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Bosch Rexroth IndraDrive Mi, Project Planning Manual

The Bosch Rexroth IndraDrive Mi offers exceptional performance and versatility in a compact modular drive system. Unlocking the full potential of your machinery, this state-of-the-art product guarantees ultimate precision and efficiency. Easily access the comprehensive Instruction Manual for free download on our website, ensuring seamless integration into your operations.

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A

Servo drives evenly distributed over the entire drive line

B

Servo drives evenly distributed at the end of the drive line

C

Servo drives evenly distributed starting at 20% of the drive line

P

42V

KCU output X53 load (without cable losses)

P

N3(KCU)

Maximum KCU power consumption from 24V supply

Fig. 7-14:

P

N3(KCU)

 vs. P

42V

 

P

N3(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 P

N3(KCU)

 and P

42V

. The typ‐

ical losses of KCU are approx. 40% less than the maximum cal‐

culated values.

Bosch Rexroth AG

 DOK-INDRV*-KCU02+KSM02-PR03-EN-P

210/337

Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03

Notes on project planning

LSA Control S.L. www.lsa-control.com [email protected] (+34) 960 62 43 01  

Summary of Contents for Rexroth IndraDrive Mi

Page 1: ...Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Project Planning Manual R911335703 Edition 03 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 2: ...th in it are the exclusive property of Bosch Rexroth AG It may not be re produced or given to third parties without its consent Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract All rights are reserved with respect to the content of this docu mentation and the availabi...

Page 3: ... 22 1 3 2 KSM02 motor integrated servo drive 23 KSM02 type code 23 1 3 3 KMS02 near motor servo drive 25 KMS02 type code 25 1 3 4 KMS03 near motor servo drive 26 KMS03 type code 26 1 3 5 KCU02 drive connection box 27 KCU02 2 type code 27 1 3 6 KMV03 supply unit 28 KMV03 type code 28 1 3 7 KNK03 mains filter 29 KNK03 type code 29 1 3 8 Firmware 29 1 4 About this documentation 30 1 4 1 Editions 30 1...

Page 4: ...and specifications 47 4 1 Acceptance tests and approvals 47 4 2 Transport and storage 49 4 2 1 Transporting the components 49 4 2 2 Storing the components 49 4 3 Installation conditions 51 4 3 1 Ambient and operating conditions 51 4 3 2 Control cabinet design and cooling 58 4 3 3 Mounting position 60 Mounting positions of components 60 Mounting Positions of Motor Integrated Servo Drives 61 4 3 4 C...

Page 5: ...cal data 106 5 8 2 Hybrid cable without communication technical data 108 5 8 3 Selecting hybrid cable incl communication for appropriate connection 110 5 8 4 Selecting hybrid cable without communication for appropriate connection 113 5 8 5 Interconnection diagrams for ready made hybrid cables incl communication 115 KCU KSM KMS 115 KSM KMS KSM KMS 117 Flexible cable tracks 119 RHS0014 terminal conn...

Page 6: ... Second connection point of equipment grounding conductor 160 6 4 KMS02 connection points 162 6 4 1 Position of connection points 162 6 4 2 X37 X38 digital inputs outputs 162 6 4 3 X103 1 X103 2 hybrid cable connection point 162 6 4 4 X104 connection for motor encoder 163 6 4 5 X107 programming module 163 6 4 6 X108 X109 communication output coupling 163 6 4 7 X118 X119 external communication 163 ...

Page 7: ... 7 KNK03 connection points 187 6 7 1 Position of connection points 187 6 7 2 Second connection point of equipment grounding conductor 187 6 7 3 XD1 mains voltage 188 6 7 4 XD1 2 supply unit 189 6 7 5 XG14 mains voltage synchronization 190 6 7 6 XG3 mains choke temperature contact 191 6 7 7 XG34 mains contactor control and feedback contacts 192 6 7 8 Connection cover Mounting options 193 7 Notes on...

Page 8: ...th key 225 Output shaft with shaft sealing ring 226 7 3 3 Bearings and shaft load 227 General information 227 Radial load axial load 228 Bearing service life 229 7 3 4 Holding brakes 230 Brake control and supply 230 Safety requirements 230 Sizing holding brakes 231 7 3 5 Mechanical attachment of driving elements 232 General information 232 Redundant bearings 232 Gear attachment 233 Coupling attach...

Page 9: ...w 250 Available connection points 250 9 1 3 Cold plate 251 9 2 KSM 252 9 2 1 Required Steps to Follow 252 Preparations for Mounting 252 Mounting KSM 252 9 2 2 Mechanical Interfaces 253 Flange Mounting 253 9 2 3 Practical tips 253 9 3 KMS 254 9 3 1 Required steps to follow 254 Preparations for mounting 254 Mounting KMS 254 9 4 KCU02 255 9 4 1 Mounting depths 255 9 4 2 Touch Guard 255 9 4 3 KCU02 co...

Page 10: ...281 10 9 RKB0011 Multi Ethernet Cable 284 10 10 RKB0013 Multi Ethernet Cable 285 10 11 RKB0033 cable for safety technology 286 10 12 RKB0043 Communication Cable 287 10 13 RKB0044 Communication Cable 288 10 14 RKS0010 Interface Cable 289 10 15 RBS0023 connector for safety zone node 290 10 16 RLS0725 KMS03 motor power cable connector 291 10 17 RGS0725 KMS03 encoder cable connector 292 10 18 RHS0725 ...

Page 11: ...ding brake service function 313 11 4 6 Saving Parameters 314 11 4 7 Firmware Update 314 11 4 8 Replacing the programming module 314 11 5 Maintenance 315 11 5 1 Maintenance of the Motor Component 315 General Information 315 Cleaning 315 Bearings 315 Connection Cables 315 Holding Brake Commissioning and Maintenance Instructions 316 11 5 2 Maintenance of the Electronic System of the Drive 317 12 Envi...

Page 12: ... 2 1 Digital Outputs Safety Technology L Options 325 14 2 2 Digital outputs safety technology S options 326 Index 329 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P X 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Table of Contents LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 13: ...o connect 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 The KNK03 and KMV03 components allow a drive system to be designed without a control cabinet The KCU02 component with the assigned supply unit e g HMV or HCS al ways requires a contr...

Page 14: ...power supply KMV HMS HMD optional Fig 1 1 Rexroth IndraDrive Mi with KSM02 Features Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 12 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 System presentation LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 15: ...y KMV HMS HMD optional Fig 1 2 Rexroth IndraDrive Mi with KMS02 Features DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 13 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 System presentation LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 16: ...Multi Ethernet communication optional MultiEthernet communication output coupling optional Safe Torque Off or Safe Motion safety technology optional Integrated Motion Logic in accordance with IEC 61131 3 RKH hybrid cable RKH0xxx DC bus connection Control voltage and signal exchange cable Communication cable RKH0800 Mains voltage Mains contactor RKH0801 Mains choke Mains voltage synchronization The...

Page 17: ...l voltage supply should not be exceeded Observe power requirements of any available motor holding brakes Tab 1 2 Maximum number of drives per drive line DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 15 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 System presentation LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 18: ...ication For this case hybrid cables without communication lines are available The hybrid cable is supplied in ready made form with connectors The bulk cable hybrid cable without connector is named REH0800 hybrid cable incl communication or REH0803 hybrid cable without communica tion Drive Connection Box KCU02 The drive connection box KCU02 supplies the motor integrated servo drives KSM and the nea...

Page 19: ...es and KMS near motor servo drives KSM motor integrated servo drive KMS near motor servo drive RKH hybrid cable See chapter Cabinet bound distributed drive technology on page 16 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosc...

Page 20: ...Possible supply units Rexroth IndraDrive HMV01 1E R or HMV02 1R supply unit Rexroth IndraDrive HCS02 1E or HCS03 1E converter makes sense if another axis is required Rexroth IndraDrive HCS01 1E W0054 converter Rexroth IndraDrive KMV03 1R supply unit The figure below shows a Rexroth IndraDrive Mi drive system containing KSM motor integrated servo drives This system struc ture also applies to Rexrot...

Page 21: ... Servo motor optional RHS Terminal connector RKB0011 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 Rexroth IndraDrive Mi drive system with HMV01 DOK INDRV KCU02 KSM02 PR03 EN P...

Page 22: ...lease see chapter Overall connection diagram on page 259 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 20 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 System presentation LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 23: ...ve 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 21 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 System presentation LSA Control S L www lsa contro...

Page 24: ...lowing aspects into ac count Observe detailed information and instructions in chapter 5 Technical data of the components on page 63 and chapter 7 Notes on project planning on page 195 Before placing a purchase order have our sales representative check whether individual options are available The figure illustrates the basic structure of the type code Our sales representative will help you with the...

Page 25: ...onvection 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 sealing ring P Shaft with keyway according to DIN ...

Page 26: ... Safe Motion with SBC 1 Supply voltage D7 DC 750 V Other design TO Multi Ethernet output coupling 2 M12 NN None ES External master communication Multi Ethernet 2 M12 Firmware FW Firmware has to be ordered as a separate subposition Size Length Winding 24 35 42 61 041 C 061 C 071 C 076 C 1 Safety options S3 and SD only possible if encoder S1 or M1 Tab 1 4 Type code KSM02 Bosch Rexroth AG DOK INDRV K...

Page 27: ...n ET Multi Ethernet Encoder interface ENH Encoder Hiperface NNN Without Safety option L3 Safe Torque Off STO S3 Safe Motion without SBC 1 SD Safe Motion with SBC 1 NN Without Other design NN Without TO Multi Ethernet output coupling 2 M12 ES External master communication Multi Ethernet 2 M12 Firmware FW Firmware has to be ordered as a separate subposition 1 Only if encoder interface ENH Tab 1 5 Ty...

Page 28: ... Master communication ET Multi Ethernet Encoder interface END Encoder Hiperface and digital encoder Safety option L3 Safe Torque Off STO SD Safe Motion with SBC 1 NN Without Other design ES External master communication Multi Ethernet 2 M12 NN Without TO Multi Ethernet output coupling 2 M12 Firmware FW Firmware has to be ordered as a separate subposition 1 Only if encoder interface END Tab 1 6 Typ...

Page 29: ...cation output ET Multi Ethernet DC fuse 025 Nominal current 25 A Interface NN None Control panel N Without Other design NN None Firmware FW Firmware has to be ordered as a separate subposition Tab 1 7 Type code KCU02 KCU02 2 vs KCU02 1 KCU02 2 is fully downward compatible with version KCU02 1 and completely replaces this type DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 27 337 Rexroth IndraDri...

Page 30: ...nting Rated power 0007 7 5 kW 1 01K5 1 5 kW 2 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 has to be ordered as a separate subposition 1 Rated power 0007 only with cooling type B 2 Rated power 01K5 only with cooling type I Tab 1 8 Type code KMV03 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 28 ...

Page 31: ...d plate mounting I Thermal interface insulated mounting Nominal current 0002 2 3 A 1 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 cooling type B only Tab 1 9 KNK03 type code 1 3 8 Firmware Type code see Functional Desc...

Page 32: ...ponents KSM02 motor integrated servo drive previously distributed servo drive KMS02 near motor servo drive previously distributed drive controller 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 c...

Page 33: ...aceholder for the current edition of the documentation e g PR01 is the first edition of a Project Planning Manual Tab 1 11 Documentations overview Title Type of documentation Document typecode1 Material number R911 Automation Terminals Of The Rexroth Inline Product Range Application Manual DOK CONTRL ILSYSINS AWxx EN P 317021 1 In the document typecodes xx is a placeholder for the current edition ...

Page 34: ... overview Firmware Title Rexroth IndraDrive Type of documentation Document typecode1 DOK INDRV Material number R911 MPx 20 Functions Application Manual MP 20VRS APxx EN P 345608 MPx 20 Version Notes Release Notes MP 20VRS RNxx EN P 345606 Power Supply Basic PSB 20 Functions Application Manual PSB 20VRS APxx EN P 345612 MPx 18 Functions Application Manual MP 18VRS APxx EN P 338673 MPx 18 Version No...

Page 35: ...hnology as of MPx 1x Safe Motion Application Manual SI3 SMO VRS APxx EN P 338920 1 In the document typecodes xx is a placeholder for the current edition of the documentation e g RE02 is the second edition of a Reference Book Tab 1 15 Documentations firmware DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 33 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 System prese...

Page 36: ... for your feedback Please send your remarks to Address for your feedback Bosch Rexroth AG Dept DC IA EDY1 Buergermeister Dr Nebel Str 2 97816 Lohr Germany E mail dokusupport boschrexroth de Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 34 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 System presentation LSA Control S L www lsa control com comercial lsa control co...

Page 37: ... are permitted It is not permitted to decompile software products or alter source codes Do not install damaged or faulty products or put them into operation Make sure that the products have been installed in the manner descri bed in the relevant documentation 2 1 2 Areas of use and application Drive controllers made by Rexroth are designed to control electric motors and monitor their operation Con...

Page 38: ...erature fluctuations or extremely high maximum temperatures Furthermore Drive controllers may not be used in applications which have not been expressly authorized by Rexroth Please carefully follow the specifications outlined in the general Safety Instructions Components of the Rexroth IndraDrive Mi system are products of Category C3 with restricted distribution in accordance with IEC 61800 3 This...

Page 39: ...f 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 control and power circuits which have been assemb...

Page 40: ...mage injury electric shock or even death 3 2 2 Requirements for safe use Read the following instructions before initial commissioning of the compo nents of the electric drive and control system in order to eliminate the risk of injury and or property damage You must follow these safety instructions Rexroth is not liable for damages resulting from failure to observe the safety instructions Read the...

Page 41: ...ion in accordance with EMC requirements can be found in the section on EMC in the respective application docu mentation The machine or installation manufacturer is responsible for compliance with the limit values as prescribed in the national regulations The technical data connection and installation conditions of the compo nents are specified in the respective application documentations and must ...

Page 42: ...ectric components in accordance with the connection diagram Even for brief measurements or tests operation is only allowed if the equipment grounding conductor has been permanently connected to the points of the components provided for this purpose Before accessing electrical parts with voltage potentials higher than 50 V you must disconnect electric components from the mains or from the power sup...

Page 43: ...ounding conductor Leakage current 3 5 mA 1 equipment grounding conductor 2 equipment grounding conductors 1 5 mm2 16 AWG 10 mm2 8 AWG 2 1 5 mm2 16 AWG 2 5 mm2 14 AWG 2 2 5 mm2 14 AWG 4 mm2 12 AWG 2 4 mm2 12 AWG 6 mm2 10 AWG 2 6 mm2 10 AWG 10 mm2 8 AWG 16 mm2 6 AWG 16 mm2 6 AWG 25 mm2 4 AWG 35 mm2 2 AWG 50 mm2 1 0 AWG 25 mm2 4 AWG 70 mm2 2 0 AWG 35 mm2 2 AWG Tab 3 1 Minimum cross section of the equ...

Page 44: ... depends upon the type of control and the state of opera tion Dangerous movements Danger to life risk of injury serious injury or property damage A risk assessment must be prepared for the installation or machine with its specific conditions in which the components of the electric drive and control system are installed As a result of the risk assessment the user must provide for monitoring func ti...

Page 45: ...t initial commissioning of the electric drive and control system for possible malfunctions when operating such high fre quency remote control and radio equipment in its possible positions of normal use It might possibly be necessary to perform a special electro magnetic compatibility EMC test 3 3 4 Protection against electromagnetic and magnetic fields during opera tion and mounting Electromagneti...

Page 46: ...by crushing shearing cutting hit ting Observe the relevant statutory regulations of accident prevention Use suitable equipment for mounting and transport Avoid jamming and crushing by appropriate measures Always use suitable tools Use special tools if specified Use lifting equipment and tools in the correct manner Use suitable protective equipment hard hat safety goggles safety shoes safety gloves...

Page 47: ... Risk of injury by improper handling of pressurized lines Do not attempt to disconnect open or cut pressurized lines risk of ex plosion Observe the respective manufacturer s operating instructions Before dismounting lines relieve pressure and empty medium Use suitable protective equipment safety goggles safety shoes safety gloves for example Immediately clean up any spilled liquids from the floor ...

Page 48: ...ON 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 in jury could occur NOTICE In case of non compliance with this sa...

Page 49: ... www ul com database Under UL File Number enter the file number or under Company Name en ter the company name Bosch Rexroth AG 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 KCU KSM KMS components HMV01 1E HMV01 1R HMV02 1R HCS01 1E HCS02 1E HCS03 1E KMV03 1R ...

Page 50: ... GMBH Category Name Servo and Stepper Motors Component File numbers MSK MSM motors E335445 Tab 4 3 C UR listing Wiring material UL ready made cables by Rexroth 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 m...

Page 51: ...ansporting the components Ambient and 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 KCU drive connection box fro...

Page 52: ...ic category IEC 721 1K3 Moisture condensation Not allowed Icing Not allowed Tab 4 5 Ambient and operating conditions for storage Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 50 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 General data and specifications LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 53: ... HLC Description Symbol Unit Value Conductive dirt contamination Not allowed Protect the devices against conductive dirt contami nation 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 Storing th...

Page 54: ...e 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 60068 2 6 2 Reduced performance data for driv...

Page 55: ... 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 perform ance data reduced by factor f2 3 are available At an installation altitude in the range hmax_ohne to hmax an isolating transformer has to be installed at the drive sy...

Page 56: ...page 49 Temperature during transport see chapter 4 2 1 Transporting the components on page 49 Allowed mounting position Definition of mounting positions See chapter Mounting positions of components on page 60 G1 G2 G3 G4 G5 KMS03 1B A reduced performance with G2 G4 G5 Installation altitude hnenn m 1000 Ambient temperature range Ta_work C 0 40 Derating vs ambient temperature The performance data ar...

Page 57: ... of protection Vibration sine axial Acceleration at 10 2000 Hz 1 g 1 With HAS10 1 001 001 NN accessories KMS 3 Axial A radial R Vibration sine radial Acceleration at 10 2000 Hz 1 g 1 With HAS10 1 001 001 NN accessories KMS 3 Overvoltage category III according to IEC 60664 1 1 According to EN 60068 2 6 Tab 4 8 Ambient and operating conditions KMS Ambient and operating conditions KMV KNK Description...

Page 58: ... installation altitude in the range hmax_ohne to hmax an isolating transformer has to be installed at the drive system mains connec tion Operation above hmax 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...

Page 59: ... conditions KMV KNK DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 57 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 General data and specifications LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 60: ...nclean air in the control cabinet NOTICE Operating a control cabinet with a fan but without the corresponding filters can damage the devices or cause malfunction Install filters at the air intake opening of the control cabinet so that un clean air cannot get into the control cabinet Service the filters at regular intervals according to the dust loading in the environment Only replace the filters w...

Page 61: ... 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 59 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM0...

Page 62: ...G5 in the technical data of the components Mounting position Description G1 Normal mounting position The air heated inside the component can flow unimpe ded 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 component forces the cooling air current 5 Co...

Page 63: ...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 cleaning agents etc and our housings materials 4 ...

Page 64: ...mponent on UN3 must be within the specified voltage range Maximum allowed overvoltage UN3max V 33 max 1 ms Tab 4 14 Control voltage Overvoltage Overvoltage greater than 33 V has to be discharged by means of the appropriate electrical equipment of the machine or installation This includes 24V power supply units that reduce incoming overvoltage to the allowed value Overvoltage limiters at the contro...

Page 65: ...at UN3 UL PN3 W Power with which the power supply unit is loaded for 24V sup ply 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_nenn V DC Voltage suppli...

Page 66: ...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 rotor inertia 1 Suitable for use on a cir...

Page 67: ...stics correspond to operation modes S1 or S3 P Load PV Electric losses Θ Temperature Θmax Highest temperature motor housing t Time TC Cycle duration 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 The duty cycle is calculated as follows ED Re...

Page 68: ...eristic 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 cycle duration 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02...

Page 69: ... Indoor use only Mass mmot kg 5 6 9 6 14 1 14 6 Average sound pressure level ac curacy class 2 at PDC_cont 1 LP dB A Less than 75 Control voltage data Rated control voltage input2 UN3 V 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 continuous current and continuous DC bus po...

Page 70: ...at dis tance 1 m out of cabinet HCS types with order code L load dependent 2 Observe supply voltage for motor holding brakes 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...

Page 71: ...minal 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 ac curacy class 2 at PDC_cont 1 LP dB A Less than 75 Control voltage data Rated control voltage input2 UN3 V 30 42 Rated power consumption control voltage input at UN3 3 PN3 W 29 5 35 5 41 5 Power...

Page 72: ...g brake inertia Jbr kg m2 0 000023 0 0 0000590 0 0001610 Last modification 2013 12 16 1 According to DIN EN ISO 11205 comparative value at dis tance 1 m out of cabinet HCS types with order code L load dependent 2 Observe supply voltage for motor holding brakes 3 See information on Rated power consumption control voltage input at UN3 4 Plus dissipation of braking resistor and control section 5 Main...

Page 73: ... 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 71 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com c...

Page 74: ...cs 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 72 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa c...

Page 75: ...s 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 73 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa c...

Page 76: ...02 1B 041C dimensions Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 74 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 77: ...K INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 75 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 78: ...r communication output coupling Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 76 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 79: ...the mounting clearance is not specified since the required mounting clearance depends on the length of the screwdriver used Fig 5 13 KSM02 1B 071C dimensions DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 77 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 80: ...sch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 78 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 81: ...y 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 ac cording to DIN 6885 A is not part of the scope of supply of the motors Centering hole according to DIN 332 part 2 ed 05 83 KSM02 1B 041 5 5 20 DS M5...

Page 82: ...41 Allowed radial force shaft and bearing load Fig 5 16 KSM02 1B 061 Allowed radial force shaft and bearing load Fig 5 17 KSM02 1B 071 Allowed radial force shaft and bearing load Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 80 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control ...

Page 83: ...2 1B 041 20 KSM02 1B 061 20 KSM02 1B 071 40 KSM02 1B 076 40 Tab 5 6 Allowed axial force DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 81 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 84: ...ower3 ULN_nenn V DC 540 750 Capacitance in DC bus CDC mF 0 02 Capacitance against housing CY nF 118 100 Rated input current ILN A 7 3 Allowed switching frequencies4 fs kHz 4 8 Maximum bypass current A 25 0 Power dissipation at continuous current and continuous DC bus power respective ly5 PDiss_cont W 50 00 Power section data output Output voltage fundamental wave for V Hz U f control Vout_eff V UD...

Page 85: ...mware and control section see parame ter description P 0 0001 Switching frequency of power output stage see P 0 4058 Amplifier type data 5 Plus dissipation of braking resistor and control section 6 7 Guide value see following note 8 See following note regarding output current reduction Tab 5 7 KMS Technical data Rated power consumption control voltage input at UN3 Plus motor holding brake plus pow...

Page 86: ...l 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 19 Dimensions Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 84 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Contr...

Page 87: ...er with 42V control voltage with integrated fuses protects the hybrid cable RKH against electric overload allows communication between the higher level control unit and the mo tor integrated servo drives KSM and near motor servo drives KMS DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 85 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the componen...

Page 88: ...t and continuous DC bus power respectively4 PDiss_cont W 90 Insulation resistance at 500 V DC Ris Mohm 50 Average sound pressure level ac curacy class 2 at PDC_cont 5 LP dB A Less than 70 Control voltage data input Control voltage input6 UN3 V 24 20 Rated power consumption control voltage input at UN3 7 PN3 W 675 Max inrush current at 24 V supply IIN3_max A 10 00 Pulse width of IEIN3 tEIN3Lade ms ...

Page 89: ...e and air outlet at device 4 Plus dissipation of braking resistor and control section 5 According to DIN EN ISO 11205 comparative value at dis tance 1 m out of cabinet HCS types with order code L load dependent 6 Observe supply voltage for motor holding brakes 7 See information on Rated power consumption control voltage input at UN3 8 Mains input L1 L2 L3 for HMV and HCS only For use on a solidly ...

Page 90: ...r Distance horizontal Fig 5 20 Air intake and air outlet at device Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 88 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 91: ... Fig 5 21 Dimensions DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 89 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 92: ... Rated input current ILN A 12 Output voltage Vout V DC 750 Output power Pout kW 7 5 Last modification 2016 03 08 1 For use on a solidly grounded wye source only Tab 5 9 KMV Ambient and operating conditions UL ratings Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 90 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www ...

Page 93: ...ing dimensions Fig 5 22 KMV03 dimensions DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 91 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 94: ...uracy class 2 at PDC_cont 4 LP dB A tbd Last modification 2016 03 08 1 2 3 Housing dimension see also related dimensional drawing 4 According to DIN EN ISO 11205 comparative value at dis tance 1 m out of cabinet HCS types with order code L load dependent Tab 5 10 KMV Data for mass dimensions sound pressure level insulation Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 92 337 Rexroth IndraDrive ...

Page 95: ...emperature increase with mini mum distances dbot dtop PBD ΔT K Last modification 2016 02 11 1 Plus dissipation of braking resistor and control section 2 See information on Rated power consumption control voltage input at UN3 Tab 5 11 KMV Cooling and power dissipation data Rated power consumption control voltage input at UN3 Plus power consumption of externally connected inputs outputs plus safety ...

Page 96: ...rol voltage input at UN3 4 PN3 W 18 Last modification 2016 02 11 1 2 3 Observe supply voltage for motor holding brakes 4 See information on Rated power consumption control voltage input at UN3 Tab 5 12 KMV Control voltage supply data Rated power consumption control voltage input at UN3 Plus power consumption of externally connected inputs outputs plus safety option Bosch Rexroth AG DOK INDRV KCU02...

Page 97: ... inductance 3 Lmin µH 50 Assigned mains filter with integra ted mains choke KNK03 1A NR B0012 P U226 A4 NNNN Minimum short circuit power of the mains for failure free operation Sk_min MVA tbd Inrush current IL_trans_max _on A tbd Maximum allowed ON OFF cycles per minute4 1 Power factor TPF λL at PDC_cont with mains choke ULN_nenn TPF tbd Power factor of fundam compo nent DPF at PDC_cont with mains...

Page 98: ...se 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 96 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV0...

Page 99: ...s choke PDC_max kW 15 00 Monitoring value maximum DC bus voltage switch off threshold UDC_lim it_max V 900 Monitoring value minimum DC bus voltage undervoltage threshold UDC_lim it_min V 500 Allowed external DC bus capaci tance nom at ULN_nenn 2 CDCext mF 2 00 Charging time at maximum al lowed CDCext external DC bus ca pacitance at ULN_nenn tlade_DC_Ce xt s 0 70 Last modification 2016 02 11 1 Only...

Page 100: ...t of mains volt age1 UR_DC_On_f V 820 Regenerative power to be absor bed WR_max kWs 7 50 Cooling of integrated braking re sistor Base plate Coldplate Last modification 2016 02 11 1 Factory setting Tab 5 15 KMV Integrated braking resistor data Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 98 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the compo...

Page 101: ...ssipation at continuous current and continuous DC bus power respectively3 PDiss_cont W 160 Insulation resistance at 500 V DC Ris Mohm tbd Required wire size in accordance with NFPA 79 and UL 508 A in ternal wiring 4 ALN AWG tbd Last modification 2016 01 20 1 2 Mains voltage ULN Use a transformer with grounded neutral point do not use autotransformers 3 Plus dissipation of braking resistor and cont...

Page 102: ...ensions Fig 5 23 KNK03 dimensions Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 100 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 103: ...rt 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 respectively5 PDiss_cont W 127 00 222 00 Powe...

Page 104: ...en fs 8 kHz output frequency fout fout_still Iout_cont0Hz _8 A 5 9 16 0 Last modification 2016 03 08 1 Observe supply voltage for motor holding brakes 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 ter description P 0 0001 ...

Page 105: ...ding 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 103 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components L...

Page 106: ...ixing clip for hybrid cable connectors More mounting clearance is required to install the HAS10 accessory with a screwdriver Fig 5 24 KMS03 1B A dimensions Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 104 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 107: ...learance is required to install the HAS10 accessory with a screwdriver 4 Mounting clearance with cable outlet away from housing B Drilling pattern Fig 5 25 KMS03 1B B dimensions DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 105 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control ...

Page 108: ...nent C 80 Leakage capacitance CY_K_typ Conductor resistance at 20 C EN 60228 class 6 R20 ohm km 8 2 5 mm Operational voltage at power cores V 850 Operational voltage at control cores V 100 Halogens Halogen free acc to VDE 0472 Part 815 Oil resistance EN 60811 2 1 and EN 50363 10 2 Flammability UL 7 58 section 40 Cable Flame Test Section 1061 according to UL 1581 and CSA C22 2 No 210 05 Sec 8 8 2 T...

Page 109: ...eters Maximum values only apply individually Tab 5 18 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 applica tion DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 107 337 Rexroth IndraDrive Mi Dri...

Page 110: ... C tbd Leakage capacitance CY_K_typ Conductor resistance at 20 C EN 60228 class 6 R20 ohm km 8 2 5 mm Operational voltage at power cores V 850 Operational voltage at control cores V 100 Halogens Halogen free acc to VDE 0472 Part 815 Oil resistance tbd Flammability IEC 60332 1 2 Flexible cable tracks Suitable for application in flexible cable tracks Yes Bending cycles 5 Bending radius with flexible...

Page 111: ...EH 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 applica tion DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 109 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Techni...

Page 112: ...KH0610 4 1 Outgoing direction A 2 Outgoing direction B 3 Outgoing direction V 4 If you wish to connect two cables RKH0700 to each other use a short cable RKH0610 as intermediate piece Tab 5 20 Hybrid Cables RKH Hybrid cable outgoing direction A horizontal towards the housing B horizontal away from the housing V vertical Tab 5 21 Hybrid Cable Outgoing Directions Bosch Rexroth AG DOK INDRV KCU02 KSM...

Page 113: ...ed 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 205 Identifying the Hybrid Cables Hybrid cables are labeled according to the following example RKH0111 030 5 The cable designation is made up of Cable number e g RKH0111 and Cable length e g 30 5 m DOK INDRV KCU02 KSM02 PR...

Page 114: ...ert 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 112 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 T...

Page 115: ...on Hybrid cable outgoing direction A horizontal towards the housing B horizontal away from the housing V vertical Tab 5 23 Hybrid Cable Outgoing Directions Identifying the hybrid cables Hybrid cables are marked according to the following example RKH0121 030 5 The cable designation is made up of Cable number e g RKH0121 and Cable length e g 30 5 m DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 11...

Page 116: ...ert 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 114 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 T...

Page 117: ... plug in connector 3 Cable type L End R End RKH0311 RKH0411 RKH0511 RHS0005 Locking pin Coding profile 4 1 Plug in connector R End for RKH0310 RKH0401 2 Plug in connector R End for RKH0501 3 Picture shows coding with view to mating side DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 115 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components...

Page 118: ... 24 Parts of ready made hybrid cables from KCU to KSM KMS Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 116 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 119: ...0800 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 117 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control co...

Page 120: ...ward compatibility of the hybrid cable for KSM01 KMS01 Tab 5 25 Parts of ready made hybrid cables from KSM KMS to KSM KMS Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 118 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 121: ...S plug in connector Cable type L End R End RKH0700 Not coded Not coded Tab 5 26 Parts of ready made hybrid cable for flexible cable tracks DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 119 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 122: ...Rx the connection point can be used for the drive system Engi neering Fig 5 29 Terminal Connector RHS0014 Tab 5 27 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 120 337 Rexroth IndraDrive Mi Driv...

Page 123: ... KMS plug in connector1 Cable type L End R End RKH0321 RHS0005 X103 1 RKH0421 RHS0005 X103 1 1 View to mating side Tab 5 28 Parts of ready made hybrid cables without communication from KCU to KSM02 KMS DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 121 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control co...

Page 124: ...021 X103 1 X103 2 RKH0120 X103 1 X103 2 RKH0121 X103 2 X103 1 RKH0220 X103 1 X103 2 1 View to mating side Tab 5 29 Parts of ready made hybrid cables without communication from KSM KMS to KSM KMS Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 122 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comer...

Page 125: ...agram KNK03 KMV03 plug in connector Cable type L End R End RKH0800 XD1 connector XG34 connector XD1 connector XG34 connector Tab 5 30 Parts of ready made hybrid cables used for mains connection DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 123 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comerc...

Page 126: ...ype L End R End RKH0801 XG14 connector XG3 connector XG14 connector XG3 connector Tab 5 31 Parts of ready made hybrid cables used for mains connection Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 124 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Technical data of the components LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 127: ...onnections of all devices and additional components to the equip ment grounding system Risk of damage to the devices by spark dis charge of static charges NOTICE In some applications e g printing or packaging high static charges can de velop Make sure that these charges can be directly discharged against ground at their point of origin Therefore connect the second connection point of equipment gro...

Page 128: ...ased 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 Rexroth IndraDrive Mi drive system connect the equipment grounding conductor connections of all devices and additional components to the equip ment grounding system Risk of damage to the devices by spark dis charge of static charges NOTICE In some appli...

Page 129: ...ductor 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 terminal connector to terminal connector p...

Page 130: ...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 For exchanging status messages X53 42 V 0 V 42...

Page 131: ...ice 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 to tal length may not exceed a maximum of 40 m The module bus connec tion can be extended by means of accessory RKB0001 When using DC bus capacitor units Do not establish t...

Page 132: ... RKB0011 Long cables 100 m at maximum to connect the drive system to the high er level control unit or remote communication nodes Minimum bending radius 48 75 mm if laid flexibly 32 50 mm if laid permanently Order code for a 30 m long cable RKB0011 030 0 RKB0013 Short cables to connect devices arranged side by side in the control cabi net 4 lengths available 0 19 m 0 25 m 0 35 m 0 55 m Order code ...

Page 133: ...I With sercos III and for the Engineering of the drive system you can connect our netSWITCH sercos III accessory into the sercos III ring DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 131 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 134: ...ization output channel 1 Dyn_Ch1 6 chapter 14 2 1 Digital Outputs Safety Technolo gy L Options on page 325 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 of X49 0V 2 Tab 6 7 Pin Assignment Function W...

Page 135: ...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 X50 2 Maximum rating 15 mA Tab 6 8 Function Pi...

Page 136: ...nection 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 134 337 Rexroth IndraDrive Mi ...

Page 137: ...G 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 KMS02 devices is switched off and LED H53 emits...

Page 138: ...re 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 136 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa...

Page 139: ... 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 supply of accessory HAS01 With contact bars 0...

Page 140: ...ct 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 feed er 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 Bus Line Bosch Rexroth AG DOK INDRV KCU02 KSM0...

Page 141: ...ces 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 139 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points L...

Page 142: ...ning 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 Function Pin Assignment Properties Contro...

Page 143: ...01 and HMV02 devices the 24V supply is connected to the drive connection box KCU with contact bars Tab 6 16 Connecting the 24V supply DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 141 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 144: ... inputs outputs X103 1 X103 2 Hybrid cable X107 Programming module X1x8 X1x9 Communication optional X108 X109 Communication output coupling X118 X119 External communica tion X141 Safety technology optional 2nd Second connection point of equipment grounding con ductor Tab 6 17 KSM02 connection points Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 142 337 Rexroth IndraDrive Mi Drive Systems with K...

Page 145: ...d 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 dis tributed over two 5 pin M12 connectors X37 and X38...

Page 146: ...d 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 protec tive 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 Voltage from external power supply Shld Shield Fi...

Page 147: ...robe 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 ex ternal 24 V power supply to increase the maximum output current of the digi tal outputs The external 24 V supply has to comply ...

Page 148: ...rmware Short circuit protection Present Overload protection Present Allowed energy content of connected in ductive 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 capacity of the outputs is used to limit volt ...

Page 149: ...d Wait at least 30 minutes after switching off the supply voltages to allow dis charging A Codings of the connection points to prevent the hybrid cables from being incorrectly connected Fig 6 6 X103 1 and X103 2 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 147 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com com...

Page 150: ...MS03 at a 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 exter nal damage in accordance with EN 61800 5 1 and EN 61800 5 2 Notes on Operation Do not remove connectors when the compo...

Page 151: ...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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 149 337 Rexroth IndraD...

Page 152: ...he bottom of the cover with the connection points there is a circuit board Always leave this circuit board at its place Other wise 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 6 22 Cover with connection points Bosch Rex...

Page 153: ...on 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 assignment properties Do not use angled connectors at the connection points Unused output coupling If you do not use the communication out...

Page 154: ...on 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 of devices without communication output coupling the communi cation signals are directly transmitted via a circuit board see fi...

Page 155: ...rcuit 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 reassem ble 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG ...

Page 156: ...M12 M12 RKB0044 M12 RJ 45 Tab 6 26 X118 X119 function pin assignment properties At KMV supply units the connection points X119 control unit and X103 2 KMS alternative X118 instead of X103 2 when using hybrid cables without communication have to be used Principle of external communica tion In the case of devices with external communication the communication sig nals are transmitted in parallel with...

Page 157: ...rake service input Fig 6 13 X141 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 155 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 158: ...n outputs power supply 5 SI_Ch1_In n c Input for selection of channel 1 preceding axis connected to X103 1 10 6 0V_In 0V 2 0V selection preceding axis connected to X103 1 9 7 SI_Ch2_In n c Input for selection of channel 2 preceding axis connected to X103 1 8 8 Dyn_Ch1 n c Channel 1 dynamization output 3 9 24V_ZBr 24V_Br Internal interface only 24 V for release brake function 10 0V 0V 2 Inputs and ...

Page 159: ...s are used for different functions short cir cuit between the two signal wirings has to be excluded Tab 6 27 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 323 Channel 2 selection SI_Ch2 2 Channel 1 dynamization output Dyn_Ch1 8 chapter 14 2 1 Digital Outputs ...

Page 160: ...nputs and outputs 5 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 Ta...

Page 161: ...react to safety technology sig nals Technical data chapter 14 1 3 Digital inputs safety technology S options on page 324 chapter 14 2 2 Digital outputs safety technology S options on page 326 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 159 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control c...

Page 162: ...tween 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 previous ly 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 drive This disables the first equipment grou...

Page 163: ...allation 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 30 Second connection point of equipment grounding conductor proper ties DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 161 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa...

Page 164: ...utput coupling X118 X119 External communica tion X141 Safety technology optional X156 Motor 2nd Second connection point of equipment grounding con ductor Tab 6 31 KSM02 connection points 6 4 2 X37 X38 digital inputs outputs See description KSM02 chapter 6 3 2 X37 X38 digital inputs outputs on page 143 6 4 3 X103 1 X103 2 hybrid cable connection point See description KSM02 chapter 6 3 3 X103 1 X103...

Page 165: ...n cable stranded wire mm2 n s n s Order type of cable RKG4201 Allowed length m n s 7 5 Tab 6 32 X104 motor encoder 6 4 5 X107 programming module See chapter 6 3 4 X107 programming module on page 149 6 4 6 X108 X109 communication output coupling See chapter 6 3 5 X108 X109 communication output coupling on page 151 6 4 7 X118 X119 external communication See chapter 6 3 6 X118 X119 external communica...

Page 166: ...ase brake service input on page 158 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 164 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 167: ... 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 33 X156 Motor 6 4 10 Second connection point of equipment grounding conductor See chapter 6 3 9 Second connection point of equipment grounding con ductor on page 160 DOK INDRV KCU02 KSM02 PR03 EN P Bosch ...

Page 168: ...ogramming module under neath the cover X1x8 X1x9 Communication optional X108 X109 Communication output coupling X118 X119 External communica tion X141 Safety technology optional XD3 Motor XG3 Brake temperature XG4 Motor encoder digital XG8 Motor encoder analog Second connection point of equipment grounding con ductor Tab 6 34 KMS03 connection points Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P...

Page 169: ...overing 3 Screws M4 2 5 Nm Fig 6 15 Connection cover with protective covering DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 167 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 170: ...y from the housing Fig 6 16 Connection cover Mounting options Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 168 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 171: ...he HAS05 1 018 dummy cover is put on the connection cov er 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 169 337 Rexroth IndraDrive Mi Drive Systems...

Page 172: ...og P Cable plate Fig 6 17 Motor cable and encoder cable Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 170 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 173: ... max Connection cable Stranded wire mm2 0 2 6 AWG 24 10 Stripped length mm 10 Tightening torque Nm 0 5 0 8 Tab 6 36 Mechanical data Electrical data Spring terminal connector Unit min max Rated voltage V 1000 Nominal current A 41 Tab 6 37 Electrical data DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 171 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection poin...

Page 174: ...ut e g from motor winding voltage flashover this voltage can travel to the housing Make sure the tem perature sensor of the connected motor is double insulated from the motor winding Risk of damage to device from excess volt age at motor temperature evaluation input NOTICE Only the allowed control voltage for the device is allowed at the motor tem perature evaluation input Excess voltage at the in...

Page 175: ...ax 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 there is enough power supply to the motor for the motor holding brake Note that voltage drops on the supply line Use connection lines with the largest possible cross section of single strands Use an external contact element in accordance with the required safet...

Page 176: ...monitoring and motor holding brake Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 174 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 177: ...485 clock positive 4 EncCLK RS485 clock negative 5 5V Encoder supply 5 V 6 12V Encoder supply 12 V 7 GND_Encoder 0V reference potential for power sup plies 8 GND_shld Signal shields connection inner shield Tab 6 41 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 42 Mechanical data DOK INDRV KCU02...

Page 178: ...sitive 3 A max 1 65 Vss track A analog negative 4 B max 1 65 Vss track B analog negative Tab 6 43 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 44 Mechanical data Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 176 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 C...

Page 179: ...hapter 6 3 4 X107 programming module on page 149 6 5 10 X108 X109 communication output coupling See chapter 6 3 5 X108 X109 communication output coupling on page 151 6 5 11 X118 X119 external communication See chapter 6 3 6 X118 X119 external communication on page 154 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 177 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 ...

Page 180: ...service input on page 158 6 5 13 Second connection point of equipment grounding conductor See chapter 6 3 9 Second connection point of equipment grounding con ductor on page 160 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 178 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 4...

Page 181: ...XG14 2 Mains voltage synchroniza tion XG34 1 Mains contactor control and feedback contacts KNK03 Second connection point of equipment grounding con ductor 1 RKH0800 cable connects KMV to KNK 2 RKH0801 cable connects KMV to KNK Tab 6 45 KMV03 connection points DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 179 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connectio...

Page 182: ...al communication on page 154 6 6 6 X141 safety technology See chapter 6 3 7 X141 Safe Torque Off safety technology and release brake service input on page 155 See chapter 6 3 8 X141 Safe Motion safety technology and release brake service input on page 158 6 6 7 Second connection point of equipment grounding conductor See chapter 6 3 9 Second connection point of equipment grounding con ductor on pa...

Page 183: ...7 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 48 Electrical data Cables Description Value Order type RKH0800 Maximum allowed length 1 m Tab 6 49 Cables DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 181 337 ...

Page 184: ...cal data Electrical data Screw terminal connector Unit Value Nominal current A 41 Nominal voltage V 600 Tab 6 52 Electrical data Cables Description Value Order type Cable cannot be ordered Customer assembles the cable HAS05 1 020 accessories required Tab 6 53 Cables Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 182 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Co...

Page 185: ... length mm 10 Tab 6 55 Mechanical data Electrical data Spring terminal connector Unit Value Nominal current A 8 Rated voltage V 160 Tab 6 56 Electrical data Cables Description Value Order type RKH0801 Maximum allowed length 1 m Tab 6 57 Cables DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 183 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Con...

Page 186: ...ripped length mm 10 Tightening torque Nm 0 8 Tab 6 59 Mechanical data Electrical data Screw terminal connector Unit Value Nominal current A 41 Rated voltage V 1000 Tab 6 60 Electrical data Cables Description Value Order type RKH0801 Maximum allowed length 1 m Tab 6 61 Cables Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 184 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03...

Page 187: ...on cable Stranded wire mm2 1 5 AWG 16 Stripped length mm 10 Tab 6 63 Mechanical data Electrical data Screw terminal connector Unit Value Nominal current A 8 Rated voltage V 160 Tab 6 64 Electrical data Cables Description Value Order type RKH0800 Maximum allowed length 1 m Tab 6 65 Cables DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 185 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 K...

Page 188: ...tions Tightening torque of the mounting screws 2 5 Nm Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 186 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 189: ... con ductor 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 Tab 6 66 KNK03 connection points 6 7 2 Second connection point of equipment grounding conductor See chapter 6 3 9 Second connection point of equipment grounding con ductor on page 160 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 1...

Page 190: ...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 69 Electrical data Cables Description Value Order type Cable cannot be ordered Customer assembles the cable HAS05 1 019 accessories required Tab 6 70 Cables Bosch Rexroth AG DOK INDRV KCU02...

Page 191: ...ta 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 73 Electrical data Cables Description Value Order type RKH0800 Maximum allowed length 1 m Tab 6 74 Cables DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 189 337 Rexroth IndraDr...

Page 192: ...pped length mm 10 Tightening torque Nm 0 8 Tab 6 76 Mechanical data Electrical data Screw terminal connector Unit Value Nominal current A 41 Rated voltage V 1000 Tab 6 77 Electrical data Cables Description Value Order type RKH0801 Maximum allowed length 1 m Tab 6 78 Cables Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 190 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 K...

Page 193: ...chanical data Electrical data Screw terminal connector Unit Value Nominal current A 8 Nominal voltage V 150 Tab 6 81 Electrical data Cables Description Value Order type RKH0801 Maximum allowed length 1 m Tab 6 82 Cables DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 191 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control...

Page 194: ... 16 Stripped length mm 10 Tab 6 84 Mechanical data Electrical data Screw terminal connector Unit Value Nominal current A 8 Rated voltage V 160 Tab 6 85 Electrical data Cables Description Value Order type RKH0800 Maximum allowed length 1 m Tab 6 86 Cables Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 192 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection poi...

Page 195: ...ions Tightening torque of the mounting screws 2 5 Nm DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 193 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Connection points LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 196: ...ch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 194 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 197: ...ting the supply unit or converter observe the allowed combinations of HNF NFD mains filter and HNL mains choke 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 supply unit HMV or HCS PDC_cont KCU Continuous power KCU PDC_cont HMV HCS Continuous power of supply unit Fig 7 1 Continuous power of supply unit Instead of PDC_cont it...

Page 198: ...n be set See also P 0 0114 Undervoltage threshold See also Functional Description of firmware Power supply 7 1 3 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 Rexroth IndraDrive Mi system with HCS01 1E W0054 on page 266 7...

Page 199: ...i cation ES PES Optional safety technology L3 PL3 n s 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 con nected motor Tab 7 1 Control voltage power requirement Control voltage ...

Page 200: ...upply 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 At a KCU it is permitted to operate KSM KMS with a...

Page 201: ...rom 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 gener ated when each KCU drive connection box is switched on The in rush current depends on the power consumption PN3 KCU see calculation above PN3 KCU 288 W Inrush curren...

Page 202: ...f power consumption in a drive line operation at partial load the measurable value Istrang at the out put 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 wattless currents the influence of these currents is insignificant in operation under rat ed conditions Continuous power Comply with continuous power The sum of...

Page 203: ...d 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 202 Peak Power when Decelerating on page 203 DC 500 V DC 565 V uncontrolled supply with 3 AC 400 V DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 201 337 Rexr...

Page 204: ...M KMS with increas ing 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 as possible to the output of KC...

Page 205: ...tion with Cable Length of 100 m and Cor ner 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 at the same time with peak torque out of max...

Page 206: ...e when the drives have been me chanically connected in such a way that the energy flows to the DC bus are inversely directed when decelerating One drive ab sorbs the energy which another drive in the same line delivers when decelerating These drives must be arranged side by side in the line Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 204 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM0...

Page 207: ...le length vs KCU performance on page 208 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 Definition of the lengths DOK INDRV KCU02 KSM...

Page 208: ...int 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 3 Cable length limit values For routing in the flexible cable track determine the maximum allowed le...

Page 209: ...700 cable can be used for the movable part of the flexible cable track connection so that it is replace able 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 at tenuation crosstalk remain in the allowed range during the service life of the cable Length of hybrid cable with...

Page 210: ...h 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 length of the entire drive line After this the servo drives are evenly distributed up to the end of the drive line The fi...

Page 211: ...mum allowed hybrid cable length of a drive line For exact calculations of the allowed hybrid cable lengths in limit cases please contact our support team drivesupport boschrexroth de FAQ_IndraDriveMiV2_NumberOfAxes_CableLengths The figure below shows PN3 KCU KCU power consumption from 24V supply depending on P42V KCU output X53 load DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 209 337 Rexroth ...

Page 212: ...U 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 typ ical losses of KCU are approx 40 less than the maximum cal culated values Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 210 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 K...

Page 213: ...h 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 length of the entire drive line After this the servo drives are evenly distributed up to the end of the drive line The fi...

Page 214: ...ngth of a drive line For exact calculations of the allowed hybrid cable lengths in limit cases please contact our support team drivesupport boschrexroth de FAQ_IndraDriveMiV2_NumberOfAxes_CableLengths The figure below shows PN3 KMV KMV power consumption from 24V supply depending on P42V KMV output XD10 load Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 212 337 Rexroth IndraDrive Mi Drive System...

Page 215: ... the drive line P42V KMV output XD10 load without cable losses PN3 KMV Maximum KMV power consumption from 24V supply Fig 7 16 PN3 KMV vs P42V DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 213 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Notes on project planning LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 216: ...ety 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 17 Safety zones Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 214 337...

Page 217: ...tive safety unit int Dyn Dynamization pulses are inter nally generated ext External safety unit for a safety zone X Connection point of the safety zone beginner Tab 7 4 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 215 3...

Page 218: ...ntation 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 216 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 K...

Page 219: ...one 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 pertinent parameters P 0 0223 P 0 0300 When a new safety zone begins a new E Stop zone can be begun via a local I O X37 4 X38 4 If a KSM KMS KMV has been configured as a safety zone beginner X141 3 n c P 0 ...

Page 220: ...itch 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 19 E Stop zone setup The E Stop zone setup is independent of whether a safety tech nology option L3 is available or not Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 218 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03...

Page 221: ... function 7 1 9 Motor fan for KSM02 Fans are not available for KSM02 motor integrated servo drives 7 1 10 Evaluation of motor encoders at KMS KMS near motor servo drives evaluate sin cos encoders 1 Vpp HIPERFACE encoder The maximum allowed nominal current consumption is 60 mA Encoders with reference track cannot be evaluated DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 219 337 Rexroth IndraDri...

Page 222: ...peak PDC_base according to performance profile UEL_P_e Observe the performance data PDC_peak and PDC_base in the per formance profile UEL_P_e of the supply unit and the perform ance data of the KCU drive connection box Selecting standard motors 3 AC 400 V exemplary profiles Description Symbol Unit KMS02 1B A018 KMS03 1B A036 KMS03 1B B036 Nominal power standard motor 3 AC 400 V 50 Hz t 10 min K 1 ...

Page 223: ...haracteristic of the selection of standard mo tors and servo drives Tab 7 6 Definition of Performance Profiles Infeeding Supply Units and Con verters DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 221 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Notes on project planning LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 224: ...r 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 drive address 1 10 4 14 See also documentatio...

Page 225: ...s 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 di rectly 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 settings or after the drive has been booted C640...

Page 226: ...Standstill n 60 min 1 Fig 7 22 Example of current limitation To determine the resulting torque or current limitations additional ly 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 is thermally connected to the motor housing the amplifi er temperature is the most important load vari...

Page 227: ...ance e g control cabi net while the local ambient temperature does not exceed the allowed ambi ent 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 dissipation e g ventilation surface in the mounting clearance particularly in ...

Page 228: ...have been balanced with the complete key This means that the machine element to be driven must be balanced without a key Modifications to the keys may be made only by the users them selves 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 designed with radial shaft sealing rings accordin...

Page 229: ...sitions 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 output shaft Design information Rexroth recommend...

Page 230: ...d 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 braking time In the exact calculation of the av...

Page 231: ...e of the bear ings 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 force in N newton Fig 7 27 Calculating the bea...

Page 232: ...s 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 when at standstill and when perform ing the drive integrated brake check The holding brake is required for hold ing the axis when the machine is in a de energized state Observe the safety requirements during the system ...

Page 233: ...er 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 func tion in periodic intervals e g every 8 hours with an appropriate check By applying a defined torque to the motor check whether the holding brake has completely release...

Page 234: ...commendation can be given 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 operation This is allowed for E Stop situations only ...

Page 235: ...when gears are attached Observe all other notes and requirements contained in the documentations on the gears 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 extremely stiff couplings the radial force which constantly change...

Page 236: ...l 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 234 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Notes on project plannin...

Page 237: ...M02 or KMS02 Documentation RBS0023 Connector for safety zone user 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 235 337 Rexroth IndraDrive Mi Drive Sys...

Page 238: ...tion HAS10 Fixing clip for hybrid cables Tab 8 3 Scope of supply 8 1 4 KMV03 Standard Optional KMV03 Documentation 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 HAS05 1 019 KNK03 mains voltage Tab 8 5 Scope of supply Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 236 337 Rexroth IndraDrive Mi Drive Systems with K...

Page 239: ...late Arrangement Fig 8 1 Type plate arrangement DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 237 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Identification LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 240: ...ent 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 Fi...

Page 241: ...ype plate arrangement DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 239 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Identification LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 242: ...ns 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 P...

Page 243: ...ype plate arrangement DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 241 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Identification LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 244: ... number 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 Control voltage input 25 Material number 26 Production date Fig 8 6 KMS03 type plate Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 242 337 Rexroth IndraDrive Mi Drive Systems with KCU0...

Page 245: ...ype plate arrangement DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 243 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Identification LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 246: ...60529 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 Control voltage input 23 Material number 24 Production date Fig 8 8 KMV03 type plate Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 244 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Identificatio...

Page 247: ...ype plate arrangement DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 245 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Identification LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 248: ... 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 246 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Identification LSA Control ...

Page 249: ...ial number 4 Bar code 5 Country of manufacture 6 Production week example 13W47 year 2013 week 47 7 Hardware revision index Fig 8 12 Type Plate DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 247 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Identification LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 250: ...L performance data plate Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 248 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Identification LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 251: ...ned 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 handling CAUTION Avoid mechanical stressing th...

Page 252: ... 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 been designed as plug in connectors This ensu...

Page 253: ...0 Flatness mm 0 1 Surface roughness Rz 6 3 Tab 9 1 Cold plate DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 251 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Mounting and installation LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 254: ...que check the functioning of the holding brake see chapter Holding Brake Commissioning and Maintenance Instructions on page 316 Mounting KSM Mounting for Easy Servicing To allow trouble free servicing make sure that the following aspects are fulfil led after you have mounted KSM Connection points X37 X38 and X141 are easily accessible Connection points X108 and X109 are easily accessible To allow ...

Page 255: ...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 elec tric 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 to be plugged in X103 1 of the first KSM KM...

Page 256: ...ss selector switches are easily accessible Diagnostic LED is visible 2 Preferably mount the device to a conductive surface If this is impossi ble later on connect the second connection point of equipment ground ing conductor at the device to the equipment grounding system of the in stallation 3 For the dimensions of the mounting holes see the dimensional drawing of the device 4 Data of the mountin...

Page 257: ...damaged 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 by means of contact bars only cutout A may be removed from the touch guard If the DC bus and the control voltage are connected by means of cables e g in case of multiple line arrangement cutouts A B and C ma...

Page 258: ...x 2 8 Nm Tab 9 4 Touch Guard at Device Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 256 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Mounting and installation LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 259: ...ction Diagram KCU02 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 257 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Mounting and installation LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 260: ...d 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 251 9 6 Electrical connection 9 6 1 General information High electrical voltage Danger to life by elec tric shock WARNING Working within the range of live parts is extremely dangerous Therefore Any work required on the electric system may be carried out only by skilled ...

Page 261: ...g 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 of the connection points NOTICE If vibrations affect the hybrid cable Install strain relief near the connection points X103 1 X103 2 so that the connectors a...

Page 262: ...ed 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 260 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Mounting and installation LSA Control S L www lsa control com comercial lsa co...

Page 263: ...ed 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 hybrid cable RKH at first KSM Fig 9 4 Drive System Rexroth IndraDrive Mi with HMV01 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 261 337 Rexroth IndraDrive Mi Drive ...

Page 264: ...ive 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 Drive System Rexroth IndraDrive Mi with HCS02 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 262 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03...

Page 265: ...r KCU 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 263 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Mounting and installation LSA Control S L www lsa control com comercial lsa cont...

Page 266: ... Rexroth IndraDrive Mi with HCS03 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 264 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Mounting and installation LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 267: ...ional 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 hybrid cable RKH at first KSM Fig 9 7 Drive System Rexroth IndraDrive Mi with HMV02 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 265 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 ...

Page 268: ... 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 cables RKH Hybrid cable hybrid cable to be ordered for connection to HCS01 is currently in preparation Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 266 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV...

Page 269: ...em For this purpose please contact our Drive Support drivesupport boschrexroth de DE_TN_51_IndraDrive_Mi_mit_HCS01_als_Versorger_V1 0 pdf For information on HCS01 drive controllers please see the Proj ect Planning Manual Rexroth IndraDrive Cs Drive Systems with HCS01 R911322210 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 267 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KM...

Page 270: ...S 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 Rexroth IndraDrive Mi system with KNK03 KMV03 KMS03 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 268 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Mounting and installation LSA Control S L www lsa control com comercial...

Page 271: ...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 Fig 9 10 Cables for Rexroth IndraDrive Mi system with KMV03 used as sup ply unit DOK INDRV KCU02 KSM02 PR03 EN P Bo...

Page 272: ...he 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 inter faces at the higher level control unit both KCUs can be directly connected to the control unit Bosch Rexroth AG DOK INDRV K...

Page 273: ...lel drive lines with two KCUs and higher level control unit 2 KCU vs 2 KMV Instead of 1 HMV 2 KCU it is possible to use 2 KMV for parallel drive lines DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 271 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Mounting and installation LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 274: ...ch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 272 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 275: ...ternal safety unit RKB0043 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 cou pling X108 X109 HAS10 1 001 002 For devices with optional communication output cou pling X108 X109 Tab 10 1 Accessories DOK INDRV KCU02 KSM02 PR03 EN P B...

Page 276: ...voltage supply Joint bar for connecting equipment grounding conductors of KCU and neighboring device For a detailed description see documentation Rexroth IndraDrive Addi tional Components and Accessories Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 274 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa con...

Page 277: ...ive 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 ca ble 3 to the corresponding support with a clip 2 Make sure that the shield 4 of the hybrid cable has good contact with the shielding plate 1 DOK INDRV KCU02 KSM02 PR...

Page 278: ...HAS03 1 002 control cabinet adapter which compensates the different mounting depths Fig 10 2 HAS03 For a detailed description see documentation Rexroth IndraDrive Addi tional Components and Accessories Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 276 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa contr...

Page 279: ...S05 1 018 dummy plate for KMS03 encoder connection DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 277 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 280: ...arts Cable gland plastic M20 range 6 12 mm Plate incl screws Connector screw terminal Coding pin Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 278 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 281: ...lowing parts Cable gland plastic M20 range 6 12 mm Plate incl screws Connector screw terminal DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 279 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 282: ...ts 1 parallel module 1 motor mains module 1 control section 004 Motor monitor grounding 005 Mounting plate for device width 200 mm 006 Mounting plate for device width 220 mm Other design NN None Tab 10 2 HAS10 type code 10 8 2 Use Use HAS10 Use HAS10 1 001 001 NN Fixing clip for hybrid cables at devices without op tion TO ES HAS10 1 001 002 NN Fixing clip for hybrid cables at devices with op tion ...

Page 283: ...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 The fixing clip increases the vibration resistance of the connected hybrid ca ble connectors The RKB0043 cable is fixed to the fixing clip with 2 cable ties Fig 10 7 HAS10 1 001 002 NN 10 8 3 Scope of supply Scope of supply Components of the accessory see product inser...

Page 284: ...ct insert HAS10 1 001 001 NN Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 282 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 285: ...ct insert HAS10 1 001 002 NN DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 283 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 286: ...le 13 5 m RKB0011 013 5 R911316888 5 m RKB0011 005 0 R911321548 Tab 10 4 RKB0033 RKB0011 Plug in connector bus Bulk cable Plug in connector bus RBS0016 S01 RJ 45 4 pin REB0400 RBS0016 S01 RJ 45 4 pin Tab 10 5 Interconnection Diagram RKB0011 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 284 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L ...

Page 287: ... RKB0013 00 55 R911317801 Tab 10 6 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 7 Interconnection Diagram RKB0013 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 285 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Cont...

Page 288: ...er 1 5 m RKB0033 001 5 R911334865 10 m RKB0033 010 0 R911335718 Tab 10 8 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 9 RKB0033 parts Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 286 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Cont...

Page 289: ...Number Length Order code Material number To be freely selec ted RKB0043 xxx x xxx x length in meters R911172134 Tab 10 10 RKB0043 RKB0043 Plug in connector Bulk cable Plug in connector M12 4 pin male D co ded Bus cable REB400 M12 4 pin male D coded Interconnection diagram A Coding groove B Coding nose Tab 10 11 Parts RKB0043 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 287 337 Rexroth IndraDri...

Page 290: ... Be Ordered Or der Code Material Number Length Order code Material number To be freely selec ted RKB0044 xxx x xxx x length in meters R911172135 Tab 10 12 RKB0044 RKB0044 Plug in connector Bulk cable Plug in connector M12 4 pin male D co ded Bus cable REB400 RJ 45 Interconnection diagram A Coding groove B Coding nose Tab 10 13 Parts RKB0044 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 288 337 ...

Page 291: ...KS0010 03 0 R911322843 Tab 10 14 RKB0013 RKS0010 Plug in connector Bulk cable Plug in connector M12 A coded shielded n s Open ends Interconnection diagram Tab 10 15 Parts RKS0010 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 289 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 292: ...pers the following connec tions 5 1 7 2 6 10 11 3 KSM KMS without optional safety technology can be op erated 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 17 Function pin assignment properties Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR...

Page 293: ...y 1 0 RLS0725 K02 x y 1 5 Fig 10 16 RLS0725 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 291 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 294: ...r Fig 10 17 RGS0725 K02 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 292 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 295: ... Fig 10 18 RHS0725 K02 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 293 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Accessories LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 296: ...g 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 18 netSWITCH sercos III Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 294 337 Rexroth IndraDrive Mi Drive Systems with KCU0...

Page 297: ... See the Functional Description of the firmware for the corresponding information The commissioning of drive controllers and control unit can 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 com missioning of the machine as a whole Observe the information and regula tions of th...

Page 298: ...g operation Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 296 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Commissioning operation diagnostics and maintenance LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 299: ... 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 opera tion power on Bb control section and power section ready for op eration mains voltage available charg DC bus charging ac tive DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 297 337 Rexroth IndraDrive Mi Drive Sys...

Page 300: ...xx 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 a cycle abbreviations on the squares GN LED permanentl...

Page 301: ...unit signals errors 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 is not connected if H54 green Connect the module bus connect...

Page 302: ... for KSM at out put X53 is faulty or control voltage is out of limits Error is stored until the device is turned off Overload at output Check the 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 Intermediate circuit L L ready for power output None Red DC bus voltage L L at output X54 not okay Check fuse...

Page 303: ...ive 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 Di agnostic message Firmware update running Loader active Do not interrupt the 24 V supply and do not unplug connectors while the firmware is being updated Drive command error Cxxxx Flashing yellow Drive warnin...

Page 304: ...xxx Read exact status via S 0 0095 Diagnostic mes sage and execute service function Firmware update Repeat firmware update Red Booting phase Wait until booting phase is over approx 2 mi nutes System error F9xxx E0800 Switch off and on replace hardware if nec essary Check whether the programming module is inserted if necessary replace KSM KMS crosswise to check whether the program ming module is de...

Page 305: ...formation on the internal state of the device The LEDs only provide general diagnostic in formation for commissioning or troubleshooting DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 303 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Commissioning operation diagnostics and maintenance LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 306: ...the safety technology Flashing red green TUNID 2 not yet set Flashing red Abortion of connections Faulty abortion of at least one active con nection 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 permanently lit green RD LED per manently lit red LED...

Page 307: ...isting 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 305 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV0...

Page 308: ... error The drive controller has not been synchronized to the EtherCAT master Communication error of the drive control ler Red two LEDs lighting up 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 on the squares GN LED permanently lit gre...

Page 309: ...mmunication error Sub device device error C1D 2 Flashing orange Identification S 0 1044 sercos Device Control C Dev bit15 1 Flashing red Internal watchdog 0 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 permanently lit green OG LED per manently lit orange RD LED permanently lit red LED is off 2 Display prior...

Page 310: ... 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 follows E1 X37 4 24 V to activate positive direction of rotation...

Page 311: ...ction 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 Logbook function DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 309 337 Rexroth IndraDrive Mi Drive Systems with KC...

Page 312: ...s charging Check whether voltage has fallen below 50 V before touching live parts The following section explains the tasks required to eliminate errors or mal function We distinguish the following actions Replacing fuses F4 and F5 Deactivation Dismounting Replacing the component Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 310 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 K...

Page 313: ... minutes until discharge time has elapsed 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 Probably the intact fuse is already damaged 5 Insert new FWP 30A14Fa fuses by BUSSMANN 6 Close fuse carriers F4 and F5 11 4 3 Deactivating and Dismounting the Drive Deactivation In the case of malfunction maintenance measures or to d...

Page 314: ...ces with tempera tures of more than 100 C CAUTION Before beginning to work let the motors cool down The thermal time constant specified in the Technical Data is a measure for the time re quired for cooling down Cooling down can require up to 140 minutes Do not work at hot surfaces Wear safety gloves 1 Observe the instructions contained in the machine documentation 2 Observe the Safety Instructions...

Page 315: ...lease holding brake service function Lethal injury caused by errors when control ling motors and working at moving parts WARNING Do not work at running or unsecured installations Before starting 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...

Page 316: ...ogramming module The programming module sits underneath a cover of the housing see chap ter 6 3 4 X107 programming module on page 149 The programming module contains the firmware and parameters so that the drive can be easily programmed during commissioning Use the Rexroth IndraWorks D software to configure the data transfer from the programming module after the control voltage has been switched o...

Page 317: ... 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 ex ceeded The motor bearings should be replaced if the nominal bearing service life has been reached running noise can be heard We recommend that you have the bearings replaced by Rexroth Connec...

Page 318: ...hecking 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 af ter the routine was run through If the braking torque is too low the con trol device ...

Page 319: ...s by hot surfaces with tempera tures 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 accumulated dirt DOK INDRV KCU02 KSM02 PR03 EN P Bo...

Page 320: ...ch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 318 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 321: ... AG Electric Drives and Controls Buergermeister Dr Nebel Strasse 2 97816 Lohr am Main Germany Packaging The packaging materials consist of cardboard wood and polystyrene These materials can be recycled anywhere without any problem For ecological reasons please refrain from returning the empty packages to us Batteries and accumulators Batteries and accumulators can be labeled with this symbol The s...

Page 322: ... parts are labeled according to EN ISO 1043 They have to be recycled separately or disposed of according to the valid legal requirements Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 320 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Environmental protection and disposal LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 323: ...dresses 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 malfunction and circumstances Type plate specific...

Page 324: ...ch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 322 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 325: ...ety 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 DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 323 337 ...

Page 326: ...echnology 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 Bosch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 324 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Appendix LSA Control S L www lsa control com comercial l...

Page 327: ...ut voltage OFF V 5 Output current ON mA 350 Allowed energy content of con nected inductive loads e g re lay coils only allowed as single pulse mJ 400 Short circuit protection Available Overload protection Available Tab 14 5 Digital Outputs Safety Technology L Options DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 325 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 A...

Page 328: ...rcuit 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 greater energy content an exter nal free wheeling ...

Page 329: ...Phase shift between two test pulses on both channels φ ms 50 Tab 14 7 Time behavior DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 327 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 Appendix LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 330: ...ch Rexroth AG DOK INDRV KCU02 KSM02 PR03 EN P 328 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 331: ...rake control 230 C C UL US listing 47 C UR US listing 48 Cables Allowed lengths hybrid cable incl com munication 205 Allowed lengths hybrid cable without communication 207 Documentation 32 Encoder cables 163 Hybrid cable incl communication techni cal data 106 Hybrid cable without communication technical data 108 Maintenance 315 Motor cable 165 RKB0011 130 284 RKB0013 130 285 RKB0033 286 RKB0043 28...

Page 332: ...ata Ambient conditions 51 Operating conditions 51 DC bus Connection 137 Output X54 136 Deactivation Of the drive 311 Declaration of conformity 47 Devices Mounting positions 60 Diagnostic display KCU02 LED H49 H52 1 H54 299 KMV LED H14 297 KSM KMS LED H14 301 Diagnostics Functions 297 LEDs 297 Parameters 308 Digital inputs Technical data safety technology L options 323 Technical data safety technol...

Page 333: ... connection 127 H H L Communication address selector switch 222 H14 LED KMV 297 LED KSM KMS 301 H25 H26 LED KSM KMS 303 H49 H52 1 H54 LEDs KCU02 299 Handling Devices 249 HAS01 1 050 072 MN 274 HAS02 1 015 NNN NN 275 HAS03 Control cabinet adapter 276 HAS05 1 018 dummy plate for KMS03 encoder connection 277 019 KNK03 mains voltage 278 020 KMV03 control voltage 279 HAS10 Fixing clip for hybrid cable ...

Page 334: ...l drawing 89 Dimensions 89 Hybrid cable length vs performance 208 KCU02 2 vs KCU02 1 27 LEDs 299 Mounting 255 Notes on project planning 198 Scope of supply 235 Supplied by HCS02 195 Technical data 86 Touch guard 255 Type code 27 Type plate 247 Use 85 KCU02 2 Type code 27 Key 225 KMS Maintenance 315 KMS02 Connection points 162 Data sheet 82 Dimensional drawing 84 Dimensions 84 Encoder cables 163 En...

Page 335: ...cal data 69 Without motor holding brake data sheet 67 Without motor holding brake technical data 67 L L L 137 L3 Safe Torque Off 132 LED H14 KMV 297 H14 KSM KMS 301 H25 H26 KSM KMS 303 H49 H52 1 H54 KCU02 299 Limitation Motor current 223 Listing C UL US 47 C UR US 48 Load Bearings and shaft 227 Logbook function 309 M Maintenance KMS 315 KSM 315 Module bus 129 Monitoring function 309 Motor Connecti...

Page 336: ...mponents 195 Notes 195 Notes on electrical project planning 222 Notes on mechanical project planning 225 Project Planning Manuals 31 Protective extra low voltage 41 Q Qualified technical staff 249 R Radial load 228 Radial shaft sealing ring 226 RBS0023 Connector for safety zone node 290 Recycling 319 Redundant bearings 232 REH0800 Hybrid cables 106 REH0803 Hybrid cables 108 Release brake Service i...

Page 337: ... X52 134 Storing Components 49 Supply unit HCS02 195 HCS03 195 HMV01 195 HMV02 195 Support 321 Switching frequency 225 System presentation 11 System structure 18 T Technical data Digital inputs safety technology L options 323 Digital inputs safety technology S options 324 Digital inputs type A standard input 323 Digital outputs safety technology L options 325 Digital outputs safety technology S op...

Page 338: ...ogy 158 Safe Torque Off safety technology 155 X156 Motor connection KMS02 165 XD1 Mains voltage KMV03 181 Mains voltage KNK03 188 XD1 2 Supply unit KNK03 189 XD3 Motor connection KMS03 171 XD10 Control voltage KMV03 182 XG3 Mains choke temperature contact KMV03 183 Mains choke temperature contact KNK03 191 Motor temperature monitoring and motor holding brake 172 XG4 Encoder connection KMS03 175 XG...

Page 339: ...DOK INDRV KCU02 KSM02 PR03 EN P Bosch Rexroth AG 337 337 Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02 KMS02 03 KMV03 KNK03 LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

Page 340: ...7 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 PR03 EN P LSA Control S L www lsa control com comercial lsa control com 34 960 62 43 01 ...

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