REXROTH Fv Series Instruction Manual Download Page 21

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Safety Instructions for Electric Drives and Controls

2.1

General Information

2.1.1

Brief Introduction

Using the Safety Instructions and Passing them on to Others
Do not attempt to install or commission this device without first reading all

documentation provided with the product. Read and understand these safety

instructions and all user documentation prior to working with the device. If

you do not have the user documentation for the device, contact your respon‐

sible Bosch Rexroth sales representative. Ask for these documents to be

sent immediately to the person or persons responsible for the safe operation

of the device. If the device is resold, rented and/or passed on to others in any

other form, then these safety instructions must be delivered with the device.

DOK-RCON02-FV*********IB01-EN-P
Rexroth Frequency Converter Fv

Bosch Rexroth AG

19/219

Safety Instructions for Electric Drives and Controls

Summary of Contents for Fv Series

Page 1: ...Electric Drives and Controls Hydraulics Linear Motion and Assembly Technologies Pneumatics Service Rexroth Frequency Converter Fv R912002625 Edition 01 Instruction Manual...

Page 2: ...tility model or design DIN 34 1 Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract All rights are re...

Page 3: ...en la entrega Si no dispusiera de documentaci n en el idioma de su pa s dir jase a su distribuidor competente de Bosch Rexroth Portugu s Brasil Utilize apenas os produtos depois de ter lido compreendi...

Page 4: ...ontaktowa z lokalnym partnerem handlowym Bosch Rexroth Bosch Rexroth Rom n Punerea n func iune a produselor trebuie efectuat dup citirea n elegerea i respectarea documentelor i instruc iunilor de sigu...

Page 5: ...Information 19 2 1 1 Brief Introduction 19 2 1 2 Explanation of Warning Symbols and Degrees of Hazard Seriousness 21 2 2 Hazards by Improper Use 21 2 3 Instructions with Regard to Specific Dangers 22...

Page 6: ...itch SW1 47 5 3 5 NPN and PNP Modes 48 5 3 6 Encoder Signal Selection Switch SW2 49 6 Commissioning 51 6 1 Operating Panel 51 6 1 1 Overview 51 6 1 2 3 Level Menu Structure 52 6 1 3 Operation Mode Des...

Page 7: ...nals 77 Group E2 Multi Speed and Simple PLC 79 Group E3 PID Control 81 Group E4 Protection and Fault Parameters 82 7 3 4 Category H Advanced Rights 84 Group H0 Communication Parameters 84 7 4 Notes on...

Page 8: ...of radio interference suppression for relays contactors switches chokes and inductive loads 160 9 5 Selection Matrix for the EMC Accessories 161 10 Accessories 163 10 1 EMC Filter 163 10 1 1 The Func...

Page 9: ...nterface 180 12 2 3 Protocol Functions 180 Supported Functions 180 Function Description 181 12 2 4 Communication Mapping Register Address Distribution 186 12 2 5 ModBus Communication Example 189 12 2...

Page 10: ...mmunication Parameter Configuration 208 Communication Related Parameter Settings in Fv 208 Parameter Configuration of Master 208 GSD File 208 12 3 6 Faults and Analysis 209 LED Display Analysis 209 Di...

Page 11: ...Directions for Use 4 Frequency Converter Mounting Product information project specific 5 Installation 6 Commissioning Actual applications for operators and re pairers 7 Parameter Settings 8 Fault Ind...

Page 12: ...irmware Integrated brake unit Operating panel Instruction manual Optional accessories Operating panel for control cabinet mounting Optional PROFIBUS adapter RS232 485 adapter Engineering software Opti...

Page 13: ...elative humidity 5 95 Absolute humidity g m3 1 29 Climate category IEC 721 1K3 Moisture condensation not allowed Icing not allowed Fig 1 3 Storage conditions 1 2 2 Definition Bosch Rexroth Fv drive sy...

Page 14: ...1 2 3 Type Coding Type Coding of Fv Series Converters Fig 1 4 Type Coding of Fv Series Converters Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 12 219 Introduction...

Page 15: ...es Operating Panel Type Coding Fig 1 5 Operating panel type coding Engineering Software Type Coding Fig 1 6 Engineering software type coding DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosc...

Page 16: ...face adapter type coding Interface Adapter Cable Type Coding Fig 1 8 Interface adapter cable type coding Operating Panel Cable Type Coding Fig 1 9 Operating panel cable type coding Bosch Rexroth AG DO...

Page 17: ...Resistor Type Coding Fig 1 10 Brake resistor type coding Brake Unit Type Coding Fig 1 11 Brake unit type coding DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 15 219 Introduc...

Page 18: ...Test Test rate High voltage test 100 EN 61800 5 1 High voltage insulation test 100 EN 61800 5 1 Before making a high voltage test for the installation in which the components are used disconnect all c...

Page 19: ...rfaces 10 digital inputs 1 encoder input for speed feedback 3 analog inputs 2 open collector outputs 1 pulse output 2 relay outputs AC 250 V DC 30 V 3 A 2 analog outputs 1 optional ModBus PROFIBUS com...

Page 20: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 18 219...

Page 21: ...tion prior to working with the device If you do not have the user documentation for the device contact your respon sible Bosch Rexroth sales representative Ask for these documents to be sent immediate...

Page 22: ...They must have adequate safety equipment and be trained in first aid Only use spare parts and accessories approved by the manufacturer Follow all safety regulations and requirements for the specific...

Page 23: ...2 Hazards by Improper Use High electric voltage and high working cur rent Risk of death or severe bodily injury by electric shock DANGER Dangerous movements Danger to life se vere bodily harm or mate...

Page 24: ...pose Before working with electrical parts with voltage potentials higher than 50 V the device must be disconnected from the mains voltage or power supply unit With electrical drive and filter componen...

Page 25: ...cal components and conductors may be connected which are equipped with a PELV Protective Extra Low Voltage system Connect only voltages and circuits which are safely isolated from dan gerous voltages...

Page 26: ...Mount the emergency stop switch in the immediate reach of the opera tor Verify that the emergency stop works before start up Don t operate the device if the emergency stop is not working Isolate the d...

Page 27: ...zards may occur 2 7 Protection Against Contact with Hot Parts Hot surfaces at motor housings on drive con trollers or chokes Danger of injury Danger of burns CAUTION Do not touch surfaces of device ho...

Page 28: ...id and compressed air as well as drive controllers can be partially supplied with externally fed of pressurized media such as com pressed air hydraulics oil cooling liquids and cooling lubricating age...

Page 29: ...ducts take the form of hardware they must remain in their origi nal state in other words no structural changes are permitted It is not permitted to decompile software products or alter source codes Do...

Page 30: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 28 219...

Page 31: ...nverter is arranged above the other make sure that the upper limit of air temperature into the in let is not exceeded See chapter 9 Technical Data on page 143 A baffle plate is recommended between the...

Page 32: ...the rated power of the frequency converter depend ing on unit dimensions and equipment 4 2 Fv Dimensions and Outline 4 2 1 Fv Dimensions Housing Fv model Dimensions mm Screw size B b T t H h h1 d L1...

Page 33: ...g 4 4 Fv outline Please refer to fig 4 3 Fv dimensions on page 30 to select four screws for converter mounting DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 31 219 Frequency...

Page 34: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 32 219...

Page 35: ...5 1 1 Removal and Mounting of Operating Panel Removal of Operating Panel Fig 5 1 Removal of operating panel Mounting of Operating Panel Fig 5 2 Mounting of operating panel DOK RCON02 FV IB01 EN P Rex...

Page 36: ...l and Mounting of Adapter Removal of Adapter Fig 5 3 Removal of adapter Mounting of Adapter Fig 5 4 Mounting of adapter Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 34 219 I...

Page 37: ...5 2 Drive System Wiring 5 2 1 Block Diagram Fig 5 5 Block diagram DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 35 219 Installation...

Page 38: ...d shutting off of power supply Surge absorbers should be added at both sides of the magnetic contactor If the wire between the frequency converter and the motor is very long particularly with low outp...

Page 39: ...to the metal surface of cable control cabinet It is recommended to use shielded cables in accordance with specified EMC classification Main Circuit Wiring Diagram Fig 5 6 Main circuit wiring diagram T...

Page 40: ...Main Circuit Wiring Steps Fig 5 7 Main circuit wiring steps Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 38 219 Installation...

Page 41: ...Cable and Fuse Dimensions The power cable dimensions and the fuse dimensions are based on the VDE 0298 part 4 and the standard for the European countries EN 60204 1 The dimension for flexible wiring...

Page 42: ...nformation please refer to the table on next page kW Input Side USA Canada Nominal current of fuse in A Cable size in AWG Screw torque for power cable terminals in Nm lb in screw size Input PE Cable s...

Page 43: ...ioning variables of the table values 1 Installation types B1 according to IEC 60364 5 52 e g stranded wires routed in ca ble duct B2 according to IEC 60364 5 52 e g multi core line routed in ca ble du...

Page 44: ...lation pipes and in installation channels that can be opened C Cables or lines on walls E Cables or lines on open cable trays Fig 5 11 Cable installation types cf IEC 60364 5 52 DIN VDE 0298 4 EN 6020...

Page 45: ...converter outputs to be connected to the motor PB Reserved terminal for external braking resistor P1 DC positive bus outputs DC negative bus output Grounding Grounding Main circuit terminals illustrat...

Page 46: ...ame potential 0 V Isolated from COM Digital output signals OUT1 CME Open collector output 1 Can be programmed as multi ple function digital outputs see parameters E1 00 E1 01 Open collector outputs Ma...

Page 47: ...als PGP1 COM Supply voltage 24 V Voltage supply 1 for the encod er Max output current 100 mA PGP2 COM Supply voltage 8 V 20 V Voltage supply 2 for the encod er Max output current 100 mA A Encoder sign...

Page 48: ...possible less than 20 m shielded cables must be used 2 Use twin contacts to handle low level signals if contacts are used in the circuit In addition do not ground the GND termi nal 3 Incorrect operat...

Page 49: ...s NPN Switch contact at position 3 A three position switch determines 1 The internal 24 V power supply or an external 24 V power supply is used for the inputs 2 The inputs are activated by connection...

Page 50: ...sive input and 24 V PNP active input inputs respecitve external 24 V power supply is also available which improves the flexibility of singal input mode Fig 5 22 NPN and PNP modes Bosch Rexroth AG DOK...

Page 51: ...als are set by three positions of SW2 Position 1 Encoder provided by PGP1 encoder signals are provided via open collector inputs A and B Position 2 Encoder provided by PGP2 encoder signals are provide...

Page 52: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 50 219...

Page 53: ...nverter and com posed of two areas display and keys The display shows mode settings and operation state of the frequency converter The keys allow the user to pro gram the frequency converter Fig 6 1 O...

Page 54: ...evel menu structure The digital operating panel can be used to toggle between menu options and set parameters after fault with buttons Func Set and Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Fre...

Page 55: ...connected to other loads 5 Check that all inputs are off before powering on to ensure that the con verter will be started as expected and no unexpected action occurs 6 Make the following checks after...

Page 56: ...motor rotation speed 1 30000 rpm 1 rpm 1440 rpm S2 02 Rated motor power 0 4 1000 0 kW 0 1 kW Depends on model S2 03 Rated motor voltage 0 480 V 1 V Depends on model S2 04 Rated motor current 0 1 1000...

Page 57: ...7 Factory defaults 6 4 Solutions for Simple Fault during Commissioning 1 Over current occurs during acceleration O C 2 Increase the accelera tion time 2 Over voltage occurs during deceleration O E 3...

Page 58: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 56 219...

Page 59: ...7 Parameter Settings 7 1 Main Functions 7 1 1 Control Command Fig 7 1 Control command DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 57 219 Parameter Settings...

Page 60: ...7 1 2 Frequency Setting Fig 7 2 Frequency setting Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 58 219 Parameter Settings...

Page 61: ...7 1 3 Start Control Fig 7 3 Start control DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 59 219 Parameter Settings...

Page 62: ...7 1 4 Stop Control Fig 7 4 Stop control Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 60 219 Parameter Settings...

Page 63: ...7 1 5 Linear S curve Acceleration Deceleration Fig 7 5 Linear S curve acceleration deceleration DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 61 219 Parameter Settings...

Page 64: ...7 1 6 Simple PLC Control Fig 7 6 Simple PLC control Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 62 219 Parameter Settings...

Page 65: ...7 1 7 PID Control Fig 7 7 PID control DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 63 219 Parameter Settings...

Page 66: ...quency Setting via Analog Inputs and Pulse Inputs Fig 7 8 Frequency setting via analog inputs and pulse inputs Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 64 219 Parameter...

Page 67: ...7 1 9 Multiple Function Digital Input Terminals Fig 7 9 Multiple function digital input terminals DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 65 219 Parameter Settings...

Page 68: ...7 1 10 Analog Output Terminals Fig 7 10 Analog output terminals Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 66 219 Parameter Settings...

Page 69: ...7 1 11 Digital Output Terminals Fig 7 11 Digital output terminals DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 67 219 Parameter Settings...

Page 70: ...ttribute Description Parameter setting can be modified when the frequency con verter is in run or stop mode Parameter setting cannot be modified when the frequency con verter is in run mode Parameter...

Page 71: ...0 06 Automatic adjustment of PWM frequency 0 Off 1 On 1 1 b0 07 LCD backlight mode 0 Energy saving 1 Always on 1 0 b0 08 LCD display in run mode 0 Output frequency 1 Output rotation speed 2 Set output...

Page 72: ...SVC 2 Field oriented vector control FOC 1 0 b1 04 Digital set frequency b1 07 b1 06 0 01 Hz 50 00 Hz b1 05 Maximum frequency 50 00 400 00 Hz 0 01 Hz 50 00 Hz b1 06 Upper limit frequency b1 07 b1 05 0...

Page 73: ...0s 0 1s 0 0s b1 19 Stop mode 0 Decelerate to stop 1 Freewheel to stop 1 0 DC brake b1 20 Startup DC brake time 0 0 20 0s 0 0 deactivates DC braking 0 1s 0 0s b1 21 Shutdown DC brake activation frequen...

Page 74: ...ue increase 0 0 Automatic increase 0 1 20 0 of rated converter voltage Manual increase 0 1 0 1 S0 09 Automatic voltage stabilization 0 Not active 1 Always active 2 Not active during deceleration and b...

Page 75: ...e factor 0 00 50 00 0 01 Depends on model S2 08 Mutual inductance factor 0 0 2000 0 0 1 Depends on model S2 09 No load current 0 0 1000 0 A 0 1 A Depends on model S2 10 Parameter auto tuning 0 No acti...

Page 76: ...ated 1 Activated 1 0 S3 08 Waiting time to restart after power off or power fault 0 1 10 0s 0 1s 1 0s S3 09 Direction change dead time 0 0 3600 0s 0 1s 4 0s S3 10 Droop control 0 00 10 00 Hz 0 01 Hz 0...

Page 77: ...ol 8 Freewheel to stop 9 Frequency increment Up 10 Frequency decrement Down 11 Set frequency to 0 12 Reserved 13 Activate DC brake 14 Switch between operating panel and external terminal control 15 Si...

Page 78: ...0 VR1 reference frequency character istic curve 0 Curve 1 1 Curve 2 1 0 E0 14 Analog channel filter time 0 000 2 000s 0 001s 0 100s E0 15 Maximum input pulse fre quency 1 0 50 0 kHz 0 1 kHz 20 0 kHz E...

Page 79: ...of maximum frequency b1 05 0 1 5 0 E1 06 Frequency detection level FDT2 0 0 100 0 of maximum frequency b1 05 0 1 50 0 E1 07 Frequency detection level FDT2 width 0 0 100 0 of maximum frequency b1 05 0...

Page 80: ...ttribute DO pulse outputs E1 16 Pulse outputs 0 Output frequency 1 Output voltage 2 Output current 1 0 E1 17 Maximum output pulse frequency 1 0 50 0 kHz 0 1 kHz 10 0 kHz Bosch Rexroth AG DOK RCON02 FV...

Page 81: ...b1 07 b1 06 0 01 Hz 0 00 Hz E2 09 Multi speed frequency 4 b1 07 b1 06 0 01 Hz 0 00 Hz E2 10 Multi speed frequency 5 b1 07 b1 06 0 01 Hz 0 00 Hz E2 11 Multi speed frequency 6 b1 07 b1 06 0 01 Hz 0 00 H...

Page 82: ...0s E2 35 Stage 7 action selection 0 31 1 0 E2 36 Stage 7 running time 0 0 5000 0s 0 1s 0 0s E2 37 Stage 8 action selection 0 31 1 0 E2 38 Stage 8 running time 0 0 5000 0s 0 1s 0 0s E2 39 Stage 9 acti...

Page 83: ...log feedback channel 0 I 1 VR2 1 0 E3 04 P Proportional gain 0 0 10 000 0 001 1 500 E3 05 Ti Integral time 0 00 100 00s 0 00 represents no integral 0 01s 0 00s E3 06 Td Derivative time 0 00 100 00s 0...

Page 84: ...on active at low speed 2 Heat protection inactive at low speed 1 1 E4 05 Motor over load protection factor 50 0 110 0 0 1 100 0 E4 06 Phase loss protection 0 Both input and output phase loss protec ti...

Page 85: ...panel read write fault KEY 11 External device fault E St 12 Communication fault R S 13 Circuit disconnection C F 14 Pulse encoder speed detection fault PULS 15 Reserved 16 EMI fault CPU 17 Short circ...

Page 86: ...8 1 1 start bit 8 data bits 1 stop bit even 2 O 8 1 1 start bit 8 data bits 1 stop bit odd 1 0 H0 03 Local address H0 00 0 1 247 0 represents broadcast ad dress 1 1 H0 00 1 1 126 H0 04 PZD4 PZD3 sett...

Page 87: ...odify nor copy parameters if an incorrect password is entered 2 Please contact the manufacturer if you forgot the set pass word b0 01 LCD language Factory default 0 Setting range 0 1 Minimum unit 1 LC...

Page 88: ...derating figures related to PWM frequency refer to chapter 9 Technical Data on page 143 b0 06 Automatic adjustment of PWM frequency Factory default 0 Setting range 0 Off 1 On Minimum unit 1 The conver...

Page 89: ...mode b0 09 equals output frequency multiplied by Scale factor of output frequency b0 10 b0 11 Parameter filter setting Factory default 0 Setting range 0 3 Minimum unit 1 Only parameters of the selecte...

Page 90: ...ult b0 02 b0 14 Firmware version Factory default Setting range Read only Minimum unit b0 15 Reserved Factory default 0 Setting range 0 1 Minimum unit 1 Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth...

Page 91: ...rameter b1 04 In stop mode If Digital set frequency saving b1 01 1 or 3 the cur rent running frequency will be saved in parameter b1 04 2 Set by external analog terminals Set the frequency by external...

Page 92: ...14 Frequency setting via external terminals Up Down Clear frequency Open Closed Up terminal Open Closed Open Closed Down terminal Open Closed Open Closed Converter frequency reaction Hold Decrease In...

Page 93: ...2 1 or 2 the Stop key on the operating panel can be ena bled with S3 15 b1 03 Control mode Factory default 0 Setting range 0 1 2 Minimum unit 1 0 V F control V F Select this mode if it is impossible t...

Page 94: ...related settings b1 04 Digital set frequency Factory default 50 00 Hz Setting range b1 07 b1 06 Minimum unit 0 01 Hz If Frequency setting mode b1 00 1 value of b1 04 is the set frequency b1 05 Maximum...

Page 95: ...ency from Maximum frequency b1 05 to 0 Hz Shown as T2 in figure fig 7 17 Acceleration time1 Deceleration time 1 on page 93 Fig 7 17 Acceleration time1 Deceleration time 1 4 groups of acceleration dece...

Page 96: ...ion mode b1 12 Time of S curve rising section 1 Factory default 20 0 Setting range 0 0 40 0 of Accelera tion time 1 b1 09 Minimum unit 0 1 b1 13 Time of S curve rising section 3 Factory default 20 0 S...

Page 97: ...the converter accelerates without braking to Start fre quency b1 17 This mode is suitable for circumstances where the load may en counter forward reverse rotation when the converter is in stop mode 2...

Page 98: ...rectly with out DC brake The larger the DC brake current the larger the braking force is Take the withstanding capability of the motor into account b1 21 Shutdown DC brake activation frequency Factory...

Page 99: ...ant torque load shown as 0 in chapter Group S0 V F Control on page 97 1 Square mode Suitable for variable torque loads shown as 1 in chapter Group S0 V F Control on page 97 Fig 7 20 Linear and square...

Page 100: ...S0 06 V F voltage 3 Factory default 0 0 Setting range 0 00 120 0 of Rated motor voltage S2 03 Minimum unit 0 1 Excessive low frequency voltages may cause the motor to over heat or result in motor dam...

Page 101: ...torque increase is shown in chap ter Group S0 V F Control on page 97 and chapter Group S0 V F Control on page 97 Fig 7 22 Linear V F curve automatic torque increase Fig 7 23 Square V F curve automati...

Page 102: ...Automatic voltage stabilization Factory default 0 Setting range 0 Not active 1 Always active 2 Not active during deceler ation and braking Minimum unit 1 Used to keep the output voltage constant withi...

Page 103: ...e resistor is in place to reduce significantly the possibility of over voltage warn ings S0 10 Reserved Factory default 0 Setting range 0 1 Minimum unit 1 DOK RCON02 FV IB01 EN P Rexroth Frequency Con...

Page 104: ...er The proportional gain should be increased without causing oscillation The integral time should be decreased to allow the system to have quick response and smaller overshoot Improperly set parameter...

Page 105: ...ferent from the set torque be cause of speed limitation 1 Always active Torque control is always active Torque control is only active for Control mode b1 03 is 2 Field oriented vector control FOC S1 0...

Page 106: ...default Depends on model Setting range 0 00 50 00 Minimum unit 0 01 S2 07 Leakage inductance factor Factory default Depends on model Setting range 0 00 50 00 Minimum unit 0 01 S2 08 Mutual inductance...

Page 107: ...ult 0 Setting range 0 1 Minimum unit 1 S2 14 Pulse encoder fault detection extent Factory default 0 0 Setting range 0 1 1000 0 rpm Minimum unit 0 1 rpm S2 15 Pulse encoder fault detection time Factory...

Page 108: ...ating panel or external computer Jog is inactive in torque control mode S3 03 Skip frequency 1 Factory Default 0 00 Hz Setting range b1 07 b1 06 Minimum unit 0 01 Hz S3 04 Skip frequency 2 Factory Def...

Page 109: ...if power on after pow er off or power fault 0 Inactive No restart after power off or power fault 1 Active Restart after power off or power fault For a running converter when Converter control command...

Page 110: ...hange dead time S3 10 Droop control Factory Default 0 00 Hz Setting range 0 00 10 00 Hz Minimum unit 0 01 Hz Used to change the decrease value of the output frequency This function is suitable for cir...

Page 111: ...utes a fast brake to stop In deceleration or breakdown braking process the brake function is de activated when DC voltate is larger than Brake unit threshold S3 12 and smaller than Brake unit threshol...

Page 112: ...ter is controlled by external commands and stopped with the Stop key in order to restart the converter the external commands have to be disabled first S3 16 Fan control Factory Default 0 Setting range...

Page 113: ...FWD REV Status 0 0 Stop 0 1 Reverse 1 0 Forward 1 1 Stop Fig 7 31 2 wire control mode 1 1 Forward Reverse Run Stop FWD REV Status 0 0 Stop 0 1 Stop 1 0 Forward 1 1 Reverse Fig 7 32 2 wire control mode...

Page 114: ...t 1 8 multifunction digital input terminals X8 can be used as a high speed pulse input terminal are available with PNP and NPN input modes and with either internal or external power supply 0 Inactive...

Page 115: ...mbination of terminal input sig nals Selected frequency Corresponding parameter S4 S3 S2 S1 OFF OFF OFF OFF Multi speed frequency 0 b1 00 OFF OFF OFF ON Multi speed frequency 1 E2 06 OFF OFF ON OFF Mu...

Page 116: ...rameter Acc Dec time 2 Acc Dec time 1 OFF OFF Acceleration time 1 b1 09 Deceleration time 1 b1 10 OFF ON Acceleration time 2 E2 00 Deceleration time 2 E2 01 ON OFF Acceleration time 3 E2 02 Decelerati...

Page 117: ...con verter resumes the status before the PLC pause 17 Switch between speed control and torque control Used to switch between speed control and torque control in vector control with feedback The relate...

Page 118: ...cation when b1 02 0 Used to switch between control with external terminals and with communication when b1 02 1 E0 09 Source of analog setting reference frequency Factory Default 0 Setting range 0 k1 V...

Page 119: ...range 0 00 b1 06 Minimum unit 0 01 Hz E0 22 Curve 2 maximum reference Factory Default 100 0 Setting range E0 20 100 0 Minimum unit 0 1 E0 23 Frequency corresponding to curve 2 maxi mum reference Fact...

Page 120: ...s as shown in fig 7 43 Reference frequency curve selection on page 118 Fig 7 43 Reference frequency curve selection Parameter E0 14 is used to define the analog channel filter time con stant for proce...

Page 121: ...as zero as shown in fig 7 44 Reference frequency and analog input voltage when E0 09 6 on page 119 Fig 7 44 Reference frequency and analog input voltage when E0 09 6 For example if E0 24 10 0 when E0...

Page 122: ...Hz 4 Frequency speed arrival signal See related parameter Frequency arrival detection width E1 03 5 Frequency level detection signal FDT1 See related parameters E1 04 E1 05 6 Frequency level detectio...

Page 123: ...E1 05 Frequency detection level FDT1 width Factory Default 5 0 Setting range 0 0 100 0 of maximum frequency b1 05 Minimum unit 0 1 E1 06 Frequency detection level FDT2 Factory Default 50 0 Setting ra...

Page 124: ...otor over load pre warning level setting Factory Default 100 0 Setting range 100 0 250 0 of rated motor current Minimum unit 0 1 If parameters E1 00 E1 02 are set to 10 Motor over load pre warning and...

Page 125: ...0 10 V 0 20 mA 0 to maximum reference frequency corresponding 2 10 V 4 20 mA 2 Output current 0 to 2 times of rated cur rent corresponding 0 10 V 0 20 mA 0 to 2 times of rated cur rent corresponding 2...

Page 126: ...7 is output via DO terminal If parameter Pulse outputs E1 16 is set to 1 Output voltage when the output voltage reaches 500 V the corresponding set value of pa rameter Maximum output pulse frequency E...

Page 127: ...Factory Default 0 00 Hz Setting range b1 07 b1 06 Minimum unit 0 01 Hz E2 07 Multi speed frequency 2 Factory Default 0 00 Hz Setting range b1 07 b1 06 Minimum unit 0 01 Hz E2 08 Multi speed frequency...

Page 128: ...r with forward reverse control terminals FWD COM and REV COM and acceleration deceleration terminals Running time of each speed is decided by the hold time of corresponding logic combination Output fr...

Page 129: ...h parameter Acceleration time 2 E2 00 10 set with parameter Acceleration time 3 E2 02 11 set with parameter Acceleration time 4 E2 04 bit1 and bit0 00 set with parameter Deceleration time 1 b1 10 01 s...

Page 130: ...Default 0 Setting range 0 31 Minimum unit 1 E2 36 Stage 7 running time Factory Default 0 0s Setting range 0 0 5000 0s Minimum unit 0 1s E2 37 Stage 8 action selection Factory Default 0 Setting range 0...

Page 131: ...0 0s Minimum unit 0 1s E2 51 Stage 15 action selection Factory Default 0 Setting range 0 31 Minimum unit 1 E2 52 Stage 15 running time Factory Default 0 0s Setting range 0 0 5000 0s Minimum unit 0 1s...

Page 132: ...ut analog feedback 3 Analog input pulse encoder feedback In this mode parameter Control mode b1 03 needs to be set as 0 V F control 4 Rotation speed digital setting pulse encoder feedback In this mode...

Page 133: ...s Setting range 0 00 100 00s 0 00 represents no integral Minimum unit 0 01s E3 06 Td Derivative time Factory Default 0 00s Setting range 0 00 100 00s 0 00 represents no derivative Minimum unit 0 01s E...

Page 134: ...e reaches parameter Upper limit frequency b1 06 or Lower limit frequency b1 07 the integral loop has two options 0 Stop integral adjustment The integral value remains unchanged When the difference bet...

Page 135: ...on level the converter output frequency stops decrease Only if bus voltage is lower than the stall over voltage protection level will the converter resume deceleration as shown in fig 7 52 Stall over...

Page 136: ...eriorated at low speed running the electronic heat pro tection value setting is unnecessary E4 05 Motor over load protection factor Factory Default 100 0 Setting range 50 0 110 0 Minimum unit 0 1 If t...

Page 137: ...Fault relay Ta Tb Tc settinng options bit0 0 Under voltage inactive 1 Under voltage active bit1 0 Auto reset inactive 1 Auto reset active Data format of this parameter is show in fig 7 55 Data format...

Page 138: ...Automatic fault reset is valid to the following fault types O C 1 O C 2 O C 3 O E 1 O E 2 O E 3 O L 1 O L 2 E St CPU and O H E4 10 Last fault Factory Default 0 Setting range 0 23 Minimum unit 1 E4 11...

Page 139: ...otherwise normal communication is impossible H0 02 Data format Factory Default 0 Setting range 0 1 2 Minimum unit Used to set data format in protocols 0 N 8 2 1 start bit 8 data bits 2 stop bits witho...

Page 140: ...ction detection is deactivated 0 1 60 0s if the interval between the current communication and next communication exceeds the communication timeout time the system will detect timeout and act accordin...

Page 141: ...has to match with converter power 7 Pulse encoder fault 7 Check pulse encoder and its connection 8 Improper V F curve 8 Adjust V F curve setting and torque increase 3 Over current during decel eration...

Page 142: ...ong time with large load at low speed 2 Use variable frequency motor or increase con verter output frequency 3 Low voltage of input power supply 3 Check input power supply 4 Too large proportion of V...

Page 143: ...ses of input pow er supply 3 Check if the imbalance situation exceeds requir ments 20 U V W out put phase loss OPH L 1 Abnormal omitted or broken connection of converter outputs 1 Check connections of...

Page 144: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 142 219...

Page 145: ...faults etc Automatic PWM frequency adaptation Load dependent adaptation of PWM frequency Customerized functions Control commands set by operating panel control terminals and serial port Frequency set...

Page 146: ...rating between 40 C and 50 C Relative humidity 90 RH without condensation Shocking 5 9 m s 0 6 g Allowed pollution degree 2 EN 50178 Construction Degrees of protection IP20 control cabinet mounting Co...

Page 147: ...bient temperature range for operation with reduced nominal data Fig 9 2 Derating and ambient temperature 9 2 2 Derating and mains voltage Reduced over current based on mains voltage The Fv frequency c...

Page 148: ...ency for the different frequency converters In case of higher pulse frequency the current is reduced insofar that the power dissipation in power section remains more or less constant For converters wi...

Page 149: ...2 2 4 0 5 5 7 5 Rated input current A 3 0 3 7 5 1 7 6 16 0 16 5 24 5 Rated output current A 1 3 2 5 4 0 5 5 10 0 13 0 17 0 Capacity kVA 0 8 1 6 2 6 3 6 6 5 8 5 11 0 Weight kg 2 7 2 7 2 7 2 8 4 8 4 9...

Page 150: ...ic device against external electric magnetic or electromagnetic interference via lines or through air Sufficiently low noise emission of electric magnetic or electromagnetic noise of an electric insta...

Page 151: ...h 3 m clamp 2 kV 2 5 kHz B Signal interface Burst IEC 61000 4 4 Length 3 m clamp 1 kV 2 5 kHz B IEC 61000 4 6 Length 3 m clamp or CDN 10 V 0 15 80 MHz A Ports of process measurement control lines Burs...

Page 152: ...tenna effect This applies to power lines too Limit values for line based distur bances According to IEC EN 61800 3 or CISPR 11 corresponds to EN 55011 the limit values in the table below are distingui...

Page 153: ...0 A 2 1 Category C3 2nd environment QSP I 100 A class A group 2 I 100 A 2 2 Category C3 2nd environment AV I 100 A class A group 2 I 100 A 3 1 Category C2 1st environment restricted distribution QSP 1...

Page 154: ...ted measures are generally recommended Nominal Current of Supply Mains The nominal current of the supply mains 100 A or 100 A is specified by the local power supply company at the connection point of...

Page 155: ...iring and installation In addition the required measures depend on the requirements of electric safety technology and economic efficiency in the application In order to prevent interference as far as...

Page 156: ...synchronization connection Lines at the motor connection Lines at the DC bus connection Generally interference injections are reduced by routing cables close to grounded sheet steel plates For this r...

Page 157: ...main switch mains side of mains filter for drives and corresponding connecting lines Control voltage or auxiliary voltage connection with power supply unit fuse and other parts unless connection is ru...

Page 158: ...s Design and installation in area A interference free area of control cabinet Arrangement of the Components in the Control Cabinet Comply with a distance of at least 200 mm distance d1 in the figure B...

Page 159: ...of the mains filter is totally or partly neu tralized This will cause the noise level of the interference emis sion to be higher within the range of 150 kHz to 40 kHz and the limit values at the conne...

Page 160: ...Modules components and lines in area B should be placed at a distance of at least d1 200 mm from modules and lines in area A Alternative Shield modules components and lines in area B by distance plate...

Page 161: ...ed mounting plates always use screw connections with tooth lock washers and zinc coated tinned screws as connection elements At the con nection points remove the lacquer so that there is safe electric...

Page 162: ...ld The guide value for the cross section is 10 mm2 You absolutely have to equip separate connections with connectors with grounded metal housing In the case of non shielded lines belongs to the same c...

Page 163: ...ories For this topic please contact us via the following email address dccx drivesupport boschrexroth com cn Please send your enquiry in English DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv...

Page 164: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 162 219...

Page 165: ...oth com cn Please send your enquiry in English 10 3 Brake Components 10 3 1 Brake Unit The Function of Brake Unit A brake unit is used to dissipate the energy produced by the motor during a braking pr...

Page 166: ...t If a resistance lower than the recommended value and no less than the minimum resistance is used contact the agent or manufacturer for calculation of resistance power Safety and flammability of surr...

Page 167: ...A LP NNNN 01V01 Internal FELR01 1N 0780 N075R D 560 NNNN 75 780W 1 11 FVCA01 1 11K0 3P4 MNA LP NNNN 01V01 Internal FELR01 1N 1K04 N050R D 560 NNNN 50 1040W 1 15 FVCA01 1 15K0 3P4 MNA LP NNNN 01V01 Int...

Page 168: ...NNN 01V01 Internal FELR01 1N 02K0 N110R D 560 NNNN 110 2 0kW 1 5 5 FVCA01 1 5K50 3P4 MNA LP NNNN 01V01 Internal FELR01 1N 01K5 N150R D 560 NNNN 150 1 5kW 2 7 5 FVCA01 1 7K50 3P4 MNA LP NNNN 01V01 Inte...

Page 169: ...easonably for intermittent braking load The power of brake resistor can be calculated by formula PR K Pmax ED in which k is the derating coefficient of brake resistor The selection of the brake torque...

Page 170: ...FELR01 1N 0260 N250R D 560 NNNN 250 260 215 197 60 30 2 5 500 0 62 Alumini um FELR01 1N 0520 N350R D 560 NNNN 350 520 335 317 60 30 2 5 500 1 03 Alumini um FELR01 1N 0260 N400R D 560 NNNN 400 260 215...

Page 171: ...2 20 Alumini um FELR01 1N 0780 N075R D 560 NNNN 75 780 400 382 61 59 2 5 M6 4 35 Alumini um FELR01 1N 1K04 N090R D 560 NNNN 90 1040 400 384 50 107 2 5 M6 3 60 Alumini um FELR01 1N 02K0 N110R D 560 NN...

Page 172: ...0 M6 18 5 Brake resistor box FELR01 1N 12K5 N017R A 560 NNNN 17 12 5 410 685 145 170 642 340 6 0 M6 20 5 Brake resistor box FELR01 1N 12K5 N018R A 560 NNNN 18 12 5 410 685 145 170 642 340 6 0 M6 20 5...

Page 173: ...0 642 340 6 0 M6 18 5 Brake resistor box FELR01 1N 04K8 N27R2 A 560 NNNN 27 2 4 8 340 600 145 170 580 291 4 0 M6 12 0 Brake resistor box FELR01 1N 10K0 N028R A 560 NNNN 28 10 0 410 685 145 170 642 340...

Page 174: ...ase refer to chapter 12 Communication Protocols on page 179 10 5 2 ModBus Adapter The ModBus adapter FVAA01 1 M NNNN 01V01 is used to connect the RS485 interface ModBus with a PC or another control un...

Page 175: ...10 14 Mounting of operating panel at the control cabinet with mounting plate 10 6 2 Operating Panel Cable for Control Cabinet Mounting The cable FRKS0001 001 0 which is 1 m long is used to connect the...

Page 176: ...parameterize the frequency converters Parameters are set on the PC and transferred to the converters via serial RS485 ModBus inter face Together with the engineering software is the ConverterPC_Fv us...

Page 177: ...f 0 V to 10 V E3 02 E3 03 E3 04 E3 05 E3 06 and E3 07 are set depending on actual conditions 11 1 2 Closed loop Speed Control System Fig 11 2 Closed loop Speed Control System Conditions and requiremen...

Page 178: ...evice Operating Principle A contactor is installed to switch a resistor to the terminals L and L of the DC bus connection to discharge the capacitors The contactor is activated via a control input whi...

Page 179: ...ible from heat sensitive components How to install the discharging device 1 Preferably install discharging device before switching on supply voltage of the first time If you install discharging device...

Page 180: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 178 219...

Page 181: ...xception response to the master station Slave stations can not communicate with each other but through the master s software which reads data from one slave station and send them to another There are...

Page 182: ...gement Each address must be unique in the network 12 2 2 Interface The communication interface of Fv converters is shown in fig 12 2 Fv com munication interface on page 180 Fig 12 2 Fv communication i...

Page 183: ...ers can not be modified in run mode Converter is in run mode 6 Read only Not allowed to write in read only parame ters 7 Invalid operation Function code does not support write via external computer or...

Page 184: ...rter with address 01H The frame structure is described in fig 12 7 Function 0x06_master request on page 182 and fig 12 8 Function 0x06_slave response on page 182 Start Transmission time for 3 5 bytes...

Page 185: ...End Transmission time for 3 5 bytes Fig 12 9 Function 0x08_master request Start Transmission time for 3 5 bytes Slave address 01H ModBus function code 08H Higher byte of test word 1 12H Lower byte of...

Page 186: ...register number 00H Lower byte of register number 02H CRC lower byte 90H CRC higher byte 36H End Transmission time for 3 5 bytes Fig 12 12 Function 0x10_slave response Function 0x17 Read write N word...

Page 187: ...e 48H CRC higher byte 72H End Transmission time for 3 5 bytes Fig 12 13 Function 0x17_master request Start Transmission time for 3 5 bytes Slave address 01H ModBus function code 17H Bytes of read regi...

Page 188: ...page 186 the lower byte rep resents the function code within the code group Function group Mapping address Function group Mapping address b0 0x00 b1 0x01 S0 0x02 S1 0x03 S2 0x04 S3 0x05 E0 0x06 E1 0x...

Page 189: ...ter This register is read only The definition of each bit is shown in fig 12 17 Communication state word register 0x5000 _bit definition on page 187 bit Value Description 15 11 Error code 10 8 Reserve...

Page 190: ...arameter auto tuning fault TUNE Fig 12 18 Error codes and meanings_ModBus Communication monitor registers 0x5001 0x500F Communication monitor registers are read only The relationship between the addre...

Page 191: ...ad dress Function code Start ad dress Number of ad dress Bytes of data Data content CRC code Request 0x01 0x06 0x4000 N A N A 0x0008 0xCC9D Response 0x01 0x06 0x4000 N A N A 0x0008 0xCC9D Fig 12 20 E...

Page 192: ...120 0 25 W Fig 12 21 ModBus networking Cables may only be connected when drive is turned off WARNING Recommendations on Networking Use shielded twisted pair cable to connect RS485 links ModBus cable...

Page 193: ...imum length of bus cable is within the scope of 100 1200 m depending on the set transmission rate When no repeater is used 32 nodes at maximum can be connected to the same PROFIBUS network if a repeat...

Page 194: ...ectrical Installations Outline Structure Fig 12 25 PROFIBUS adapter dimensions Bus Terminal Resistor Switch S1 on PROFIBUS adapter is used to switch On Off built in bus termi nal resistor of the adapt...

Page 195: ...IBUS Link Cable used is shielded twisted pair cable The shield is able to improve elec tromagnetic compatibility EMC ability Unshielded twisted pair cable may be used if there is less electromagnetic...

Page 196: ...able signal cable must be twisted and shielded and installed separately with electrical power cable with a distance of at least 20 cm Bus cable shielding layer should be grounded at one end Termi nal...

Page 197: ...er Area on page 195 and chapter PZD Process Data Area on page 201 Fig 12 31 PPO type PKW Parameter Area This data area is composed of ID IND VALUE_high and VALUE_low as shown in fig 12 32 PKW area dat...

Page 198: ...default is 0 3rd VALUE_high 15 0 0 Reserved default is 0 4th VALUE_low 15 0 xxxxH 1 When reading parameters default is 0 2 When modifying parame ters it is modified value 3 It can be of any value in...

Page 199: ...of no operation 4 It returns error code when PKW area execution fails Fig 12 34 Response Data Frame in PKW Area_from slave to master Error message after execution failure in PKW area Error code Meani...

Page 200: ...roup 0 06 is the index serial No of the parameter within the group then request and response data frames in PKW area are shown in fig 12 36 Example 1_request and response data frames of PKW area on pa...

Page 201: ...limit of parameter S3 06 is the modified value then request and response data frames in PKW area are shown in fig 12 39 Ex ample 4_request and response data frames of PKW area on page 199 ID IND VALU...

Page 202: ...a on page 200 ID IND VALUE_high VALUE_low Request data frame of PKW area 0x2005 0x0600 0x0000 0x0BB8 Response data frame of PKW area 0x7005 0x0600 0x0000 0x0005 Fig 12 42 Example 7_request and respons...

Page 203: ...rea are re spectively corresponding to status word SW and actual output frequency ACT and PZD3 PZD10 are corresponding to status monitoring values such as output current output voltage AC bus voltage...

Page 204: ...celeration 1 Accelerating 2 0 Not in jog 1 Jogging 1 0 In stop 1 In run 0 0 Forward 1 Reverse Fig 12 46 Bit definition of status word In case of system faults fault records can be read in parameters E...

Page 205: ...ceeds the maximum frequency then the PPO request and response messages are shown in fig 12 48 Ex ample 1_PPO request and response messages on page 203 PZD1 PZD2 PPO request message CW REF 0x0001 0x4E2...

Page 206: ...4 bits and monitored value is shown in fig 12 50 Process data PZD3 PZD 10 values and func tion code settings on page 204 00 Output current 01 Reference freqeuency 02 Output current 03 DC bus voltage 0...

Page 207: ...message SW ACT 0x0000 0x0206 0x02DD 0x0019 0x0002 0x1388 Fig 12 51 Example 1 for PZD process data area_request and response messag es of PPO In this example request and response data frame is the mess...

Page 208: ...Hz to stop the converter as parame ter settings please refer to example 1 PZD1 PZD2 PZD3 PZD4 PZD5 PZD6 PPO request message CW REF 0x0000 0x0000 0x0000 0x0000 0x000C 0x1388 PPO response message SW AC...

Page 209: ...So its index of parameters within the group is 0 03 As high 3 bit of 11 bit function code bit10 8 of ID must be 000B in order to describe it in sexadecimal sys tem function code group No stated in thi...

Page 210: ...by the Stop key on the operating panel adapter is isolated from communication software of the frequency converter If communi cation is to be re established Stop and Reset commands must be sent to the...

Page 211: ...ware connection between the bus adapter and the fre quency converter Net This light indicates the status of communication between the bus adapter and PROFIBUS master If this light is always flashing i...

Page 212: ...Reserved 7 Diag Deactivated set by master reset by slave 1 slave inactive Third byte Station_Status_3 0 6 Reserved 7 Diag Ext_Diag_Overflow set by slave 1 more diagnosis information in Ext_Diag_Date...

Page 213: ...to be expected Materials contained in the electronic devices steel aluminum copper synthetic materials electronic components and modules Recycling Due to their high content of metals most of the produ...

Page 214: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 212 219...

Page 215: ...40 49 41 e mail service svc boschrexroth de Internet http www boschrexroth com You will also find additional notes regarding service maintenance e g delivery addresses and training 1 Central European...

Page 216: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 214 219...

Page 217: ...tion of PROFIBUS DB9 Pins 193 Delivery and Storage 10 Derating and ambient temperature 145 Derating and mains voltage 145 Derating of electrical data 145 Derating of the output current depending on th...

Page 218: ...cription 43 Main circuit terminals illustration 43 Main Circuit Wiring 36 Main Circuit Wiring Diagram 37 Main Circuit Wiring Steps 38 Main Functions 57 Mains Chokes 163 Materials contained in the elec...

Page 219: ...ructions for Electric Drives and Controls 19 Selection Matrix for the EMC Accessories 161 Service and Support 213 Simple Applications of Process Control 175 Simple PLC Control 62 S Solutions for Simpl...

Page 220: ...Bosch Rexroth AG DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv 218 219...

Page 221: ...Notes DOK RCON02 FV IB01 EN P Rexroth Frequency Converter Fv Bosch Rexroth AG 219 219...

Page 222: ...Controls Co Ltd No 3999 Shangji Road Caotan Eco Industrial Park Economic and Technological Development Zone Xi an 710021 P R China Phone 49 9352 40 5060 Fax 49 9352 40 4941 service svc boschrexroth d...

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