC mF 4 7 20 Power dissipation at continuous current and continuous DC bus power respectively PDiss_cont W 30 Maximum discharge time from UR_DC_On to DC 50 V tentl_ZK sec 660 Allowed input current at L L Imax rms A 25 Insulation resistance at DC 500 V Ris Mohm 50 Tab 5 16 KLC03 technical data IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 101 407 Technical data of...

Page 116: ...ace A Minimum mounting clearance B Boring dimensions Fig 5 27 KLC03 1N B04M7 thermal interface dimensions 102 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 117: ...ion A Minimum mounting clearance B Boring dimensions Fig 5 28 KLC03 1N A04M7 natural convection dimensions IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 103 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 118: ...ing A Minimum mounting clearance B Boring dimensions Fig 5 29 KLC03 1N W04M7 forced cooling dimensions 104 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 119: ...nt A 8 1 12 2 3 9 5 Typical inductance per winding at Icont Ltyp µH 2 3 Power dissipation at continuous current and continuous DC bus power respectively3 PDiss_cont W 147 175 104 160 Allowed leakage capacitance CAbl nF 226 Allowed Y capacitance CY nF 2200 Insulation resistance at 500 V DC Ris Mohm 1 Required wire size in accordance with NFPA 79 and UL 508 A internal wiring 4 ALN AWG 14 Latest amen...

Page 120: ...ace A Minimum mounting clearance B Boring dimensions Fig 5 30 KNK03 1A NR B Ixxxx thermal interface dimensions 106 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 121: ...ion A Minimum mounting clearance B Boring dimensions Fig 5 31 KNK03 1A NR Axxxx natural convection dimensions IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 107 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 122: ...ing A Minimum mounting clearance B Boring dimensions Fig 5 32 KNK03 1A NR Wxxxx forced cooling dimensions 108 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 123: ...at UN3 2 PN3 W 17 5 Power section data Short circuit current rating SCCR A rms 42000 Rated input voltage power3 ULN_nenn V DC 540 750 Capacitance in DC bus CDC mF 0 05 Capacitance against housing CY nF 100 100 Rated input current ILN A 10 5 19 3 Allowed switching frequencies4 fs kHz 4 8 Maximum bypass current A Bypass max 25 A Power dissipation at continuous current and continuous DC bus power res...

Page 124: ...output current when fs 8 kHz output frequency fout less than fout_still Iout_cont0Hz _8 A 5 9 16 0 Latest amendment 2018 02 22 1 Observe supply voltage for motor holding brake 2 See information on Rated power consumption control voltage input at UN3 3 Mains input L1 L2 L3 for HMV and HCS only For use on a solidly grounded wye source only 4 Also depending on firmware and control section see parame ...

Page 125: ...uced output current at motor standstill Depending on the electric output frequency 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 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 111 407 Technical data of the components R911335...

Page 126: ...ore mounting clearance with HAS10 accessory fixing clip for hybrid cable connectors More mounting clearance is required to install the HAS10 accessory with a screwdriver Fig 5 33 KMS03 1B A dimensions 112 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 127: ...p for hybrid cable connectors More mounting clearance is required to install the HAS10 accessory with a screwdriver 4 Mounting clearance with cable outlet away from housing B Drilling pattern Fig 5 34 KMS03 1B B dimensions IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 113 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 128: ...olor RAL2003 Wire insulation material according to EN 13602 CU ETP A Conductor resistance at 20 C EN 60228 class 6 R20 Ω km 8 2 5 mm Diameter D mm 16 2 0 5 Specific cable weight m kg m 0 355 Application in flexible cable tracks Bending cycles 5 106 Bending radius with flexible routing mm 10 D Bending radius with permanent routing mm 5 D Bending and torsional stress m max 30 Max horizontal travel d...

Page 129: ...um values only apply individually 5 UL file number according to cable marking Tab 5 19 REH Technical data The hybrid cable contains both power lines and control lines Route hybrid cables in accordance with EN 61800 5 1 and EN 61800 5 2 protected against external damage Select the types of protective measures according to the respective application IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02...

Page 130: ...N 60228 class 6 R20 Ω km 8 2 5 mm Diameter D mm 11 4 0 3 Specific cable weight m kg m 0 234 Application in flexible cable tracks Yes Bending cycles 5 106 Bending radius with flexible routing mm 8 D Bending radius with permanent routing mm 4 D Bending and torsional stress m not suitable Max horizontal travel distance2 s m 50 Maximum travel velocity3 v m s 5 Maximum acceleration4 amax m s 50 5 m UL ...

Page 131: ...ins both power lines and control lines Route hybrid cables in accordance with EN 61800 5 1 and EN 61800 5 2 protected against external damage Select the types of protective measures according to the respective application IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 117 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 132: ...RKH0213 RKH0213 RKH0901 2 X103 2 RKH0110 RKH0210 RKH0215 RKH0215 RKH0904 3 X103 2 RKH0212 RKH0214 RKH0610 RKH0610 RKH0906 RKH0700 RKH0212 RKH0214 RKH0610 4 tbd Circular connector RKH0902 RKH0905 RKH0907 tbd RKH0900 1 Outgoing direction A 2 Outgoing direction B 3 Outgoing direction V 4 To interconnect two RKH0700 cables use a short RKH0610 cable as an intermediate piece 5 HCS01 1E W0054 with HAS05 ...

Page 133: ...eplace the flexible cable track cable for servicing the cable in the example used in the flexible cable track has been equipped with connectors at the inputs Observe the maximum allowed length of the hybrid cable in the flexible cable track see chapter Length of hybrid cable incl communication on page 227 Identifying the hybrid cables Hybrid cables are labeled according to the following example RK...

Page 134: ...rection It is not allowed to subsequently invert the direction of a hybrid cable by removing the locking pins Otherwise the signals for E Stop and safety technology would not be valid When mounting hybrid cables in cable ducts or flexible cable tracks make sure that the direction of the hybrid cables is correct 120 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 K...

Page 135: ...22 RKH0224 RKH0620 4 1 Outgoing direction A 2 Outgoing direction B 3 Outgoing direction V 4 To interconnect two RKH0710 cables use a short RKH0620 cable as an intermediate piece Tab 5 23 RKH hybrid cable without communication Hybrid cable outgoing direction A horizontal towards the housing B horizontal away from the housing V vertical Tab 5 24 Hybrid cable outgoing directions Identifying the hybri...

Page 136: ...ure that hybrid cables run in the right direction It is not allowed to subsequently invert the direction of a hybrid cable by removing the locking pins Otherwise the signals for E Stop and safety technology would not be valid When mounting hybrid cables in cable ducts or flexible cable tracks make sure that the direction of the hybrid cables is correct 122 407 Technical data of the components Indr...

Page 137: ...nd RKH0311 RKH0411 RKH0511 RHS0005 RHS0011 RHS0016 Locking pin Coding profile 5 1 R End plug in connector for RKH0311 RKH0411 2 R End plug in connector for RKH0511 4 Picture shows coding with view to mating side 5 The coding profile ensures the downward compatibility of the hybrid cable for KSM01 KMS01 Tab 5 25 Parts of ready made hybrid cables from KCU to KSM KMS IndraDrive Mi Drive Systems with ...

Page 138: ...lug in connector RHS0011 C03 RHS0016 C03 REH0800 RHS0011 C03 RHS0016 C03 Interconnection diagram Coding at KSM KMS plug in connector 1 Cable type L End X103 1 R End X103 2 RKH0011 RKH0110 RKH0210 RKH0212 RKH0214 RKH0610 124 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 139: ...ng side 2 The coding profile ensures the downward compatibility of the hybrid cable for KSM01 KMS01 Tab 5 26 Parts of ready made hybrid cables from KSM KMS to KSM KMS IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 125 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 140: ...C03 Interconnection diagram Coding at KSM KMS plug in connector Cable type L End R End RKH0700 Not coded Not coded Tab 5 27 Parts of ready made hybrid cable for flexible cable tracks 126 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 141: ...21 C03 REH0800 RHS2322 C031 RHS0011 C032 RHS0016 C033 Interconnection diagram RHS2321 RHS2322 Interconnection diagram RHS2321 RHS0011 RHS0016 1 RKH0900 2 RKH0901 RKH0904 3 RKH0906 Tab 5 28 RKH0900 RKH0901 RKH0904 RKH0906 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 127 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 142: ... RHS2321 C031 RHS0011 C032 RHS0016 C033 Interconnection diagram RHS2322 RHS2321 Interconnection diagram RHS2322 RHS0011 RHS0016 1 RKH0900 2 RKH0902 RKH0905 3 RKH0907 Tab 5 29 RKH0900 RKH0902 RKH0905 RKH0907 128 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 143: ...ctor RHS0005 C03 REH0800 RHS2321 C03 Interconnection diagram Tab 5 30 Parts of ready made hybrid cables from KCU to circular connector IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 129 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 144: ...tor RHS0015 CM03 REH0800 RHS2321 CM03 Interconnection diagram Tab 5 31 Parts of ready made hybrid cables from HAS05 1 023 to circular connector 130 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 145: ...to the circular connector This allows hybrid cable housing ducts to be implemented with a pluggable connection at the housing control cabinet machine See chapter 10 24 Metallic flange for circular connectors on page 337 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 131 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 146: ... 4 1 R End plug in connector for RKH0341 RKH0441 2 R End plug in connector for RKH0541 3 Picture shows coding with view to mating side 4 The coding profile ensures the downward compatibility of the hybrid cable for KSM01 KMS01 Tab 5 33 Parts of ready made hybrid cables from HAS05 1 023 to KSM KMS HAS05 1 023 chapter 10 9 HAS05 1 023 HCS01 adapter on page 310 132 407 Technical data of the component...

Page 147: ...acts for Multi Ethernet communication Tx Tx Rx Rx the connection point can be used for the drive system Engi neering Fig 5 38 RHS0014 terminal connector Tab 5 34 Internal M12 socket wiring If it is difficult to access the M12 socket in your drive system Connect a cable e g RKB0043 to the M12 socket and position the end of the cable at an easily accessible point IndraDrive Mi Drive Systems with KCU...

Page 148: ... KSM KMS plug in connector3 Cable type L End R End RKH0321 RHS0008 X103 1 RKH0421 RHS0008 X103 1 RKH0521 RHS0008 X103 1 1 R End plug in connector for RKH0321 RKH0421 2 R End plug in connector for RKH0521 3 View to mating side Tab 5 35 Parts of ready made hybrid cables without communication from KCU to KSM02 KMS 134 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 K...

Page 149: ...21 CM02 REH0803 RHS0021 CM02 1 RHS0022 CM02 2 Interconnection diagram KSM KMS plug in connector3 Cable type L End R End RKH0021 X103 1 X103 2 RKH0120 X103 1 X103 2 RKH0121 X103 2 X103 1 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 135 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 150: ...220 2 R End plug in connector for RKH0222 3 View to mating side Tab 5 36 Parts of ready made hybrid cables without communication from KSM KMS to KSM KMS 136 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 151: ...CM02 Interconnection diagram Coding at KSM KMS plug in connector Cable type L End R End RKH0710 Not coded Not coded Tab 5 37 Parts of ready made hybrid cable for flexible cable tracks IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 137 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 152: ...17 K03 REH0803 RHS0018 K03 Interconnection diagram KNK03 KMV03 plug in connector Cable type L End R End RKH0800 XD1 connector XG34 connector XD1 connector XG34 connector Tab 5 38 Parts of ready made hybrid cables used for mains connection 138 407 Technical data of the components IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 153: ...diagram KNK03 KMV03 plug in connector Cable type L End R End RKH0801 XG14 connector XG3 connector XG14 connector XG3 connector Tab 5 39 Parts of ready made hybrid cables used for mains connection IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 139 407 Technical data of the components R911335703_Edition 04 Bosch Rexroth AG ...

Page 154: ... 40 Parts of ready made hybrid cables used for DC bus connection KLC03 KLC03 RKH0803 Applies to RKH0803 KLC03 plug in connector Bulk cable KLC03 plug in connector RHS0009 KM04 REL0015 RHS0009 KM04 Interconnection diagram KLC03 KLC03 plug in connector Cable type L End R End RKH0803 XG9 connector XG9 connector Tab 5 41 Parts of ready made hybrid cables used for DC bus connection 140 407 Technical da...

Page 155: ...ct the equipment grounding conductor connections of all devices and additional components to the equipment grounding system Risk of damage to the devices by spark discharge of static charges NOTICE In some applications e g printing or packaging high static charges can develop Make sure that these charges can be directly discharged against ground at their point of origin Therefore connect the secon...

Page 156: ...Drive Mi product range are devices with increased leakage current greater than AC 3 5 mA or DC 10 mA Therefore always install a stationary connection of the equipment grounding conductor In a IndraDrive Mi drive system connect the equipment grounding conductor connections of all devices and additional components to the equipment grounding system Risk of damage to the devices by spark discharge of ...

Page 157: ...onjunction with the equipment grounding conductor Ground the housings of the devices 1 Connect the bare metal back panel of the devices 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 2 drive lines If you connect 2 drive lines from...

Page 158: ...onnection to supply unit via contact bars part of basic accessory HAS01 L L DC bus For connection to supply unit via contact bars part of basic accessory HAS01 X1 Module bus Keep ribbon cable in parking position when there is no connection to neighboring device X29 1 X29 2 Multi Ethernet Signals are looped through X49 Safety technology L3 Safe Torque Off X50 E Stop E Stop input X52 Status messages...

Page 159: ... module bus connection to the neighboring device Tab 6 3 X1 Module Bus Installation instructions Keep the ribbon cable in the parking position if the connection to the neighboring device is not established If used for the module bus extension cables must be shielded Their total length may not exceed a maximum of 40 m The module bus connection can be extended by means of accessory RKB0001 When usin...

Page 160: ...eady made cables that can be ordered RKB0021 Long cables 100 m at maximum to connect the drive system to the higher level control unit or remote communication nodes Minimum bending radius 48 75 mm with flexible installation 32 50 mm with permanent installation Order code for a 30 m long cable RKB0021 030 0 RKB0013 Short cables to connect devices arranged side by side in the control cabinet 4 lengt...

Page 161: ...ler Tab 6 5 RKB0013 00 55 netSWITCH sercos III With sercos III and for the Engineering of the drive system you can connect our netSWITCH sercos III accessory into the sercos III ring IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 147 407 Connection points R911335703_Edition 04 Bosch Rexroth AG ...

Page 162: ...on page 369 Selection channel 2 SI_Ch2 1 Dynamization output channel 1 Dyn_Ch1 6 chapter 14 2 1 Digital outputs safety technology L options on page 371 Dynamization output channel 2 Dyn_Ch2 5 Power supply of isolated inputs and outputs 24V 4 DC 19 2 30 V The power supply for X49 must be external e g external 24 V power supply The connection point X50 E Stop input must not be used for power supply ...

Page 163: ...cable AWG 20 16 Allowed input voltage V 3 30 Input voltage H V 15 30 Input current H mA 2 15 Input voltage L V 0 5 Input current L mA 0 0 5 Input resistance kΩ 2 5 1 Exclusively use the 24 V output for the E Stop input in conjunc tion with the jumper from X50 3 to X50 4 Maximum power rat ing 15 mA 2 Exclusively use the 0 V output for the E Stop input in conjunc tion with the jumper from X50 1 to X...

Page 164: ...nnection X49 2 X52 4 5 GY SI_Ch1 Internal connection X49 3 X52 5 Spring terminal connector at hybrid cable Unit Min Max Connection cable stranded wire mm2 n s Connection cable AWG Voltage range V 0 24 10 Voltage level H V 15 n s Voltage level L V n s 5 Output current mA n s 500 Conductor color of the ready made cable RKH Tab 6 9 Function Pin Assignment Properties 150 407 Connection points IndraDri...

Page 165: ...on via hybrid cable RKH Connection cable AWG Output data Uout Pout see technical data of KCU02 Short circuit protection Present Overload protection Present Conductor color of the ready made cable RKH Tab 6 10 Function Pin Assignment Properties Control Voltage Monitoring The control voltage is constantly monitored If the allowed voltage range is left the control voltage for the connected KSM02 KMS0...

Page 166: ...ybrid cable Unit Connection cable stranded wire Connection via hybrid cable RKH Connection cable Short circuit protection L L Fuses F4 F5 Voltage L L V Uout see technical data of KCU02 Conductor color of the ready made cable RKH Tab 6 11 Function Pin Assignment Properties 152 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_E...

Page 167: ... bus connections L Screw connection M6 thread at device terminal block Unit Min Max Tightening torque Nm 5 5 6 5 Short circuit protection Via fusing elements connected in the incoming circuit to the mains connection Overload protection Via fusing elements connected in the incoming circuit to the mains connection Current carrying capacity looping through from L to L L to L contact bars in scope of ...

Page 168: ...rwards only strip the insulation of the contact surface of the ring terminal When connecting the lines make sure the polarity is correct Length of twisted wire Max 2 m Line cross section Min 10 mm2 but not smaller than cross section of supply feeder Line protection By means of fuses in the mains connection Dielectric strength of single strand against ground 750 V e g strand type H07 Tab 6 13 DC Bu...

Page 169: ...djusting Mounting Depths HMV01 and HCS03 devices have greater mounting depths than the drive connection box KCU For connecting the drive connection box KCU to an HMV01 or HCS03 device you must therefore use the control cabinet adapter HAS03 1 002 which compensates the different mounting depths IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 155 407 Connection points R911335...

Page 170: ...device terminal block Unit Min Max Tightening torque Nm 5 5 6 5 Power consumption W PN3 see technical data Voltage load capacity V UN3 see technical data Polarity reversal protection Within the allowed voltage range by internal protective diode Current carrying capacity looping through from 24V to 24V 0V to 0V contact bars in scope of supply of accessory HAS01 With contact bars 072 A 220 Tab 6 15 ...

Page 171: ... cross section min 6 mm2 AWG 10 For HCS03 HMV01 and HMV02 devices the 24V supply is connected to the drive connection box KCU with contact bars Tab 6 16 Connecting the 24V supply IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 157 407 Connection points R911335703_Edition 04 Bosch Rexroth AG ...

Page 172: ...ch 10 L Address selector switch 1 X37 X38 Digital inputs outputs X103 1 X103 2 Hybrid cable X107 Programming module X1x8 X1x9 Communication optional X108 X109 Communication output coupling X118 X119 External communication X141 Safety technology optional 2nd Second connection point of equipment grounding conductor Tab 6 17 KSM02 connection points 158 407 Connection points IndraDrive Mi Drive System...

Page 173: ... can be used as probe X38 5 PE For cable shield M12 5 pin A coded female Unit min max Connection cable stranded wire mm2 0 25 0 25 Cable cross section AWG Ready made connection cable RKS0010 optional accessory Tab 6 18 Function pin assignment properties The digital inputs outputs comply with IEC 61131 2 type 1 Properties There is a total of 4 configurable isolated inputs outputs which are distribu...

Page 174: ...f 1 A is possible In the condition as supplied there is an O ring at the root of the thread between the female connector insert and the electronics housing which assures the tightness of the M12 female connectors Neither the protective cap nor the connector is tight without this O ring Internal design dig I Digital input dig O Digital output 24 Vint Voltage from internal power supply 24 Vext Volta...

Page 175: ...the signal edges Fig 6 5 Signal detection at probe input Probe inputs are inputs used to acquire fast digital input signals For control use bounce free switching elements e g electronic switches to avoid incorrect evaluation External power supply At the pins 1 and 3 of the connectors X37 and X38 you can connect an external 24 V power supply to increase the maximum output current of the digital out...

Page 176: ... s n s 100 Update interval ns Depending on firmware Short circuit protection Present Overload protection Present Allowed energy content of connected inductive loads e g relay coils only allowed as single pulse mJ n s n s 400 Tab 6 20 Digital outputs The digital outputs have been realized with high side switches This means that these outputs only can actively supply current The energy absorption ca...

Page 177: ...at least 30 minutes after switching off the supply voltages to allow discharging Risk of damage from frequently plugging in the hybrid cable NOTICE Allowed number of plugging cycles 50 A Codings of the connection points to prevent the hybrid cables from being incorrectly connected Fig 6 6 X103 1 and X103 2 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 163 407 Connection p...

Page 178: ... KCU02 or KMV03 Always connect the hybrid cable of KCU02 to the connection point X103 1 of the first KSM02 KMS02 of a drive line Hybrid cables contain power lines and control lines Always route hybrid cables in such a way that the hybrid cables are protected against external damage in accordance with EN 61800 5 1 and EN 61800 5 2 Notes on operation Do not remove connectors when the component has b...

Page 179: ... programming module NOTICE Neither plug nor remove the programming module when voltage has been applied Clean the device housing before removing the programming module cover Make sure that neither dirt nor moisture penetrate the housing A Cover is fixed to the device with 4 screws tightening torque 1 Nm B Programming module C X107 Fig 6 8 Removing the programming module IndraDrive Mi Drive Systems...

Page 180: ...the plug in connections might be damaged At the bottom of the cover with the connection points there is a circuit board Always leave this circuit board at its place Otherwise the seals O rings might fall out of the cover Before placing the cover back onto the housing and tightening the screws Ensure that the circuit board with the connection points is still correctly plugged in under the cover Tab...

Page 181: ... 2 Rx Receive Differential Input A 3 Tx Transmit Differential Output B 4 Rx Receive Differential Input B 5 Shield Shield connection Only use shielded cables for which the shield has been connected to ground over the largest possible surface area via the housing Female connector M12 5 pin D coded Ready made connection cable RKB0043 M12 M12 RKB0044 M12 RJ 45 Tab 6 24 X108 X109 function pin assignmen...

Page 182: ...circuit board see figure LK_A If neither a component nor the RKB0043 cable has been connected to X108 and X109 the communication in the drive line is interrupted ext External component or RKB0043 cable int Internal signal processing LK_A Internal circuit board for communication output coupling X_serc Internal communication interface Fig 6 10 Devices with communication output coupling In the case o...

Page 183: ...ed At the bottom of the cover 4 there is a circuit board 5 Always leave the circuit board 5 at its place Otherwise the seals 2 might fall out of the cover 4 The figure shows how the parts are correctly arranged in case you have to reassemble the parts 1 Protective caps 2 2 Seals O rings 2 3 Screws 4 the screws are locked and cannot fall out of the cover 4 Cover 5 Circuit board Tab 6 25 Parts Indra...

Page 184: ... Differential Input A 3 Tx Transmit Differential Output B 4 Rx Receive Differential Input B 5 Shield Shield connection Only use shielded cables for which the shield has been connected to ground over the largest possible surface area via the housing Female connector M12 5 pin D coded Ready made connection cable RKB0043 M12 M12 RKB0044 M12 RJ 45 Tab 6 26 X118 X119 function pin assignment properties ...

Page 185: ...ignal is input via the RKB0044 connection cable at the RHS0014 terminal connector or at connection point X118 X119 cannot be used and it is transmitted to KCU via the hy brid cable The unused connection points X118 and X119 are deactivated IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 171 407 Connection points R911335703_Edition 04 Bosch Rexroth AG ...

Page 186: ... to KCU via the RKB0043 and RKB0044 connection cables RKB0043 Connection cable M12 M12 RKB0044 Connection cable M12 RJ 45 RHS0014 Terminal connector int Internal signal processing LK_C Internal circuit board for communication X_serc Internal communication interface Tab 6 27 Connection 172 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG...

Page 187: ...g to the devices and device options Distributed drive chapter X141 safety technology Safe Torque Off on page 174 chapter X141 safety technology Safe Motion S3 SD options on page 176 chapter X141 without safety technology on page 177 Distributed supply unit chapter 6 6 5 X141 safety technology KMV03 on page 200 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 173 407 Connecti...

Page 188: ...6 V Release brake Short circuit to X141 9 input voltage 24 V 20 4 24V Dynamization outputs power supply 5 SI_Ch1_In Input for selection of channel 1 preceding axis connected to X103 1 10 6 0V_In 0V selection preceding axis connected to X103 1 9 7 SI_Ch2_In Input for selection of channel 2 preceding axis connected to X103 1 8 8 Dyn_Ch1 Channel 1 dynamization output 1 9 24V_ZBr Internal interface on...

Page 189: ...ons short circuit between the two signal wirings has to be excluded Tab 6 28 Function pin assignment properties Technical data Function Signal Connection Technical data Channel 1 selection SI_Ch1 1 chapter 14 1 2 Digital inputs safety technology L options on page 369 Channel 2 selection SI_Ch2 2 Channel 1 dynamization output Dyn_Ch1 8 chapter 14 2 1 Digital outputs safety technology L options on p...

Page 190: ... SI_In_Ch1_Zone Input 1 from preceding axis 6 0V_Zone 0 V from preceding axis 7 SI_In_Ch2_Zone Input 2 from preceding axis 8 SI_Out_Ch1 Safe output channel 1 9 24V_Br Internal interface only 24 V for release brake function 10 0V Power supply of the inputs and outputs 11 GND GND for zone detection function 12 SI_Out_Ch2 Safe output channel 2 Ready made connection cable RKB0033 Can be used for proce...

Page 191: ...male connector M12 12 pin D coded 1 n c 2 n c 3 Zone_Br X141 3 has to be accordingly controlled for the desired function Release brake Short circuit to X141 9 input voltage 24 V 20 4 n c 5 n c 6 n c 7 n c 8 n c 9 24V_Br Internal interface only 24 V for release brake function 10 n c 11 12 n c Ready made connection cable RKB0033 Can be used to release brake Tab 6 31 Function pin assignment propertie...

Page 192: ...he installation if the electric resistance between the mechanical holder of the flange and the equipment grounding system of the installation is greater than 5 ohm If you would like to measure the resistance the following conditions previously must have been complied with The installation has been switched off This avoids parasitic leakage currents The hybrid cables have not been connected to the ...

Page 193: ...ct KSM0x KMS0x to a grounded part of the installation e g the machine base Thread M5 for ring cable lug Unit min max Tightening torque Nm 2 6 3 1 Cable cross section stranded wire mm2 2 5 AWG 14 Tab 6 32 Second connection point of equipment grounding conductor proper ties IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 179 407 Connection points R911335703_Edition 04 Bosch R...

Page 194: ... KMS02 1B xxxx x xx xx ENA xx xx xx KMS02 1B xxxx x xx xx xxx xx WN WT WE xx Angular connector X107 Programming module X1x8 X1x9 Communication optional X108 X109 Communication output coupling X118 X119 External communication X141 Safety technology optional X156 Motor KMS02 1B xxxx x xx xx ENA xx xx xx Motor motor encoder KMS02 1B xxxx x xx xx xxx xx WN WT WE xx Angular connector 2nd Second connect...

Page 195: ...outputs on page 159 6 4 3 X103 1 X103 2 hybrid cable connection point See description KSM02 chapter 6 3 3 X103 1 X103 2 hybrid cable connection point on page 163 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 181 407 Connection points R911335703_Edition 04 Bosch Rexroth AG ...

Page 196: ...nnector housing 10 pin female connector Unit min max Connection cable stranded wire mm2 n s n s Order type of cable RKG4201 Allowed length m n s 7 5 Tab 6 34 X104 motor encoder 6 4 5 X107 programming module See chapter 6 3 4 X107 programming module on page 165 6 4 6 X108 X109 communication output coupling See chapter 6 3 5 X108 X109 communication output coupling on page 167 6 4 7 X118 X119 externa...

Page 197: ...r 0V 9 GND_shld Shield 9 pin female connector Unit Min Max Output for controlling the motor holding brake X156 7 8 Output current A A 0 15 1 1 Continuous power overvoltage protection B W n s 1 5 Energy absorption B Ws n s 3 Cable RKL4305 Allowed length m n s 7 5 1 With deactivated brake current monitoring 0 A Tab 6 35 X156 motor IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC...

Page 198: ...y 8 GND_Encoder Power supply reference potential 9 EncData Data transmission 10 EncData Data transmission 11 pin female connector Unit min max Output for controlling the motor holding brake X156 4 5 Output current A A 0 15 1 1 Continuous power overvoltage protection B W n s 1 5 Energy absorption B Ws n s 3 Cable RH2 030DB Allowed length m n s 5 1 With deactivated brake current monitoring 0 A Tab 6...

Page 199: ...or connection point See chapter 6 3 8 Second connection point of equipment grounding conductor on page 178 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 185 407 Connection points R911335703_Edition 04 Bosch Rexroth AG ...

Page 200: ...inputs outputs X103 1 X103 2 Hybrid cable X107 Programming module underneath the cover X1x8 X1x9 Communication optional X108 X109 Communication output coupling X118 X119 External communication X141 Safety technology optional XD3 Motor XG3 Brake temperature XG4 Motor encoder digital XG8 Motor encoder analog Second connection point of equipment grounding conductor Tab 6 37 KMS03 connection points 18...

Page 201: ...as supplied 1 Connection cover 2 Protective covering 3 Screws M4 2 5 Nm Fig 6 14 Connection cover with protective covering IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 187 407 Connection points R911335703_Edition 04 Bosch Rexroth AG ...

Page 202: ...away from the housing Fig 6 15 Connection cover Mounting options Two piece connection cover See chapter 14 3 Two piece connection cover on page 374 188 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 203: ...d to connect the separate encoder cable and the HAS05 1 018 dummy cover is put on the connection cover 3 Screw on cable plate at connection cover with 2 5 Nm 4 Put encoder cable connector RGS0725 through small opening and plug connector XG4 XG8 into device 5 Screw on cable plate at connection cover with 2 5 Nm 6 Screw on connection cover with 2 5 Nm IndraDrive Mi Drive Systems with KCU02 KSM02 KMS...

Page 204: ... Motor encoder digital XG8 Motor encoder analog P Cable plate Fig 6 16 Motor cable and encoder cable 190 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 205: ...0 Stripped length mm 10 Tightening torque Nm 0 5 0 8 Tab 6 39 Mechanical data Electrical data Spring terminal connector Unit min max Rated voltage V 1000 Nominal current A 41 Tab 6 40 Electrical data Cables Description Value Order type See description of connectors RLS0725 RHS0725 Maximum allowed length 7 5 m Maximum allowed length of all motor cables when using KNK03 KMV03 50 m Tab 6 41 Cables In...

Page 206: ...m the housing Excess voltage at the input e g by the motor winding voltage flashing over can get to the housing Make sure that the temperature sensor of the connected motor is double insulated from the motor winding Risk of damage to device from excess voltage at motor temperature evaluation input NOTICE Only the allowed control voltage for the device is allowed at the motor temperature evaluation...

Page 207: ...minimum allowed resistance of motor holding brake Ubr max maximum supply voltage of motor holding brake If Ubr max 24 V 5 25 2 V then Rbr min 19 53 Ω applies to all operating and ambient conditions Motor holding brake Notes on in stallation Make sure the power supply is sufficient for the motor holding brake at the motor Observe that voltage drops on the supply line Use connection lines with the l...

Page 208: ...ram Fig 6 17 Connection of motor temperature monitoring and motor holding brake 194 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 209: ...5V Encoder supply 5 V 6 12V Encoder supply 12 V 7 GND_Encoder 0V reference potential for power supplies 8 GND_shld Signal shields connection inner shield Tab 6 46 Pin assignment Mechanical data Spring terminal connector Unit min max Connection cable Stranded wire mm2 0 2 1 5 AWG 24 16 Stripped length mm 10 Tab 6 47 Mechanical data Cables Description Value Order type See description of connectors R...

Page 210: ...ative 4 B max 1 65 Vpp track B analog negative Tab 6 49 Pin assignment Mechanical data Spring terminal connector Unit min max Connection cable Stranded wire mm2 0 2 1 5 AWG 24 16 Stripped length mm 10 Tab 6 50 Mechanical data Cables Description Value Order type See description of connectors RGS0725 Maximum allowed length 7 5 m Maximum allowed length of all encoder cables when using KNK03 KMV03 50 ...

Page 211: ...coupling See chapter 6 3 5 X108 X109 communication output coupling on page 167 6 5 11 X118 X119 external communication See chapter 6 3 6 X118 X119 external communication on page 170 6 5 12 X141 safety technology See chapter 6 3 7 X141 safety technology and service input release brake on page 173 6 5 13 Second equipment grounding conductor connection point See chapter 6 3 8 Second connection point ...

Page 212: ... KMV03 1R Wxxxx Fan XG3 2 Mains choke temperature contact XG14 2 Mains voltage synchronization XG34 1 Mains contactor control and feedback contacts KNK03 Second connection point of equipment grounding conductor 1 RKH0800 cable connects KMV to KNK 2 RKH0801 cable connects KMV to KNK 3 RKB0054 cable Tab 6 52 KMV03 connection points 198 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM...

Page 213: ...n be assigned to parameters 6 6 3 X103 1 X103 2 hybrid cable connection point See description KSM02 chapter 6 3 3 X103 1 X103 2 hybrid cable connection point on page 163 6 6 4 X118 X119 external communication See chapter 6 3 6 X118 X119 external communication on page 170 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 199 407 Connection points R911335703_Edition 04 Bosch Re...

Page 214: ...connected to X103 2 9 11 n c 12 n c Ready made connection cable RKB0033 Can be used to input the signals for Safe Torque Off safety technology Tab 6 53 Function pin assignment properties Technical data Function Signal Connection Technical data Channel 1 selection SI_Ch1 1 chapter 14 1 2 Digital inputs safety technology L options on page 369 Channel 2 selection SI_Ch2 2 Tab 6 54 Technical data 6 6 ...

Page 215: ...length mm 10 Tightening torque Nm 0 8 Tab 6 56 Mechanical data Electrical data Screw terminal connector Unit Value Occurring current load and minimum required connection cross section A See technical data IL_cont IL_max and ALN Occurring voltage load V See technical data ULN Tab 6 57 Electrical data Cables Description Value Order type RKH0800 Maximum allowed length 1 m Tab 6 58 Cables IndraDrive M...

Page 216: ...th mm 10 Tightening torque Nm 0 8 Tab 6 60 Mechanical data Cables Description Value Order type Cable cannot be ordered Customer assembles the cable HAS05 1 020 accessories required Tab 6 61 Cables 6 6 9 XD13 fan power supply Connection point for RKB0054 cable See chapter 10 17 RKB0054 fan cable on page 330 202 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 ...

Page 217: ...echanical data Spring terminal connector Unit max Connection cable Stranded wire mm2 1 5 AWG 16 Stripped length mm 10 Tab 6 63 Mechanical data Cables Description Value Order type RKH0801 Maximum allowed length 1 m Tab 6 64 Cables IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 203 407 Connection points R911335703_Edition 04 Bosch Rexroth AG ...

Page 218: ...signment Mechanical data Screw terminal connector Unit max Connection cable Stranded wire mm2 6 AWG 8 Stripped length mm 10 Tightening torque Nm 0 8 Tab 6 66 Mechanical data Cables Description Value Order type RKH0801 Maximum allowed length 1 m Tab 6 67 Cables 204 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 219: ...s filter XG34 3 4 4 Tab 6 68 Pin assignment Mechanical data Spring terminal connector Unit max Connection cable Stranded wire mm2 1 5 AWG 16 Stripped length mm 10 Tab 6 69 Mechanical data Cables Description Value Order type RKH0800 Maximum allowed length 1 m Tab 6 70 Cables IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 205 407 Connection points R911335703_Edition 04 Bosch...

Page 220: ...tions Tightening torque of the mounting screws 2 5 Nm 6 6 14 Two piece connection cover See chapter 14 3 Two piece connection cover on page 374 206 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 221: ... contacts Second connection point of equipment grounding conductor 1 Coding pins prevent the connectors XD1 and XD1 2 from being incorrectly plugged 2 RKH0800 cable connects KMV to KNK 3 RKH0801 cable connects KMV to KNK 4 RKB0054 cable Tab 6 71 KNK03 connection points 6 7 2 Second equipment grounding conductor connection point See chapter 6 3 8 Second connection point of equipment grounding condu...

Page 222: ...rque Nm 0 8 Tab 6 73 Mechanical data Electrical data Screw terminal connector Unit Value Occurring current load and minimum required connection cross section A See technical data IL_cont IL_max and ALN Occurring voltage load V See technical data ULN Tab 6 74 Electrical data Cables Description Value Order type Cable cannot be ordered Customer assembles the cable HAS05 1 019 accessories required Tab...

Page 223: ...al data Screw terminal connector Unit Value Occurring current load and minimum required connection cross section A See technical data IL_cont IL_max and ALN Occurring voltage load V See technical data ULN Tab 6 78 Electrical data Cables Description Value Order type RKH0800 Maximum allowed length 1 m Tab 6 79 Cables 6 7 5 XD13 fan power supply Connection point for RKB0054 cable See chapter 10 17 RK...

Page 224: ...nnection cable Stranded wire mm2 6 AWG 8 Stripped length mm 10 Tightening torque Nm 0 8 Tab 6 81 Mechanical data Electrical data Screw terminal connector Unit Value Nominal current A 41 Rated voltage V 1000 Tab 6 82 Electrical data Cables Description Value Order type RKH0801 Maximum allowed length 1 m Tab 6 83 Cables 210 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 K...

Page 225: ... 1 5 AWG 16 Stripped length mm 10 Tab 6 85 Mechanical data Electrical data Screw terminal connector Unit Value Nominal current A 8 Nominal voltage V 150 Tab 6 86 Electrical data Cables Description Value Order type RKH0801 Maximum allowed length 1 m Tab 6 87 Cables IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 211 407 Connection points R911335703_Edition 04 Bosch Rexroth A...

Page 226: ...ax Connection cable Stranded wire mm2 1 5 AWG 16 Stripped length mm 10 Tab 6 89 Mechanical data Electrical data Screw terminal connector Unit Value Nominal current A 8 Rated voltage V 160 Tab 6 90 Electrical data Cables Description Value Order type RKH0800 Maximum allowed length 1 m Tab 6 91 Cables 212 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bo...

Page 227: ...ions Tightening torque of the mounting screws 2 5 Nm 6 7 10 Two piece connection cover See chapter 14 3 Two piece connection cover on page 374 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 213 407 Connection points R911335703_Edition 04 Bosch Rexroth AG ...

Page 228: ...ion points 6 8 2 Second equipment grounding conductor connection point See chapter 6 3 8 Second connection point of equipment grounding conductor on page 178 6 8 3 XD13 fan power supply Connection point for RKB0054 cable See chapter 10 17 RKB0054 fan cable on page 330 214 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Editi...

Page 229: ...ctrical data Screw terminal connector Unit Value Occurring current load and minimum required connection cross section A See technical data IL_cont IL_max and ALN Occurring voltage load V See technical data ULN Tab 6 95 Electrical data Cables Description Value Order type RKH0802 KMV03 KLC03 RKH0803 KLC03 KLC03 Maximum allowed length tbd m Tab 6 96 Cables IndraDrive Mi Drive Systems with KCU02 KSM02...

Page 230: ...tion cover Mounting options on page 213 6 8 6 Two piece connection cover See chapter 14 3 Two piece connection cover on page 374 216 407 Connection points IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 231: ... C Cs HCS components See chapter 14 4 Sizing mains filters drive system on page 375 7 1 3 Power supply by HMV01 HMV02 HCS01 HCS02 or HCS03 Supply units Both supply units HMV01 HMV02 and converters HCS01 HCS02 HCS03 can be used as supply units for an IndraDrive Mi drive system The sum of the electric powers of all KCU at the DC bus of the supply unit should not exceed PDC_cont and PDC_max of the su...

Page 232: ...r supply monitoring that can be set See also P 0 0114 Undervoltage threshold See also Functional Description of firmware Power supply 7 1 4 Power supply by HCS01 HCS01 1E W0054 drive controllers can be used to supply power to KSM0x motor integrated servo drives or KMS0x near motor servo drives In this case the KCU drive connection box is not required See fig 9 8 IndraDrive Mi system with HCS01 1E ...

Page 233: ... power required Optional external master communication ES PES Optional safety technology L3 PL3 Power requirement contained in basic power of the component PBasic Motor holding brake KSM 041 PBr 12 Motor holding brake KSM 061 18 Motor holding brake KSM 071 24 Motor holding brake KSM 076 24 Motor holding brake KMS n s See specification of motor holding brake of the connected motor Tab 7 1 Control v...

Page 234: ...s 24V supply for operation From the applied 24V supply KCU supplies itself and at X53 control voltage output generates the 42V control voltage for the KSM KMS in the drive line Control voltage KCU KSM KMS BR Circuit for brake control I O Inputs outputs int Internal electronics KCU Drive connection box KMS Near motor servo drive KSM Motor integrated servo drive Fig 7 3 Control voltage KCU KSM KMS A...

Page 235: ...ig 7 4 Load X53 KCU power consumption from 24V supply PN3 KCU KCU power consumption fSMPS 1 2 correction factor for KCU power supply unit losses P42V KCU load at X53 Fig 7 5 KCU power consumption from 24V supply The 24V supply has to make available the inrush current generated when each KCU drive connection box is switched on The inrush current depends on the power consumption PN3 KCU see calculat...

Page 236: ...small number of KSM KMS and a low degree of power consumption in a drive line operation at partial load the measurable value Istrang at the output of KCU is above the value which would result from the calculation of the power PLN of KSM KMS and Uout of KCU The deviation is due to reactive currents The influence of these currents is insignificant in operation under rated conditions Continuous power...

Page 237: ...e increases the peak power available at the cable end is reduced Peak power depending on the cable length Due to occurring voltage drops the effective length of the cable influences the available peak power at KSM KMS Observe the following diagrams and the sections Peak power when accelerating on page 224 Peak Power when Decelerating on page 225 DC 500 V DC 565 V IndraDrive Mi Drive Systems with K...

Page 238: ...s peak power is available at KSM KMS with increasing length of the motor cable During acceleration this becomes noticeable by the reduction of the corner speed The figure shows exemplary curves of reduction to 80 and 90 of the data sheet corner speeds The maximum speed is proportional to the DC bus voltage available at the motor In the drive line place the KSM KMS with the greatest power as near a...

Page 239: ... and Motor Fig 7 10 Example of power distribution with cable length of 100 m and corner speed reduced to 90 Peak Power when Decelerating The peak power when decelerating is independent of the supply unit used and the mains voltage But the peak power is reduced as of a cable length of approx 80 m due to the voltage limitation taking effect in KSM KMS The critical case is when all motors decelerate ...

Page 240: ...e e g for return motions Avoids load peaks on the mains side when using the Smart Energy Mode A maximum of 2 KLC03 at one KMV03 are allowed per drive line Resulting maximum DC bus capacitance CKMV03 2 CKLC03 2 35 mF 2 4 7 mF 11 75 mF Project planning software The project planning software HMV_SmartEnergyMode exe by Rexroth can be used to size the DC bus capacitance If necessary please contact our ...

Page 241: ...wed cable length see also chapter Hybrid cable length vs KCU performance on page 231 Definition of the cable lengths ltotal Total length lseg Segment length lseg_out_1 Segment length with communication output coupling D1_X108 external component lseg_out_2 Segment length with communication output coupling external component D1_X109 D1_X103 2 D2_X103 1 lschlepp Flexible cable track length Fig 7 11 D...

Page 242: ... length Total cable length from connection point of supply component e g KCU to last KSM KMS of a drive line 2 For electric decoupling at rated current 3 Segment length Cable length between two KSM KMS 4 For thermal decoupling of the connection points at rated cur rent 5 Segment length Cable length between external component and KSM KMS Tab 7 4 Cable length limit values For routing in the flexible...

Page 243: ...ngth of the movable part of the cable connection between two motors The RKH0700 cable can be used for the movable part of the flexible cable track connection so that it is replaceable and thereby easy to maintain Technical justification of the specified lengths Only within the specified lengths is it ensured that the properties of the Ethernet communication attenuation crosstalk remain in the allo...

Page 244: ...g 7 13 Definition of the lengths Allowed lengths Limit values Symbol Unit Value min max For permanent routing Total length 1 ltotal m 3 200 Segment length from supply component e g KCU to first KSM KMS lseg_1 m 3 2 75 Segment length 3 lseg_2 m 1 4 75 1 Total length Total cable length from connection point of supply component e g KCU to last KSM KMS of a drive line 2 For electric decoupling at rate...

Page 245: ...tributed over the entire length of the drive line The cables between the individual servo drives all have the same length B Servo drives evenly distributed at the end of the drive line The servo drives are arranged at the end of the drive line and interconnected with short cables 1 m C Servo drives evenly distributed starting at 20 of the drive line The first servo drive is arranged at 20 of the l...

Page 246: ...th of a drive line P42V KCU output X53 load without cable losses Fig 7 14 Maximum allowed hybrid cable length of a drive line For exact calculations of the allowed hybrid cable lengths in limit cases please contact our sales representative The figure below shows PN3 KCU KCU power consumption from 24V supply depending on P42V KCU output X53 load 232 407 Notes on project planning IndraDrive Mi Drive...

Page 247: ...er consumption from 24V supply Fig 7 15 PN3 KCU vs P42V PN3 KCU is a value for the project planning of the 24V supply It is impossible to deduce thermal losses in the control cabinet from the difference between the power PN3 KCU and P42V The typical losses of KCU are approx 40 less than the maximum calculated values IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 233 407 No...

Page 248: ... distributed over the entire length of the drive line The cables between the individual servo drives all have the same length B Servo drives evenly distributed at the end of the drive line The servo drives are arranged at the end of the drive line and interconnected with short cables 1 m C Servo drives evenly distributed starting at 20 of the drive line The first servo drive is arranged at 20 of t...

Page 249: ...P42V 489 5 W ltotal_max Maximum allowed hybrid cable length of a drive line P42V KMV output XD10 load without cable losses Fig 7 16 Maximum allowed hybrid cable length of a drive line For exact calculations of the allowed hybrid cable lengths in limit cases please contact our sales representative The figure below shows PN3 KMV KMV power consumption from 24V supply depending on P42V KMV output XD10...

Page 250: ...o drives evenly distributed starting at 20 of the drive line P42V KMV output XD10 load without cable losses PN3 KMV Maximum KMV power consumption from 24V supply Fig 7 17 PN3 KMV vs P42V 236 407 Notes on project planning IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 251: ...M without optional safety technology not a safety zone node RBS0023 Connector for safety zone node at connection point X141 only required for KSM KMS with optional safety technology RKB0033 Cable for transmitting the safety related signals S 1 S 2 Signals of the individual safety zones SI Zone 1 SI Zone 2 Safety zones X49 X141 Connection points of safety technology Fig 7 18 Safety zones IndraDrive...

Page 252: ...y unit via a safety PLC Passive safety unit Active safety unit int Dyn Dynamization pulses are internally generated ext External safety unit for a safety zone X Connection point of the safety zone beginner Tab 7 6 Signal input Safety zone node When a KSM KMS with optional safety technology is to be a safety zone node within a safety zone X141 has to be equipped with the connector RBS0023 238 407 N...

Page 253: ...not react to safety technology signals Documentation The subject of safety technology is very complex so that it is not explained in detail in this Project Planning Manual For detailed information on safety technology see the documentation Rexroth IndraDrive Integrated Safety Technology as of MPx 1x mat no R911332634 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 239 407 N...

Page 254: ...n each KSM KMS Assigning and transmitting E Stop signals If a KSM KMS KMV has been configured as a safety zone beginner X141 3 n c P 0 0249 2 and an E Stop signal has been assigned to this KSM KMS KMV via an I O X37 X38 with KMV X37 4 X38 4 this E Stop signal is transmitted to the subsequent KSM KMS parameters involved P 0 0223 P 0 0300 When a new safety zone begins a new E Stop zone can be begun ...

Page 255: ... any element of P 0 0300 default state 2 Position of switch if X141 equipped with RKB0033 cable or open P 0 0249 2 zone beginner 3 Position of switch if X141 equipped with RBS0023 connector P 0 0249 1 zone node Fig 7 20 E Stop zone setup The E Stop zone setup is independent of whether a safety technology option L3 is available or not IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK0...

Page 256: ... Functional Description of firmware E Stop function 7 1 11 Motor fan for KSM02 Fans are not available for KSM02 motor integrated servo drives 7 1 12 Evaluating motor encoders at KMS KMS02 chapter 6 4 4 X104 motor encoder connection on page 182 KMS03 chapter 6 5 5 XG4 digital motor encoder connection on page 195 chapter 6 5 6 XG8 analog motor encoder connection on page 196 242 407 Notes on project ...

Page 257: ...V 50 Hz at mains voltage ULN 3 AC 400 V or Operation at minimum switching frequency fs fs min Rotary field at output with fout fout_still Overload ratio K PDC_peak PDC_base according to UEL_P_e performance profile Observe the performance data PDC_peak and PDC_base in the UEL_P_e performance profile of the supply unit and the performance data of the KCU drive connection box Selecting standard motor...

Page 258: ...erformance profile of the supply unit or converter Profile Explanation Performance profile UEL_P_e Characteristic of the selection of standard motors and servo drives Tab 7 8 Definition of Performance Profiles Infeeding Supply Units and Con verters 244 407 Notes on project planning IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 259: ... the factory setting of the address selector switches This setting is not applied The individual drive address must be set in parameter S 0 1040 Drive address of master communication 01 99 H 0 9 L 0 9 Drive address H 10 L Settings of the address selector switches are applied to S 0 1040 Drive address of master communication during the booting process Example for setting drive address 14 H 1 L 4 dr...

Page 260: ...alue 13 to S 0 1040 3 Drive has the IP address 192 168 0 13 with subnet mask 255 255 255 0 Manual assignment Manual assignment of the IP address means The desired value is always directly written to the parameter S 0 1020 The drive address or the address selector switches are without effect The value in S 0 1020 is only valid after the IP settings have been activated C6100 Command Activate IP sett...

Page 261: ...tial commissioning See also P 0 0141 Thermal drive load k Overload ratio A Rotating shaft n 60 min 1 B Standstill n 60 min 1 Fig 7 23 Example of current limitation To determine the resulting torque or current limitations additionally take the motor current limitations into account See KSM02 characteristics or for KMS02 the data sheet of the motor used 7 2 4 Motor temperature Since the electronics ...

Page 262: ...possible to dissipate the power dissipation generated in the mounting clearance e g control cabinet while the local ambient temperature does not exceed the allowed ambient temperature Ta_work KCU ventilation Take the air intake and air outlet into account for ventilation Observe the data dtop dbot and dhor in the data sheet of KCU KSM KMS mounting clearance Make sure there is sufficient heat dissi...

Page 263: ...lancing with the complete key The motors have been balanced with the complete key This means that the machine element to be driven has to be balanced without a key Modifications to the keys may be made only by the users themselves and on their own responsibility Rexroth does not provide any warranty for modified keys or motor shafts Output shaft with shaft sealing ring The motors have been designe...

Page 264: ... of the shaft sealing ring Vertical mounting positions IM V3 The degree of protection on the flange side of motors with a shaft sealing ring is IP 65 Therefore tightness is ensured only in case of splashing fluids Fluid levels present on side A require a higher degree of protection If the motor is mounted in vertical position output shaft pointing up there should not be any fluid present at the ou...

Page 265: ...on the following factors Arithmetic mean speed nmean Point of application of force x Bearing service life Allowed axial force Faxial The maximum allowed axial force Faxial is specified in the technical data Average speed The run up and braking times can be ignored in the calculation if the time in which the drive is operated at a constant speed is significantly greater than the acceleration and br...

Page 266: ...uences of inadmissible loads Premature failure of the bearings due to increased wear or mechanical damage Avoid exceeding the load limits Mechanical bearing service life at increased radial force Otherwise the bearing service life is reduced as follows L10h Bearing service life according to ISO 281 ed 12 1990 Fradial Determined allowed radial force in N newton Fradial_ist Actually acting radial fo...

Page 267: ... brake should not be used for safety relevant purposes either Holding brakes are available as an option The supplied holding brake has been adapted to the corresponding motor Safety requirements In normal operation use the brake only in standstill and for performing the drive integrated brake test The holding brake is required for holding the axis when the machine is in a de energized state Observ...

Page 268: ...t counterbalancing of the vertical axes Other appropriate measures Controlling the holding brake The control electronics controls the integrated holding brake which excludes user errors Function check Before commissioning and in operation check the holding brake for its function in periodic intervals e g every 8 hours with an appropriate check By applying a defined torque to the motor check whethe...

Page 269: ...dation Considering these factors the following recommendation can be made for sizing holding brakes at axes The holding torque required for the application should not exceed a maximum of 60 of the static holding torque M4 of the holding brake used Holding torque reduction and premature wear occur when braking moving axes NOTICE Do not use the holding brake to stop a moving axis during normal opera...

Page 270: ... characteristics have to be reduced by approx 10 20 when gearboxes are attached Observe all other notes and requirements contained in the documentations on the gearboxes used Coupling attachment The machine design and the attachment elements used have to be carefully adapted to the motor type so that the load limits of shaft and bearing are not exceeded Risk of damage NOTICE When connecting extrem...

Page 271: ...e risk of exceeding the maximum allowed axial force or of the backlash within the gears increasing to an impermissible degree In such cases you should therefore preferably use drive elements with their own bearings which are connected to the motor shaft via axially compensating couplings IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 257 407 Notes on project planning R9113...

Page 272: ...258 407 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 273: ...1 2 KSM02 KMS02 Standard Optional KSM02 or KMS02 Documentation System type plate RBS0023 Connector for safety zone node RKB0033 Safety technology cable X141 external safety unit RKB0043 Cable for communication M12 D M12 D RKB0044 Cable for communication M12 D RJ 45 RKS0010 Interface cable M12 A open ends HAS10 Fixing clip for hybrid cables Tab 8 2 Scope of supply IndraDrive Mi Drive Systems with K...

Page 274: ...n HAS10 Fixing clip for hybrid cables Tab 8 3 Scope of supply 8 1 4 KMV03 Standard Optional KMV03 Documentation System type plate HAS05 1 020 KMV03 control voltage HAS10 Fixing clip for hybrid cables Tab 8 4 Scope of supply 8 1 5 KNK03 Standard Optional KNK03 System type plate HAS05 1 019 KNK03 mains voltage Tab 8 5 Scope of supply 8 1 6 KLC03 Standard Optional KLC03 System type plate Tab 8 6 Scop...

Page 275: ...ing the delivered components 8 2 1 KSM type plate Arrangement Fig 8 1 Type plate arrangement IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 261 407 Identification R911335703_Edition 04 Bosch Rexroth AG ...

Page 276: ...nt conditions according to UL50 50E 21 Holding brake torque optional 22 Rated power t 10 min 23 Rated input voltage power UL 24 Company address 25 Maximum bypass current UL 26 Ambient temperature during operation 27 Short circuit current rating UL SCCR 28 Cooling type 29 Rated power consumption control voltage input at UN3 UL 30 Rated control voltage input UL 31 Parts number 32 Production date Fig...

Page 277: ...8 2 2 KMS02 type plate Arrangement Fig 8 3 Type plate arrangement IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 263 407 Identification R911335703_Edition 04 Bosch Rexroth AG ...

Page 278: ...s according to UL50 50E 19 Rated input current UL 20 Rated input voltage UL 21 Company address 22 Maximum bypass current UL 23 Allowed ambient temperature 24 Short circuit current rating UL 25 Cooling type 26 Rated power consumption control voltage input at UN3 UL 27 Rated control voltage input UL 28 Parts number 29 Production date Fig 8 4 Type Plate KMS02 System type plate chapter 8 2 7 System ty...

Page 279: ...8 2 3 KMS03 type plate Arrangement Fig 8 5 Type plate arrangement IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 265 407 Identification R911335703_Edition 04 Bosch Rexroth AG ...

Page 280: ...ber 16 Mass 17 Rated input current 18 Rated input voltage 19 Company address 20 Maximum bypass current 21 Allowed ambient temperature 22 Cooling type 23 Rated power consumption control voltage input at UN3 24 Rated control voltage input 25 Material number 26 Production date Fig 8 6 KMS03 type plate System type plate chapter 8 2 7 System type plate module of configured variants on page 273 266 407 ...

Page 281: ...8 2 4 KMV03 type plate Arrangement Fig 8 7 Type plate arrangement IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 267 407 Identification R911335703_Edition 04 Bosch Rexroth AG ...

Page 282: ...9 14 Serial number 15 Mass 16 Rated input current 17 Rated input voltage 18 Company address 19 Allowed ambient temperature 20 Cooling type 21 Control current input 22 Rated control voltage input 23 Material number 24 Production date Fig 8 8 KMV03 type plate System type plate chapter 8 2 7 System type plate module of configured variants on page 273 268 407 Identification IndraDrive Mi Drive Systems...

Page 283: ...Arrangement Fig 8 9 Type plate arrangement A second type plate is enclosed with the product IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 269 407 Identification R911335703_Edition 04 Bosch Rexroth AG ...

Page 284: ...code 13 Hardware revision index 14 Degree of protection in accordance with IEC 60529 15 Serial number 16 Mass 17 Rated input current 18 Rated input voltage 19 Company address 20 Allowed ambient temperature 21 Cooling type 22 Material number 23 Production date Fig 8 10 KNK03 type plate 270 407 Identification IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R9...

Page 285: ...rrangement Fig 8 11 Type plate arrangement A second type plate is enclosed with the product IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 271 407 Identification R911335703_Edition 04 Bosch Rexroth AG ...

Page 286: ...Hardware revision index 12 Degree of protection in accordance with IEC 60529 13 Serial number 14 Input current 15 Input voltage 16 Company address 17 Allowed ambient temperature 18 Cooling type 19 Material number 20 Production date Fig 8 12 KLC03 type plate 272 407 Identification IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 287: ...gured variants SET with the KMS03 component 1 Trademark 2 Revision index 3 Production date YYWww 4 QR code 5 Manufacturing plant 6 Service hotline 7 Country of manufacture 8 Component A 9 Component A material number 10 Component B 11 Component B material number 12 Serial number module of configured variants 13 Material number module of configured variants 14 MAC address Ethernet ID 15 Type designa...

Page 288: ... design 1 Device type 2 Material number 3 Serial number 4 Bar code 5 Country of manufacture 6 Production week example 13W47 year 2013 week 47 7 Hardware revision index Fig 8 15 Type Plate 274 407 Identification IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 289: ...esign of UL performance data plate Fig 8 16 UL performance data plate IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 275 407 Identification R911335703_Edition 04 Bosch Rexroth AG ...

Page 290: ...276 407 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 291: ...herein Qualified technical staff must be trained instructed and qualified to switch electrical circuits and devices on and off in accordance with technical safety regulations to ground them and to mark them Qualified technical staff must possess appropriate safety equipment and have been trained in first aid Handling the devices Injuries or damage and invalidation of the warranty due to improper h...

Page 292: ...nection points The electrical connections of all sizes of KSM KMS have been standardized Two power connections hybrid connectors for power control voltage master communication and status messages to loop through the bus cable Two I O connectors M12 5 pin One safety technology interface M12 12 pin Optional two connection points for connecting the communication M12 4 pin Notes All connections have b...

Page 293: ...escription Unit Value Surface temperature C 60 Flatness mm 0 1 Surface roughness Rz 6 3 Tab 9 1 Cold plate IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 279 407 Mounting and installation R911335703_Edition 04 Bosch Rexroth AG ...

Page 294: ...ake does not attain the specified holding torque check the functioning of the holding brake see chapter Holding Brake Commissioning and Maintenance Instructions on page 362 Mounting KSM Mounting for Easy Servicing To allow trouble free servicing make sure that the following aspects are fulfilled after you have mounted KSM Connection points X37 X38 and X141 are easily accessible Connection points X...

Page 295: ... The screwed connections for flange assembly must be able to take up both the force due to weight of the motor and the forces acting during operation 9 2 3 Practical tips High electrical voltage Danger to life by electric shock WARNING Never remove live hybrid cable connectors X103 1 X103 2 Observe the following aspects for installation and mounting The hybrid cable coming from the supply unit has...

Page 296: ...ble Address selector switches are easily accessible Diagnostic LED is visible 2 Preferably mount the device to a conductive surface If this is impossible later on connect the second connection point of equipment grounding conductor at the device to the equipment grounding system of the installation 3 For devices of the W and A cooling types only the mounting position G1 is allowed 4 For the dimens...

Page 297: ... Immediately replace a damaged touch guard by an undamaged touch guard Keep the cutouts at the touch guard as small as possible Only remove the cutouts if necessary Cutouts at the touch guard If the DC bus and the control voltage are connected via contact bars only cutout A may be removed from the touch guard If the DC bus and the control voltage are connected via cables e g in the case of multipl...

Page 298: ... the device with a screw Tightening torque Max 2 8 Nm Tab 9 4 Touch guard at device 284 407 Mounting and installation IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 299: ...U02 connection diagram Optional Fig 9 3 Connection Diagram KCU02 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 285 407 Mounting and installation R911335703_Edition 04 Bosch Rexroth AG ...

Page 300: ... of B or I cooling type Thread M5 Tightening torque 6 Nm Devices of A or W cooling type Thread M6 Tightening torque 6 Nm Cold plate Devices of cooling type B are mounted on a cold plate Required cold plate properties See chapter 9 1 3 Cold plate on page 279 9 6 Electrical connection 9 6 1 General information High electrical voltage Danger to life by electric shock WARNING Working within the range ...

Page 301: ...e function It is supplied as ready made cable The outgoing direction of the hybrid cable cannot be changed subsequently Risk of damage by subsequently changing the outgoing direction of the hybrid cable NOTICE Do not try to reverse the cable outgoing direction of a ready made connector The flexible leads in the connector have individual lengths for each outgoing direction Risk of damage by leakage...

Page 302: ... Other mains connection options are described in the documentation Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 The additional components DST HNL HNF contained in the figure are not absolutely necessary As regards the detailed configuration of a drive system see documentation Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 288 407 Mounting and insta...

Page 303: ...0 KCU Drive connection box KSM Motor integrated servo drive MSK Servo motor optional RHS Terminal connector RKB Communication cable RKG Encoder cable optional RKH Hybrid cable RKL Motor cable optional X14 Mains synchronization only with regenerative HMVs X103 1 Connection of RKH hybrid cable at first KSM Fig 9 4 IndraDrive Mi drive system with HMV01 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS...

Page 304: ...or out put at HCS02 K1 Mains contactor KCU Drive connection box KSM Motor integrated servo drive MSK Servo motor 24V 24V supply RHS Terminal connector RKB Communication cable RKG Encoder cable RKH Hybrid cable RKL Motor cable X103 1 Connection of hybrid cable at first KSM Fig 9 5 IndraDrive Mi drive system with HCS02 290 407 Mounting and installation IndraDrive Mi Drive Systems with KCU02 KSM02 KM...

Page 305: ... Drive connection box KSM Motor integrated servo drive MSK Servo motor RHS Terminal connector RKB Communication cable RKH Hybrid cable RKG Encoder cable RKL Motor cable 24V 24V supply X103 1 Connection of hybrid cable at first KSM Fig 9 6 IndraDrive Mi drive system with HCS03 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 291 407 Mounting and installation R911335703_Editio...

Page 306: ...or integrated servo drive MSK Servo motor optional RHS Terminal connector RKB Communication cable RKG Encoder cable optional RKH Hybrid cable RKL Motor cable optional X14 Mains synchronization only with regenerative HMVs X103 1 Connection of RKH hybrid cable at first KSM Fig 9 7 IndraDrive Mi drive system with HMV02 292 407 Mounting and installation IndraDrive Mi Drive Systems with KCU02 KSM02 KMS...

Page 307: ...depending on the Y capacitances of KSM KMS HNL Mains choke optional K1 Mains contactor KSM Motor integrated servo drive alternative KMS near mo tor servo drive and motor MSK Servo motor RHS Terminal connector RKG Encoder cable RKH Hybrid cable RKL Motor cable X103 1 Connection of hybrid cable at first KSM Fig 9 8 IndraDrive Mi system with HCS01 1E W0054 IndraDrive Mi Drive Systems with KCU02 KSM02...

Page 308: ...tegrated mains choke and integrated mains contactor RHS Terminal connector RKG Encoder cable optional RKH Hybrid cable RKL Motor power cable X103 1 Connection of RKH hybrid cable at first KMS Fig 9 9 IndraDrive Mi drive system with KNK03 KMV03 KMS03 294 407 Mounting and installation IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 309: ...3 2 to KMS KSM X103 1 the actual hybrid cable RKH0xxx depends on the desired cable outgoing direc tions at the X103 1 and X103 2 connection points RKH0800 Ready made hybrid cable connects KMV XD1 XG34 to KNK XD1 2 XG34 RKH0801 Ready made hybrid cable connects KMV XG3 XG14 to KNK XG3 XG14 RKH0802 Ready made hybrid cable connects KMV X103 1 to KLC XG9 RKH0803 Ready made hybrid cable interconnects 2 ...

Page 310: ...t is necessary to additionally interconnect the second connection points of the equipment grounding conductor of the two KSM with a sepa rate cable RHS Terminal connector RKH Hybrid cable X103 1 Hybrid cable connection Fig 9 11 Parallel drive lines In the case of 2 drive lines 2 KCUs and 2 unassigned communication interfaces at the higher level control unit both KCUs can be directly connected to t...

Page 311: ...nit 2 KCU vs 2 KMV Instead of 1 HMV 2 KCU it is possible to use 2 KMV for parallel drive lines Fan connection Components of the W cooling type forced cooling need the RKB0054 cable material number R911378870 for the electrical connection of the fan See chapter 10 17 RKB0054 fan cable on page 330 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 297 407 Mounting and installati...

Page 312: ...298 407 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 313: ...KB0043 Cable for communication M12 D M12 D RKB0044 Cable for communication M12 D RJ 45 RKS0010 Cable with open ends M12 A open Fixing clip for hybrid cables HAS10 1 001 001 For devices without optional communication output coupling X108 X109 HAS10 1 001 002 For devices with optional communication output coupling X108 X109 HAS05 1 021 Hybrid joint HAS05 1 023 HCS01 adapter HAS05 1 024 Passive 42 V ...

Page 314: ... 019 KNK03 mains voltage connection plate HAS05 1 020 KMV03 control voltage connection plate RKB0054 Fan cable Tab 10 2 Accessories KMV03 KNK03 KMS03 KLC03 300 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 315: ...t bars for connecting the DC bus the control voltage supply Joint bar for connecting equipment grounding conductors of KCU and neighboring device For a detailed description see documentation Rexroth IndraDrive Additional Components and Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 301 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 316: ...ection Mount the shielding plate 1 to the drive connection box KCU according to the desired outgoing direction of the hybrid cable horizontal or 45 According to the diameter of the hybrid cable 3 the shielding plate 1 provides two supports 12 18 mm or 19 30 mm Fix the hybrid cable 3 to the corresponding support with a clip 2 Make sure that the shield 4 of the hybrid cable has good contact with the...

Page 317: ...r HCS03 device you therefore have to use the HAS03 1 002 control cabinet adapter which compensates the different mounting depths Fig 10 2 HAS03 For a detailed description see documentation Rexroth IndraDrive Additional Components and Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 303 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 318: ...umber R911371165 Fig 10 3 HAS05 1 018 dummy plate for KMS03 encoder connection The accessory contains the following parts Plate incl screws 304 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 319: ... KNK03 mains voltage The accessory contains the following parts Cable gland plastic M20 range 6 12 mm Plate incl screws Connector screw terminal Coding pin IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 305 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 320: ...1 020 KMV03 control voltage The accessory contains the following parts Cable gland plastic M20 range 6 12 mm Plate incl screws Connector screw terminal 306 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 321: ... hybrid cable and connects two devices mounted side by side Hybrid cable with communication Distance connector center connector center 62 87 mm Degree of protection IP65 Material number R911374654 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 307 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 322: ...nt 15 A Degree of protection IP65 External power supply required 42 VDC 10 e g PULS CPS20 361 100 240 V 480 W or QT20 361 380 480 V 480 W Material number R911392277 The accessory allows the drive line to be expanded by more components if one of the following conditions applies Power of the DC DC converter 24V 42V in KCU or KMV has already been used to capacity e g due to many motors with integrate...

Page 323: ...ction cable stranded wire mm2 1 5 1 5 Cable cross section AWG 16 16 Connection cable e g PHOENIX CONTACT power cable SAC 4P M12MRT 10 0 PUR SH 1424127 Tab 10 3 Function pin assignment properties IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 309 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 324: ...ready made hybrid cables RKH0341 RKH0441 RKH0541 RKH0909 D 36 mm Fig 10 8 HAS05 1 023 HCS01 adapter The minimum allowed top mounting clearance specified in the HCS01 dimensional drawings remains unchanged For information on the HCS01 drive controller please see the Project Planning Manual Rexroth IndraDrive Cs Drive Systems with HCS01 R911322210 310 407 Accessories IndraDrive Mi Drive Systems with...

Page 325: ...Hybrid cable shield RKH0341 RKH0441 RKH0541 RKH0909 X52 Status messages hybrid cable connection X52 1 Status messages HCS01 connection X47 X49 X53 Control voltage hybrid cable connection X53 1 Control voltage 42 V power supply unit connection Suitable power supply units PULS CPS20 361 input voltage AC 100 240 V PULS QT20 361 input voltage AC 380 480 V Tab 10 4 Connection points IndraDrive Mi Drive...

Page 326: ... 1 Control voltage negative pole 2 Control voltage positive pole Tab 10 5 Pin assignment Mechanical data Screw terminal connector Unit max Connection cable Stranded wire mm2 2 5 AWG 12 Stripped length mm 8 Tightening torque Nm 0 6 Tab 10 6 Mechanical data 312 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 327: ...10 Tab 10 8 Mechanical data X52 1 connection point View Connec tion Function 1 ModBus 2 ModBusGND 3 SI_Ch2 4 0V 5 SI_Ch1 6 nE Stop Tab 10 9 Pin assignment Mechanical data Spring terminal connector Unit max Connection cable Stranded wire mm2 1 5 AWG 16 Stripped length mm 10 Tab 10 10 Mechanical data IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 313 407 Accessories R9113357...

Page 328: ...05 1 023 product insert page 1 Fig 10 11 HAS05 1 023 product insert page 1 314 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 329: ...05 1 023 product insert page 2 Fig 10 12 HAS05 1 023 product insert page 2 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 315 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 330: ...he DC DC converter 24V 42V in KCU or KMV has already been used to capacity e g due to many motors with integrated holding brakes Voltage drop on the control voltage lines in the hybrid cable has reached its allowed limit e g due to long cables The basic sizing criteria like DC power or leakage capacitances for the allowed length of the drive line and the number of axes also apply when the accessor...

Page 331: ...ltages galvanically isolated between the zones before and after the accessory Allowed current 15 A Degree of protection IP65 External power supply required 42 VDC 10 e g PULS CPS20 361 100 240 V 480 W or QT20 361 380 480 V 480 W IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 317 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 332: ...g clip for hybrid cable connectors More mounting clearance is required to install the HAS10 accessory with a screwdriver B Drilling pattern Fig 10 15 HAS05 1 024 dimensions 318 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 333: ...oss section AWG 16 16 Connection cable e g PHOENIX CONTACT power cable SAC 4P M12MRT 10 0 PUR SH 1424127 Tab 10 11 Function pin assignment properties X103 1 X103 2 hybrid cable connection point chapter 6 3 3 X103 1 X103 2 hybrid cable connection point on page 163 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 319 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 334: ...tion 004 Motor monitor grounding 005 Mounting plate for device width 200 mm 006 Mounting plate for device width 220 mm 007 Fixing clip for increased vibration resistance maritime applications 008 335 mm Cross bar for HAS10 1 002 007 NN 009 555 mm Cross bar for HAS10 1 002 007 NN 010 775 mm Cross bar for HAS10 1 002 007 NN 011 995 mm Cross bar for HAS10 1 002 007 NN 012 Push through technology fram...

Page 335: ...10 1 001 001 NN The accessory HAS10 1 001 001 NN consists of a fixing clip with a screw The fixing clip is screwed to a KSM or KMS and increases the vibration resistance of the connected hybrid cable connectors Fig 10 16 HAS10 1 001 001 NN HAS10 1 001 002 NN The HAS10 1 001 002 NN accessory consists of the following parts Fixing clip with screw tightening torque 1 5 1 7 Nm RKB0043 cable Cable tie ...

Page 336: ...002 NN 10 11 3 Scope of supply Scope of supply Components of the accessory see product insert 322 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 337: ...10 1 001 001 NN product insert Fig 10 18 HAS10 1 001 001 NN product insert IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 323 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 338: ...10 1 001 002 NN product insert Fig 10 19 HAS10 1 001 002 NN product insert 324 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 339: ...e freely selected max 100 m RKB0021 xxx x xxx x length in meters Example 13 5 m RKB0021 013 5 R911389159 5 m RKB0021 005 0 R911389205 Tab 10 14 RKB0021 RKB0021 Plug in connector bus Bulk cable Plug in connector bus RJ 45 4 pin REB0400 RJ 45 4 pin Tab 10 15 RKB0021 interconnection diagram IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 325 407 Accessories R911335703_Edition ...

Page 340: ...ode Length Order code Material number 0 55 m RKB0013 00 55 R911317801 Tab 10 16 RKB0013 RKB0013 Plug in connector bus Bulk cable Plug in connector bus RJ 45 8 pin sercos III cable 100 Base T CAT5E shielded RJ 45 8 pin Use instruction only fixed lengths Tab 10 17 RKB0013 interconnection diagram 326 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth...

Page 341: ... order code Length Order code Material number 1 5 m RKB0033 001 5 R911334865 10 m RKB0033 010 0 R911335718 Tab 10 18 RKB0033 RKB0033 Plug in connector Bulk cable Plug in connector M12 12 pin Bus cable Open ends Interconnection diagram Use instruction only fixed lengths Tab 10 19 RKB0033 parts IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 327 407 Accessories R911335703_Edi...

Page 342: ...ngth That Can Be Ordered Or der Code Material Number Length Order code Material number To be freely selected RKB0043 xxx x xxx x length in meters R911172134 Tab 10 20 RKB0043 RKB0043 Plug in connector Bulk cable Plug in connector M12 4 pin male D coded Bus cable REB400 M12 4 pin male D coded Interconnection diagram A Coding groove B Coding nose Tab 10 21 Parts RKB0043 328 407 Accessories IndraDriv...

Page 343: ...es A higher level control unit Length That Can Be Ordered Or der Code Material Number Length Order code Material number To be freely selected RKB0044 xxx x xxx x length in meters R911172135 Tab 10 22 RKB0044 RKB0044 Plug in connector Bulk cable Plug in connector M12 4 pin male D coded Bus cable REB400 RJ 45 Interconnection diagram A Coding groove B Coding nose Tab 10 23 Parts RKB0044 IndraDrive Mi...

Page 344: ...e forced cooling Length that can be ordered order code material number Length Order code Material number To be freely selected RKB0054 xxx x xxx x length in meters R911378870 Tab 10 24 RKB0054 330 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 345: ...umber Length Order code Material number 3 m RKS0010 03 0 R911322843 Tab 10 25 RKB0013 RKS0010 Plug in connector Bulk cable Plug in connector M12 A coded shielded n s Open ends Interconnection diagram Tab 10 26 Parts RKS0010 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 331 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 346: ...he connector RBS0023 The connector RBS0023 jumpers the following connections 5 1 7 2 6 10 11 3 KSM KMS without optional safety technology can be operated within a safety zone without the connector RBS0023 because the signals are directly transmitted to the next safety zone node via X103 1 and X103 2 2 7 3 11 4 n c 5 1 6 10 7 2 8 n c 9 n c 10 6 11 3 12 n c Tab 10 28 Function pin assignment properti...

Page 347: ...xxx x M40 2 5 mm2 RL2 049EB NN xxx x MS2N 100K KMS03 Motor power cable M17 1 0 mm2 RL2 009CB NN xxx x M23 1 0 mm2 RL2 029CB NN xxx x M23 1 5 mm2 RL2 029DB NN xxx x M40 1 5 mm2 RL2 049DB NN xxx x M40 2 5 mm2 RL2 049EB NN xxx x M58 2 5 mm2 RL2 069EB NN xxx x IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 333 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 348: ... Fig 10 28 RGS0725 K02 KMS03 Encoder cable RG2 003AAB NN xxx x digital encoder RG2 003ABB NN xxx x analog encoder 334 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 349: ...d motor cable connector Fig 10 29 RHS0725 K02 MS2N KMS03 Hybrid motor cable RH2 029DBB NN xxx x IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 335 407 Accessories R911335703_Edition 04 Bosch Rexroth AG ...

Page 350: ...ve allowed cable length 2 Line cross section 0 2 mm 3 Line cross section 0 75 mm Fig 10 30 RH2 030DB MS2N KMS02 Hybrid motor cable RH2 030DBB NN xxx x 336 407 Accessories IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 351: ...the housing control cabinet machine A Clamping screw B Housing control cabinet wall C Gasket D Flange E Mounted to front wall F Mounted to back wall Tab 10 29 Metallic flange for circular connectors Supply source Intercontec Produkt GmbH Metallic flange hinged with sealing ring E0 222 02 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 337 407 Accessories R911335703_Edition ...

Page 352: ...accessory for detailed information Engineering The accessory netSWITCH sercos III can be looped into the sercos III ring for drive system engineering Drive system engineering is also possible via a connected control unit MLC or via a drive with an open sercos ring can be connected at terminal connector RHS0014 Tab 10 30 netSWITCH sercos III 338 407 Accessories IndraDrive Mi Drive Systems with KCU0...

Page 353: ...ained in the corresponding product documentation See the Functional Description of the firmware for the corresponding information The commissioning of drive controllers and control unit may require additional steps The functionality and performance check of the installations is not part of motor commissioning Instead it is carried out within the scope of the commissioning of the machine as a whole...

Page 354: ... conditions described are complied with during operation 340 407 Commissioning operation diagnostics and maintenance IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 355: ...Hardware defective Replace hardware Flashing green Firmware update active Transition command active PM parameter mode bb control section ready for oper mains voltage not available ZKS DC bus short circuit Ab drive ready for operation power on Bb control section and power section ready for operation mains voltage available charg DC bus charging active IndraDrive Mi Drive Systems with KCU02 KSM02 KM...

Page 356: ... and carry out service function Communication error F4xxx If necessary read detailed state via S 0 0095 Diagnostic message Red Booting phase Wait until booting phase is over approx 2 minutes System error F9xxx Switch off and on replace hardware if necessary Check whether programming module has been plugged 1 Flashing pattern One square corresponds to a duration of 250 ms the arrow marks the end of...

Page 357: ... regular status None Red Supply unit signals error Bb_V Check power supply see also F2086 Error supply module H52 3 Warning Green Supply unit without warning Warn regular status None Red Supply unit signals warning Check supply unit see also E2086 Prewarning supply module overload H52 4 DC Bus In Off DC bus voltage L L too low Switch power on at supply unit Module bus not connected if H54 green Co...

Page 358: ...ontrol voltage at output X53 okay None Red Control voltage at output X53 faulty or control voltage outside of tolerance Error is saved until switch off Overload at output Check control voltage supply Check voltage at X53 Reduce load Remove short circuit H54 DC Bus Out Off DC bus L L not ready for power output None Green DC bus L L ready for power output None Red DC bus voltage L L at output X54 no...

Page 359: ... If necessary read exact status via S 0 0095 Diagnostic message Green Power on and DC bus voltage available Ab Drive is error free in operation and runs according to inputs Drive in control AF AH or drive command active Cxxxs Flashing green yellow Switching command active C01xx C02xx Switching command error C01xx C02xx If necessary read exact status via S 0 0095 Diagnostic message Firmware update ...

Page 360: ... scan P 1 If necessary read exact status via S 0 0095 Diagnostic message Flashing red Error F2xxx F3xxx F6xxx F7xxx F8xxx Read exact status via S 0 0095 Diagnostic message and execute service function Firmware update Repeat firmware update Red Booting phase Wait until booting phase is over approx 2 minutes System error F9xxx E0800 Switch off and on replace hardware if necessary Check whether the p...

Page 361: ...al diagnostic information for commissioning or troubleshooting in the scope of safety technology These pieces of status information do not provide any safety relevant information in terms of functional safety IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 347 407 Commissioning operation diagnostics and maintenance R911335703_Edition 04 Bosch Rexroth AG ...

Page 362: ... identifier Flashing red green Indentifying the safety technology Flashing red green TUNID 2 not yet set Flashing red Abortion of connections Faulty abortion of at least one active connection Permanently lit red Critical error Critical connection error 1 Flashing pattern One square corresponds to a duration of 250 ms the arrow marks the end of a cycle abbreviations on the squares GN LED permanentl...

Page 363: ...established without error Flashing red The existing I O connection was unexpectedly aborted e g watchdog Permanently lit red The Duplicate IP Adress Check showed that the IP address which was set already exists in the network Flashing red green The device is running up and carries out a self test Tab 11 6 Diagnostic LED IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 349 40...

Page 364: ...n error Red lighting up once Synchronization error The drive controller has not been synchronized to the EtherCAT master Communication error of the drive controller Red lighting up twice Timeout watchdog Timeout while cyclic process data are monitored Watchdog of the EtherCAT master 1 Flashing pattern One square corresponds to a duration of 200 ms the arrow marks the end of a cycle abbreviations o...

Page 365: ... orange green HP0 hot plug phase 0 active 6 Flashing orange green HP1 hot plug phase 1 active 6 Flashing orange green HP2 hot plug phase 2 active 6 Flashing green Transition from Fast forward to Loopback 5 Flashing red orange Application error sub device device error C1D 4 Flashing red green MST warning 4 S 0 1045 Sercos Device Status S Dev bit15 3 Permanently lit red Communication error sub devic...

Page 366: ...reviations on the squares GN LED permanently lit green OG LED per manently lit orange RD LED permanently lit red LED is off 2 Display priority 1 highest priority the state of the highest priority is displayed 3 NRT None Real Time 4 MST Master synchronization telegram Tab 11 8 Diagnostic LED 352 407 Commissioning operation diagnostics and maintenance IndraDrive Mi Drive Systems with KCU02 KSM02 KMS...

Page 367: ...hed without error Flashing red The existing I O connection was unexpectedly aborted e g watchdog Permanently lit red The Duplicate IP Adress Check showed that the IP address which was set already exists in the network Flashing red green The device is running up and carries out a self test Tab 11 9 Diagnostic LED IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 353 407 Commis...

Page 368: ... 3 4 Diagnostic messages via parameters The usual diagnostic parameters are used S 0 0095 S 0 0390 P 0 0009 See also parameter description of firmware 11 3 5 Firmware functions Easy startup mode The easy startup mode is intended for initial commissioning Easy startup can be carried out with the Rexroth IndraWorks D commissioning software For easy startup the digital inputs have been preset as foll...

Page 369: ...tch function you can read or write controller internal memory cells See Functional Description of firmware Patch function Monitoring function The monitoring function provides extended diagnostic possibilities See Functional Description of firmware Monitoring function Logbook function With the logbook function you can reproduce the internal firmware sequence See Functional Description of firmware L...

Page 370: ... switching off the supply voltages to allow discharging Check whether voltage has fallen below 50 V before touching live parts The following section explains the tasks required to eliminate errors or malfunction We distinguish the following actions Replacing fuses F4 and F5 Deactivation Dismounting Replacing the component 356 407 Commissioning operation diagnostics and maintenance IndraDrive Mi Dr...

Page 371: ...s Fig 11 5 Fuses F4 and F5 Replacing fuses F4 and F5 1 Switch off power voltage to drive system 2 Wait at least 30 minutes to allow discharging 3 Open fuse carriers F4 and F5 4 Remove fuses F4 and F5 Note Always replace both fuses even if only one of them is defective The intact fuse probably was already damaged 5 Insert new fuses material number R911319963 FWP 30A14Fa by BUSSMANN 6 Close fuse car...

Page 372: ...rting to dismount secure the machine against accidental movements and unauthorized operation Before dismounting them secure the motor and the supply lines unit against falling or movements before unfastening the mechanical connections Burns caused by hot surfaces with temperatures of more than 100 C CAUTION Before beginning to work let the motors cool down The thermal time constant specified in th...

Page 373: ...7 of new component check sealing ring of cover for damage if sealing ring damaged provide new sealing ring mount cover screw tightening torque 1 Nm 11 Mount new component 12 Connect new component according to machine circuit diagram 13 Switch on 24V supply 14 Put machine into ready for operation state again according to machine manufacturer s instructions 15 Check functions of drive 11 4 5 Release...

Page 374: ...the defective drive cannot be read any longer Parameters can be managed in the control unit or saved and loaded with the Rexroth IndraWorks D software 11 4 7 Firmware Update See Functional Description of firmware Firmware Replacement 11 4 8 Replacing the programming module The programming module sits underneath a cover of the housing see chapter 6 3 4 X107 programming module on page 165 The progra...

Page 375: ...ould clean the cooling ribs of the motors in regular intervals at the latest after one year is over Bearings The nominal service life of the bearings is L10h 30000 h according to DIN ISO 281 ed 1990 if the permissible radial and axial forces are not exceeded The motor bearings should be replaced if the nominal bearing service life has been reached running noise can be heard We recommend that you h...

Page 376: ...g brakes by means of the soft ware function Checking the Holding Torque M4 via P 0 0541 C2100 Command Holding system check 1 The efficiency of the holding brake and the opened state are checked by the control device by starting the routine P 0 0541 C2100 Command Holding system check If the holding brake is operational the drive is in an operational state after the routine was run through If the br...

Page 377: ... to limitations in availability Risk of burns by hot surfaces with temperatures of more than 60 C CAUTION After switching the devices off wait 15 minutes to allow them to cool down before touching them Do not work at hot surfaces In regular intervals at the latest after one year is over check the heat sink of the electronic system of the drive for accumulated dirt e g dust deposits Remove accumula...

Page 378: ...364 407 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 379: ...reign material or foreign components Deliver the products free domicile to the following address Bosch Rexroth AG Electric Drives and Controls Buergermeister Dr Nebel Straße 2 97816 Lohr am Main Germany Packaging Packaging materials consist of cardboard wood and polystyrene They can be recycled anywhere without any problem For ecological reasons please refrain from returning the empty packages to ...

Page 380: ... assemblies can also be recycled by means of special separation processes Plastic parts of the products may 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 applicable legal provisions 366 407 Environmental protection and disposal IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KL...

Page 381: ... 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 description of mal...

Page 382: ...368 407 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 383: ...gital inputs type A 14 1 2 Digital inputs safety technology L options The digital inputs correspond to IEC 61131 type 2 Fig 14 2 Symbol Data Unit Min Max Allowed input voltage V 3 30 High V 11 30 Low V 3 5 Current consumption 1 mA 7 15 1 For KCU02 the specified values must be multiplied with the number of zone nodes of the drive line Tab 14 2 Digital inputs safety technology L options IndraDrive M...

Page 384: ...ption mA 2 5 Tab 14 3 Digital inputs safety technology S options Time behavior Description Unit min max Test pulse width tPL µs 0 1000 Percentage of High time TPH TP 100 90 100 Phase shift between two test pulses on both channels φ ms Tab 14 4 Time behavior 370 407 Appendix IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 385: ...n Iext mA 700 Output voltage ON V 18 2 30 Output voltage OFF V 5 Output current ON mA 350 Allowed energy content of connected inductive loads e g relay coils only allowed as single pulse mJ 400 Short circuit protection Available Overload protection Available Tab 14 5 Digital outputs safety technology L options IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 371 407 Appendix...

Page 386: ...rors are detected Wiring error with short circuit to high Wiring error with short circuit to low Wiring error with short circuit between the two channels Internal errors In the case of an error the control panel shows the corresponding error message F83xx 1 At a maximum switching frequency of 1 Hz 2 In the case of inductive loads with currents 200 mA or in the case of inductive loads with a greate...

Page 387: ... tPL μs 100 200 Periodic time TP ms 500 1000 Phase shift between two test pulses on both channels φ ms 50 Tab 14 7 Time behavior IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 373 407 Appendix R911335703_Edition 04 Bosch Rexroth AG ...

Page 388: ...andling for plugging in and removing the connectors Easy access to the connection points e g for measurements Tightening torque of screws 2 5 Nm Fig 14 4 Two piece connection cover 374 407 Appendix IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 389: ...n and observe the Project Planning Manual Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 R911309636 An Excel based tool is available for sizing mains filters If required please ask our sales representative FAQ_EMC_mains_filter_application_tool_EN Drive system In the drive system described below the components IndraDrive M HMS HMD or IndraDrive C Cs HCS are operated together...

Page 390: ...itance Cleak Leakage capacitance k Hybrid cable damping factor Fig 14 5 Drive system 376 407 Appendix IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 391: ...ains filter CY_limit nF Cleak_limit nF HNF01 2D M900 4080 1100 HNF01 2D F240 2450 290 HNF01 1A H350 2040 450 NFD03 1 1200 100 NFE02 1 1 378 90 KNK03 2200 226 1 Cannot be used with IndraDrive Mi can only be used for sin gle phase operation 1 230 V AC nominal current 8 A Tab 14 9 Mains filter Limit values CY_sum CY_sum CY_KCU CY_Hxx k CY_KMS CY_KSM CY_sum CY sum CY_KCU CY KCU CY_Hxx CY HMS HMD or HC...

Page 392: ...pacitance MSK motor by Rexroth at HMS HMD or HCS Cleak_cable_KMS Sum of leakage capacitance standard motor power cable by Rexroth at KMS Cleak_motor_KMS Sum of leakage capacitance MSK motor by Rexroth at KMS Cleak_motor_KSM Sum of leakage capacitance KSM Tab 14 12 Cleak_sum IndraDrive Mi capacitances Component CY nF Cleak_motor_KSM nF KSM02 1B 041C 42 150 1 4 KSM02 1B 061C 35 150 2 4 KSM02 1B 061C...

Page 393: ...0 200 HCS02 1E W0100 200 HCS03 1E W0070 200 HCS03 1E W0150 200 HCS03 1E W0210 200 HCS03 1E W0280 200 HCS03 1E W0350 200 Tab 14 14 IndraDrive C Cs capacitances IndraDrive M capacitances Component CY nF HMS01 1N W0020 136 HMS01 1N W0036 136 HMS01 1N W0054 136 HMS01 1N W0070 136 HMS01 1N W0110 200 HMS01 1N W0150 200 HMS01 1N W0210 200 HMS01 1N W0300 200 HMS01 1N W0350 200 HMS01 2N W0028 136 HMS01 2N ...

Page 394: ...0 0 mm2 1 3 REL0105 1 0 mm2 0 4 REL0753 1 0 mm2 0 4 REL0106 1 5 mm2 0 4 REL0107 2 5 mm2 0 4 REL0108 4 0 mm2 0 5 REL0109 6 0 mm2 0 5 REL0110 10 0 mm2 0 5 REL0111 16 0 mm2 0 6 REL0112 25 0 mm2 0 6 REL0113 35 0 mm2 0 6 REH0804 1 5 mm2 0 4 Tab 14 16 Cables capacitances Motor capacitances Motor Cleak_motor nF MAD100B 0050 6 0 MAD100B 0100 5 7 MAD100B 0150 5 7 MAD100B 0200 6 0 MAD100B 0250 6 0 380 407 A...

Page 395: ...050 20 0 MAD130C 0100 20 9 MAD130C 0150 20 5 MAD130C 0200 19 3 MAD130C 0250 20 1 MAD130D 0050 27 5 MAD130D 0100 27 3 MAD130D 0150 30 5 MAD130D 0200 27 5 MAD130D 0250 26 4 MAD160B 0050 25 5 MAD160B 0100 35 0 MAD160B 0150 35 0 MAD160B 0200 34 4 MAD160C 0050 28 0 MAD160C 0100 24 4 MAD160C 0150 27 2 MAD160C 0200 32 3 MAD180C 0050 29 2 MAD180C 0100 25 2 MAD180C 0150 28 3 IndraDrive Mi Drive Systems wit...

Page 396: ... 0150 8 6 MAF100C 0200 8 5 MAF100C 0250 9 4 MAF100D 0050 11 0 MAF100D 0100 11 2 MAF100D 0150 11 0 MAF100D 0200 10 0 MAF100D 0250 9 2 MAF130B 0050 16 0 MAF130B 0100 16 0 MAF130B 0150 16 0 MAF130B 0200 11 6 MAF130B 0250 13 2 MAF130C 0050 20 0 MAF130C 0100 15 4 MAF130C 0150 20 0 MAF130C 0200 16 8 MAF130C 0250 20 0 MAF130D 0050 27 5 MAF130D 0100 26 7 MAF130D 0150 27 5 382 407 Appendix IndraDrive Mi Dr...

Page 397: ... MAF180D 0100 38 0 MAF180D 0150 30 3 MAF180D 0200 50 0 MAF225C 0050 40 0 MAF225C 0100 39 7 MAF225C 0150 43 9 MCP015A L040 0 3 MCP015B L040 0 3 MCP020B V180 0 2 MCP020B V720 0 3 MCP020C V180 0 3 MCP020D V720 0 3 MCP030B V180 0 4 MCP030B V390 0 4 MCP030C V180 0 4 MCP030C V390 0 4 MCP030D V180 0 4 MCP030D V390 0 4 MCP040A V300 0 2 MCP040B V070 0 3 MCP040B V300 0 3 IndraDrive Mi Drive Systems with KCU...

Page 398: ...040B 0150 1 3 MLP040B 0250 1 3 MLP040B 0300 1 6 MLP052A 0300 1 8 MLP052B 0300 3 1 MLP070A 0150 2 2 MLP070A 0220 2 2 MLP070A 0300 2 3 MLP070B 0100 2 9 MLP070B 0120 2 9 MLP070B 0150 2 9 MLP070B 0250 2 9 MLP070B 0300 2 9 MLP070C 0120 4 2 MLP070C 0150 4 2 MLP070C 0240 4 2 MLP070C 0300 4 2 MLP100A 0090 4 1 MLP100A 0120 4 1 MLP100A 0150 4 1 MLP100A 0190 4 1 384 407 Appendix IndraDrive Mi Drive Systems w...

Page 399: ...0 11 1 MLP140Z 0060 3 0 MLP152A 0060 18 0 MLP152B 0060 20 0 MLP152C 0060 22 0 MLP152D 0060 23 7 MLP200A 0090 8 2 MLP200A 0120 8 2 MLP200B 0040 12 0 MLP200B 0120 12 0 MLP200C 0090 15 8 MLP200C 0120 15 9 MLP200C 0170 15 8 MLP200D 0060 19 2 MLP200D 0100 19 6 MLP200D 0120 19 6 MLP300A 0090 12 3 MLP300A 0120 12 3 MLP300B 0070 18 0 MLP300B 0120 18 0 MLP300C 0060 23 7 IndraDrive Mi Drive Systems with KCU...

Page 400: ...06 F_BK 2 7 ML3P06 F_BR 2 7 ML3P06 H_BK 3 4 ML3P06 H_BR 3 4 ML3P11 D_BF 2 9 ML3P11 D_BQ 2 9 ML3P11 E_BC 3 5 ML3P11 E_BQ 3 5 ML3P11 L_BC 6 4 ML3P11 L_BQ 6 4 MSK030B 0900 0 7 MSK030C 0900 1 3 MSK040B 0450 1 3 MSK040B 0600 1 5 MSK040C 0450 2 0 MSK040C 0600 2 0 MSK050B 0300 2 1 MSK050B 0450 1 4 MSK050B 0600 2 1 MSK050C 0300 2 6 MSK050C 0450 2 4 386 407 Appendix IndraDrive Mi Drive Systems with KCU02 K...

Page 401: ...070E 0150 6 3 MSK070E 0300 3 5 MSK070E 0450 6 7 MSK071C 0200 4 6 MSK071C 0300 4 6 MSK071C 0450 4 2 MSK071D 0200 6 9 MSK071D 0300 7 2 MSK071D 0450 7 8 MSK071E 0200 8 9 MSK071E 0300 9 3 MSK071E 0450 9 5 MSK075C 0300 3 2 MSK075C 0450 3 5 MSK075D 0200 4 6 MSK075D 0300 4 7 MSK075D 0450 4 7 MSK075E 0200 5 8 MSK075E 0300 6 5 MSK076C 0300 6 5 MSK076C 0450 6 0 IndraDrive Mi Drive Systems with KCU02 KSM02 K...

Page 402: ...C 0450 6 8 MSK101D 0200 13 2 MSK101D 0300 9 1 MSK101D 0450 13 2 MSK101E 0200 15 2 MSK101E 0300 16 7 MSK101E 0450 16 7 MSK103A 0300 1 5 MSK103B 0300 2 1 MSK103D 0300 6 0 MSK131B 0200 14 3 MSK131D 0200 27 7 MSK133B 0202 14 4 MSK133B 0203 10 7 MSK133C 0202 15 2 MSK133C 0203 15 2 MSK133D 0202 16 4 MSK133D 0203 18 4 MSK133E 0202 24 3 MSK133E 0203 22 6 MSM019A 0300 0 3 388 407 Appendix IndraDrive Mi Dri...

Page 403: ...SS182A 0250 0 6 MSS182B 0280 4 2 MSS182D 0260 5 4 MSS182F 0200 7 8 MSS202A 0200 4 4 MSS202B 0150 5 9 MSS202B 0210 5 9 MSS202D 0170 7 3 MSS202F 0120 10 2 MSS242B 0100 8 2 MSS242D 0070 7 8 MSS242F 0060 14 4 MSS272B 0065 12 8 MSS272B 0080 MSS272D 0050 10 3 MSS272F 0040 20 5 MSS312B 0035 19 9 MSS312D 0028 24 9 MSS312D 0060 24 9 MSS312F 0028 29 8 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KM...

Page 404: ... 0050 17 5 MST210A 0027 4 8 MST210C 0027 9 5 MST210C 0050 9 5 MST210D 0070 13 3 MST210E 0027 19 0 MST210R 0010 8 2 MST210E 0035 8 2 MST290B 0018 8 4 MST290D 0002 15 6 MST290D 0004 12 6 MST290D 0018 14 7 MST290E 0004 21 0 MST290E 0018 20 0 MST360B 0018 9 0 MST360D 0012 13 5 MST360D 0018 13 5 MST360D 0045 14 0 MST360E 0018 20 0 MST450B 0012 9 6 MST450D 0006 14 5 390 407 Appendix IndraDrive Mi Drive ...

Page 405: ...1 MS2E04 B0BTN 1 1 MS2E04 C0BTN 1 8 MS2E05 B0BTN 1 2 MS2E05 C0BTN 1 5 MS2E05 D0BRN 3 3 MS2E06 C0BNN 1 2 MS2E06 D0BNN 5 0 MS2E06 D0BRN 2 6 MS2E06 E0BRN 3 9 MS2E07 C0BQN 2 2 MS2E07 D0BNN 4 0 MS2E07 D0BRN 4 0 MS2E07 E0BNN 6 1 MS2E07 B0BQN 6 2 MS2N03 B0BYN 0 8 MS2N03 D0BYN 1 6 MS2N04 B0BNN 1 1 MS2N04 B0BTN 1 1 MS2N04 C0BNN 2 2 MS2N04 C0BTN 1 8 MS2N04 D0BHN 3 0 IndraDrive Mi Drive Systems with KCU02 KS...

Page 406: ...N07 C0BQN 2 2 MS2N07 C1BNN 1 9 MS2N07 D0BHN 4 1 MS2N07 D1BHN 3 1 MS2N07 D0BRN 4 0 MS2N07 D1BNN 3 0 MS2N07 E0BHN 7 1 MS2N07 E0BNN 6 1 MS2N07 E0BQN 6 2 MS2N07 E1BNN 4 7 MS2N07 E1BHA 4 7 MS2N07 D0BNN 4 0 MS2N07 D1BHA 3 1 MS2N07 D1BHB 3 1 MS2N07 D1BNA 3 0 MS2N07 D1BNB 3 0 MS2N07 E0BNA 6 1 MS2N07 E0BNB 6 1 MS2N07 E0BQA 6 2 MS2N07 E0BQB 6 2 MS2N10 C0BHN 1 9 392 407 Appendix IndraDrive Mi Drive Systems w...

Page 407: ...S2N10 D0BNA 4 1 MS2N10 D0BNB 4 1 MS2N10 D1BNA 3 3 MS2N10 D1BNB 3 3 MS2N10 E0BHA 6 2 MS2N10 E0BHB 6 2 MS2N10 E0BNA 6 2 MS2N10 E0BNB 6 2 MS2N10 E1BNA 5 0 MS2N10 E1BNB 5 0 MS2N10 F0BHA 8 7 MS2N10 F0BHB 8 7 MS2N10 F1BHA 6 7 MS2N10 F1BHB 6 7 Tab 14 17 Motor capacitances IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 393 407 Appendix R911335703_Edition 04 Bosch Rexroth AG ...

Page 408: ...394 407 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 Bosch Rexroth AG R911335703_Edition 04 ...

Page 409: ...ble connection KMS02 184 Adapter For adjusting mounting depths 303 Additional documentations 27 Address selector switch Communication 245 Ambient conditions 50 Analog outputs 355 Approvals 45 ATEX KSM02 dimensions 74 Average speed 251 Axial load 251 B Batteries 365 Bearing load 79 Bearings Load 250 Maintenance 361 Redundant 255 Service life 252 Brake control 253 C C UL US listing 45 C UR US listin...

Page 410: ...onnection cover Two piece 374 Connection diagram Drive system 288 HCS01 1E W0054 293 KCU02 285 Connection point Equipment grounding conductor 141 Connection points KCU02 144 KLC03 214 KMS02 180 KMS03 186 KMV03 198 KNK03 207 KSM02 158 Contained substances see Significant components 365 Continuous power Drive line 222 Control cabinet Cooling 56 Design 56 Control section RoHS 34 Control voltage Contr...

Page 411: ...Continuous power 222 Number of drives per drive line 6 Parallel drive lines 296 Peak power 223 Drive system 35 Connection diagram 288 Sizing mains filters 375 Driving elements Mechanical attachment 255 Dummy plate for KMS03 encoder connection HAS05 1 018 NNN NN 304 Duty cycle 63 E E Stop Function 240 Input X50 149 Easy startup mode 354 Editions Documentation 24 Electric drive system 35 Encoder cab...

Page 412: ...zard warning 254 Safety requirements 253 Sizing 254 Hotline 367 Housing overtemperature 63 Hybrid cables 7 Between KCU and first KSM KM 123 Between KCU and first KSM KMS 134 Between KLC03 and KMV03 140 Between KNK03 and KMV03 138 Between two KSM KMS 124 135 Connection 163 Flange 337 Flexible cable tracks 126 137 HAS05 1 023 132 Housing duct 337 Identification 119 121 incl communication allowed len...

Page 413: ...awing 89 Dimensions 89 Hybrid cable length vs performance 231 KCU02 2 vs KCU02 1 20 LEDs 343 Mounting 283 Notes on project planning 220 Scope of supply 259 Supplied by HCS02 217 Technical data 87 Touch guard 283 Type code 20 Type plate 274 Use 86 KCU02 2 Type code 20 Key 248 KLC03 Connection cover mounting options 216 Connection points 214 DC bus capacitor unit application notes 226 Features 4 KLC...

Page 414: ...ed cooling 104 KNK03 1A NR Axxxx dimensional draw ing natural convection 107 KNK03 1A NR Axxxx dimensions natu ral convection 107 KNK03 1A NR B Ixxxx dimensional draw ing thermal interface 106 KNK03 1A NR B Ixxxx dimensions ther mal interface 106 KNK03 1A NR Wxxxx dimensional draw ing forced cooling 108 KNK03 1A NR Wxxxx dimensions forced cooling 108 Mounting 286 Scope of supply 260 Second connect...

Page 415: ... encoder Single cable connection at KMS02 X156 184 Mounting 277 Cold plate 279 KCU02 283 KLC03 286 KMS02 282 KMV03 286 KNK03 286 KSM02 280 Mounting clearance 248 Mounting depths 155 283 Adapter 303 Mounting position Definition G1 G2 G3 G4 G5 58 Motor integrated servo drive 59 MS2N Hybrid motor cable KMS02 336 Hybrid motor cable KMS03 335 Motor power cable KMS03 333 Single cable connection KMS02 18...

Page 416: ...S0725 KMS03 encoder cable connector 334 RH2 029DB KMS03 MS2N hybrid motor cable 335 RH2 030DB KMS02 MS2N hybrid motor cable 336 RHS0014 Terminal connector 133 RHS0725 KMS03 hybrid motor cable connector 335 RKB0013 146 Cables 326 RKB0021 146 Cables 325 RKB0033 Cables 327 RKB0043 Cables 328 RKB0044 Cables 329 RKB0054 Cables 330 Fan connection 297 RKH 7 Hybrid cable incl communication selec tion 118 ...

Page 417: ...ion S3 SD 176 X141 176 Safe Torque Off L3 148 X49 148 Safety instructions for electric drives and controls 35 Safety technology Cables RKB0033 327 KMV03 X141 200 L3 Safe Torque Off 148 RBS0023 connector for safety zone node 332 S3 SD Safe Motion 176 Safety zone 237 Safety zone beginner 237 Safety zone node 237 X141 173 X141 KSM02 Safe Motion 176 X141 KSM02 Safe Torque Off 174 X141 without safety t...

Page 418: ...3 Testing Factory side 59 Insulation resistance 59 Voltage testing 59 Touch Guard KCU02 283 Transporting Components 47 Troubleshooting 356 Type code KCU02 20 KCU02 2 20 KLC03 23 KMS02 17 KMS03 19 KMV03 21 KNK03 22 KSM02 14 Type plate KCU02 274 KLC03 271 KMS02 263 KMS03 265 KMV03 267 KNK03 269 KSM02 261 Module of configured variants 273 System type plate 273 U UL File numbers 46 Listing 45 46 Unint...

Page 419: ...8 XD1 2 Supply unit KNK03 209 XD3 Motor connection KMS03 191 XD10 Control voltage KMV03 202 XD13 Fan power supply 202 209 214 XG3 Mains choke temperature contact KMV03 203 Mains choke temperature contact KNK03 211 Motor temperature monitoring and motor holding brake 192 XG4 Encoder connection KMS03 195 XG8 Encoder connection KMS03 196 XG14 Mains voltage synchronization KMV03 204 Mains voltage sync...

Page 420: ...Notes 406 407 IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 ...

Page 421: ...Notes IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 KLC03 407 407 ...

Page 422: ...ectric 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 R911335703 R911335703 DOK INDRV KCU02 KSM02 PR04 EN P ...

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