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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 safety instruction, property damage could

occur.

Bosch Rexroth AG

DOK-INDRV*-SYSTEM*****-PR06-EN-P

Rexroth IndraDrive Drive Systems with HMV01/02 HMS01/02, HMD01, HCS02/03

46/309

Safety Instructions for Electric Drives and Controls

Summary of Contents for IndraDrive

Page 1: ...Planning Manual Electric Drives and Controls Pneumatics Service Linear Motion and Assembly Technologies Hydraulics Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 R911309636 Edi...

Page 2: ...ut 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...

Page 3: ...ontrol Sections 28 1 9 Documentations 28 1 9 1 About This Documentation 28 1 9 2 Overview of Documentations 29 Drive Systems System Components 29 Motors 30 Cables 31 Firmware 31 1 9 3 Your Feedback 34...

Page 4: ...10 Drive Controllers HCS03 50 4 11 Components KCU KSM KMS 50 4 12 DC Bus Resistor Unit HLB01 51 4 13 Braking Resistor HLR01 51 4 14 DC Bus Capacitor Unit HLC01 52 4 15 Fan Unit HAB01 52 4 16 Motor Fil...

Page 5: ...5 Fusing by Protective Grounding in TN S Mains 86 Fusing by Protective Grounding in TN C Mains 87 Fusing by Protective Grounding in IT Mains Ungrounded Mains 88 7 5 3 Connection for the Equipment Grou...

Page 6: ...ponents 120 8 4 1 Additional Components at the DC Bus 120 General Information 120 HLR Braking Resistors and DC Bus Resistor Units HLB 122 8 4 2 Additional Components at the Motor Output 125 General In...

Page 7: ...ve DC Bus Short Circuit is Activated 155 General Information 155 Control Circuits With DC Bus Short Circuit ZKS 157 9 4 4 Deceleration in the Case of Emergency Stop or Mains Failure 166 General Inform...

Page 8: ...allations With Drive Controllers in Compliance With EMC 203 EMC Optimal Installation in Facility and Control Cabinet 204 Ground Connections 211 Installing Signal Lines and Signal Cables 212 General Me...

Page 9: ...rd Party Motors 242 14 2 1 General Information 242 14 2 2 Voltage Load of the Third Party Motor 242 14 2 3 Minimum Inductance of Third Party Motor 243 14 2 4 Temperature Evaluation of Third Party Moto...

Page 10: ...Data of Mains Filters 273 Reducing Allowed Operating Voltage Depending on Actual Temperature Rise Due to Harmonics 273 Current Reduction in the Case of Overtemperature 274 15 4 Other Calculations 276...

Page 11: ...age Glossary Definitions of Terms Abbreviations 297 Index 301 DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 Bosch Rexroth AG IX 309 Table of Content...

Page 12: ...Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 X 309...

Page 13: ...d Series HCS01 HCS02 HCS03 HCS04 HMV01 HMV02 HMS01 HMS02 HMD01 CSE CSB CDB CSH Component W0003 W0054 W0012 W0070 W0070 W0210 W0350 W1540 W0015 W0120 W0020 W0350 W0012 W0036 02 01 02 01 02 Tab 1 2 Hier...

Page 14: ...3 Integrated inverters Integrated 24V control voltage supply optional for HCS02 Additional components DC bus resistor units DC bus capacitor units Braking resistors The figure below illustrates the sy...

Page 15: ...ing an HNK mains filter at HCS03 devices connect the mains contactor between mains supply and mains filter DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS0...

Page 16: ...supply Integrated mains contactor except for HMV01 1R W0120 Modular extension of number of axes is possible Two series mounting depths of HMV and HMS available Additional components DC bus resistor un...

Page 17: ...0 HNL Optional mains choke HNL for HMV01 1E required for HMV01 1R HNF Optional mains filter HNF depends on EMC requirements Fig 1 2 Drive System Rexroth IndraDrive M Series 01 DOK INDRV SYSTEM PR06 EN...

Page 18: ...B HLB01 1C optional HLC HLC01 1C optional Fig 1 3 Drive System Rexroth IndraDrive M Series 02 Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01...

Page 19: ...3 External mains contactor K1 required only for HMV01 1R W0120 Fig 1 4 System Structure Rexroth IndraDrive Mi with HMV The figure below illustrates the system structure of the drive system Rexroth Ind...

Page 20: ...Fig 1 5 System Structure Rexroth IndraDrive Mi with HCS03 Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 18 309 System Presentation...

Page 21: ...Fig 1 6 System Structure Rexroth IndraDrive Mi with HCS02 DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 Bosch Rexroth AG 19 309 System Presentation...

Page 22: ...0120 KCU Drive connection box KSM Motor integrated servo drive MSK Servo motor optional RHS Terminal connector RKB Communication cable RKG Encoder cable optional RKH Hybrid cable RKL Motor cable optio...

Page 23: ...HCS02 K1 Mains contactor KCU Drive connection box KSM Motor integrated servo drive MSK Servo motor 24V 24V supply RHS Terminal connector RKB Communication cable RKG Encoder cable RKH Hybrid cable RKL...

Page 24: ...tion box KSM Motor integrated servo drive MSK Servo motor RHS Terminal connector RKB Communication cable RKH Hybrid cable RKG Encoder cable RKL Motor cable 24V 24V supply X103 1 Connection of hybrid c...

Page 25: ...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 regenerati...

Page 26: ...V02 supply units HCS02 and HCS03 converters Allowed combinations of components See chapter 8 Configuring the Drive System on page 93 1 6 Basic Design of the Devices 1 6 1 General Information 1 Power s...

Page 27: ...a separate component which is plugged into the power section The control section consists of Basic control section circuit board with interfaces Optional modules only for configurable control sections...

Page 28: ...ices Compact converters Modular inverters Type current Contin current Iout_cont_4k A 1 Peak current Iout_max_4k A 1 Nominal motor power kW 2 HCS01 W00033 3 HCS01 W00054 5 HCS01 W00063 6 HCS01 W00084 8...

Page 29: ...2 E W0054 9 1 16 0 35 18 HCS02 E W0070 13 3 19 0 5 25 HMV01 R W0018 18 45 0 4 36 HCS03 E W0070 25 40 opt opt HMV01 E W0030 30 45 1 5 36 HCS03 E W0100 43 59 opt opt HCS03 E W0150 56 89 opt opt HMV02 R...

Page 30: ...cumentations relevant to your drive system Purpose of Documentation This documentation contains Overview information of the Rexroth IndraDrive drive system Description of the allowed combinations of R...

Page 31: ...with HLB01 1D included Arranging the Compo nents in the Control Cabinet Chapter EMC Optimal Installation in Facility and Control Cabinet revised Project Planning of Cooling System Contents revised Env...

Page 32: ...L ILSYSINS AWxx EN P 317021 1 In the document typecodes xx is a wild card for the current edition of the documentation example AW01 is the first edition of an Applica tion Manual Tab 1 8 Documentation...

Page 33: ...r Drive Controllers MPH 04 MPB 04 MPD 04 Functional Description MP 04VRS FKxx EN P 315485 Firmware for Drive Controllers MPH 03 MPB 03 MPD 03 Functional Description MP 03VRS FKxx EN P 308329 Firmware...

Page 34: ...1x Safe Motion Application Manual DOK INDRV SI3 SMO VRS APxx EN P 338920 Rexroth IndraDrive Rexroth IndraMotion MLD 2G Libraries as of MPx 18 Reference Book DOK INDRV MLD SYSLIB3 RExx EN P 338916 Rexr...

Page 35: ...K INDRV MLD PAGENT AWxx EN P 323947 1 In the document typecodes xx is a wild card for the current edition of the documentation example AW01 is the first edition of an Applica tion Manual Tab 1 13 Docu...

Page 36: ...d changes you suggest we would be grateful 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 m...

Page 37: ...al state in other words no structural changes are permitted It is not permitted to decompile software products or alter source codes Damaged or faulty products may not be installed or put into operati...

Page 38: ...ot meet the specified ambient conditions This includes for example operation under water under extreme temperature fluctuations or extremely high maximum temperatures Furthermore Drive controllers may...

Page 39: ...es Installation An installation consists of several devices or systems interconnected for a defined purpose and on a defined site which however are not intended to be placed on the market as a single...

Page 40: ...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 i...

Page 41: ...pplication 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 insta...

Page 42: ...ts 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 com...

Page 43: ...ductor Minimum cross section equipment grounding 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...

Page 44: ...occur The extent of faulty drive movements 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 asses...

Page 45: ...ontrol 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 speci...

Page 46: ...ation guards shieldings or barriers or safety instructions in the ap plication documentation 3 3 6 Protection During Handling and Mounting Risk of injury by improper handling Injury by crushing sheari...

Page 47: ...ting 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 due to the...

Page 48: ...with this safety instruction minor or moderate in jury could occur NOTICE In case of non compliance with this safety instruction property damage could occur Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN...

Page 49: ...achine tools Metal forming General automation For these applications there are different device types of graduated perform ance 4 3 Mains Transformers DST and DLT DST and DLT transformers are used to...

Page 50: ...of 200 m motor cable length Integrated switch disconnector Tab 4 2 Usage of Mains Filters Only operate expressly allowed components at the mentioned mains filters Operating for example blowers pumps...

Page 51: ...ers HMS01 HMS02 and HMD01 In the modular drive system HMS and HMD drive controllers control single and double axes Type Usage HMD01 1 Have two power outputs to operate two motors independently of each...

Page 52: ...rollers HCS03 HCS03 drive controllers control single axes Type Usage HCS03 Have a power output to operate a motor Power range 18 5 kW to 75 kW Tab 4 8 Usage of HCS03 Drive Controllers In their standar...

Page 53: ...energy For this purpose the line covers a wide range of continuous power and energy absorption capacity Type Usage HLR01 1A Type of construction A version for device mounting To be mounted to drive c...

Page 54: ...ents of the motor lines reduce interference voltage on the motor lines Type Usage HMF01 1 At the motor output of HCS drive controllers Tab 4 14 Usage of HMF01 Motor Filters 4 17 Accessories HAS The HA...

Page 55: ...which can be used for sophisticated motion tasks See also Functional Description of the firmware index entry Saturation method requires Iout_max and Sine wave method requires unrestricted movement of...

Page 56: ...Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 54 309...

Page 57: ...nts are listed by UL Underwriters Laboratories Inc You can find the evidence of certification on the Internet under http www ul com un der Certifications by entering the file number or the Company Nam...

Page 58: ...US Listing The motors are listed by UL Underwriters Laboratories Inc You can find the evidence of certification on the Internet under http www ul com under Certifications by entering the file number...

Page 59: ...of Products acc first Cata logue 2 Scope of application according to CNCA document Application Scope for Compulsory Certification of Products acc first Catalogue 3 For the IEC product standard used t...

Page 60: ...Supply units and drive con trollers KCU 25 55 Motors KSM KMS 20 60 Relative humidity 5 95 Absolute humidity g m3 1 29 Climatic category IEC721 1K3 Moisture condensation Not allowed Icing Not allowed T...

Page 61: ...62 G1 Installation altitude hnenn m 1000 Ambient temperature range Ta_work C 0 40 Derating vs ambient temperature In the ambient temperature range Ta_work_red the performance data are reduced by the f...

Page 62: ...ne Acceleration at 32 200 Hz2 g 1 3 15 Vibration noise random frequency1 Hz 20 500 Vibration noise random spectral acceleration density amplitude1 g2 Hz 0 05 Vibration noise random rms value of total...

Page 63: ...ated power is reduced to PDC_cont_red PDC_cont FTa PDC_cont 1 50 40 0 03 PDC_cont 0 7 Operation at ambient temperatures outside of Ta_work and Ta_work_red is not allowed Ta_work_red C 40 55 fTa K 3 De...

Page 64: ...performance data for drive controllers Allowed DC bus con tinuous power braking resistor continuous power continuous current 4 Reduced performance data for motors Performance torque S1 and S3 Tab 5 7...

Page 65: ...tegrated Servo Drives IM B5 IM V1 IM V3 Flange mounting on drive side of flange The drive electronics of a motor integrated servo drive can be oriented as desired Flange mounting on drive side of flan...

Page 66: ...ving a maximum thickness of 40 m Before applying the paint coat verify the adhe sion and resistance of the new coat When applying a paint coat subsequently provide paint protection on all safety label...

Page 67: ...24 20 15 When using supply units HMV01 1E HMV01 1R HMV02 1R HLB01 1D 22 8 27 3 24 5 26 5 Control voltage for drive systems with op eration of motor holding brakes in Rexroth motors UN3 V Depending on...

Page 68: ...allation This includes 24V power supply units that reduce incoming overvoltage to the allowed value Overvoltage limiters at the control cabinet input that limit ex isting overvoltage to the allowed va...

Page 69: ...components need the 24V supply for correct operation At components of the Rexroth IndraDrive range the external 24V supply takes place via the connection X13 or via the connections 24V and 0V at the...

Page 70: ...imensioned such that the voltage at the input of the devices 24V supply 24V 0V is within the allowed voltage UN3 Take into account that due to voltage drops the output voltage of the power supply unit...

Page 71: ...wer Supply Unit Supply When switched on the power supply unit must supply the sum of the occur ring inrush currents IEIN3 or charges IEIN3 tEIN3Lade When the power supply unit is switched on the power...

Page 72: ...veral power supply units for 24 V supply Interconnect reference conductors 0 V of the individual pow er supply units with low impedance The output voltages of the power supply units must be within the...

Page 73: ...ry calculation for 3 drive controllers Fig 6 4 Continuous Current The result ID must be smaller than the specified current carrying capacity of the connection point Looping through at HCS02 The curren...

Page 74: ...Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 72 309...

Page 75: ...Unit Value of the respective component Short circuit current rating UL SCCR A rms See chapter 7 4 2 Mains Short Circuit Power on page 80 Nominal mains voltage ULN_nenn V Reference value for performanc...

Page 76: ...voltage dips with mains frequencies of 50 Hz and 60 Hz dt Duration of voltage dip dU ULN Relative voltage dip fLN Mains frequency ULN Mains voltage Fig 7 1 Maximum Allowed Voltage Dips in of the Mains...

Page 77: ...8 Installation altitudes of more than 2000 m to a maximum of 4000 m require overvoltage limiters be tween outer conductor and ground recommended protection level 2 5 kV Overvoltages at the devices can...

Page 78: ...mains Fig 7 2 TN S Mains Type 7 3 2 TN C Mains Type T Direct grounding of a point station ground N Exposed conductive parts directly connected to station ground C Neutral conductor and equipment grou...

Page 79: ...evice For operation at the IT mains type the drive system including mains filter and mains choke should be galvanically decoupled from the mains via an isolating transformer In this way the ground fau...

Page 80: ...s among other things 7 3 4 TT System T Direct grounding of a point station ground T Exposed conductive parts directly grounded independent of ground ing of current source station ground Fig 7 5 TT Mai...

Page 81: ...from the mains connected load observe the following corridor of the mains short circuit power for the mains connection Minimum required mains short circuit power mains connected load for interference...

Page 82: ...7 8 Mains Short Circuit Current UL requirement maximum short circuit current SCCR In the scope of CSA UL devices with C UL listing may only be operated at mains nodes with a symmetrical short circuit...

Page 83: ...high mains short circuit power Use mains chokes at mains with Lk Lmin Example UN 400 V SK 20 MVA Lk 25 46 H Data Lmin of drive controller in technical data 40 H Lk Lmin Use of assigned mains choke is...

Page 84: ...ed load of all electric loads at connection point apparent power of fundamental wave SLN Sum of mains connected loads of the supply units or converters Fig 7 10 Mains Short Circuit Ratio The following...

Page 85: ...idered as guide values RSC Allowed THD of mains current Allowed distortion factor of mains current 1000 THD 48 K 45 120 THD 48 K 45 33 THD 13 K 12 Tab 7 4 Allowed THD Distortion Factor with Given RSC...

Page 86: ...ains supply units and if necessary mains choke 1 Determine maximum current of mains connection at place of destination of application 2 Determine mains short circuit power Sk of mains at place of dest...

Page 87: ...rs motor circuit breakers installed at the mains connection For details see figure Overcurrent protection generally is sized or set with a release current of 1 3 nominal current of the loads connected...

Page 88: ...easures Contact voltage 50 V at housing DC bus connection L L Fig 7 11 Protection Against Contact by Protective Grounding with Overcurrent Protection Device in TN S Mains Bosch Rexroth AG DOK INDRV SY...

Page 89: ...protective measures Contact voltage 50 V at housing DC bus connection L L Fig 7 12 Protection Against Contact by Overcurrent Protection Device in TN C Mains DOK INDRV SYSTEM PR06 EN P Rexroth IndraDr...

Page 90: ...or Aim of protective measures Contact voltage 50 V at housing DC bus connection L L Fig 7 13 Protection Against Contact by Overcurrent Protection Device in IT Mains Bosch Rexroth AG DOK INDRV SYSTEM P...

Page 91: ...ff when equipment ground ing conductor interrupted case of error Routing of a second equipment grounding conductor via separate ter minal connectors with the same cross section as the first equipment...

Page 92: ...s the leakage current in the ground wire is inevitably increased especially when switching on or in the case of mains unbalance Given these operating conditions residual current operated circuit break...

Page 93: ...circuit breaker Connect the neutral point of the secondary winding of the isolating transform er to the equipment grounding conductor of the drive system Adjust the ground fault loop impedance to the...

Page 94: ...in the case of ground fault which means in the case of error without having to switch off the electrical equipment When the monitor signals an error the ground fault is detected and removed without o...

Page 95: ...or output Cables For power supply to the motor For signal evaluation from motor to control electronics 8 2 Type of Supply for Power Sections 8 2 1 General Information The requirements to the individua...

Page 96: ...r e g HMS Property damage caused by operation of combinations which are not allowed NOTICE Only operate the listed allowed combinations Operating components not mentioned in this documentation at the...

Page 97: ...ee chapter 8 3 3 Mains Connection for HCS Converters on page 113 Detailed combinations of HMV supply unit mains filter mains choke See chapter 8 3 2 Mains Connection of HMV Supply Units on page 109 In...

Page 98: ...ly is characterized by one mains connection mains circuit breaker mains transformer mains filter mains choke for the drive system Other drive controllers and additional compo nents are connected to th...

Page 99: ...Do not exceed allowed peak and continuous powers in the DC bus Comply with minimum value of mean phase control factor see data of con tinuous power of supply unit in the technical data calculation se...

Page 100: ...gray background color Optional depending on the application HMVxx xR Mains filter and mains choke necessary HMVxx xR W0120 Mains filter mains choke external mains contactor necessary Fig 8 3 Parallel...

Page 101: ...DC bus and the mains supply have been dimensioned with regard to operation under rated conditions of the converter When HCS converters are used as supply units the power of the converter PDC_cont PDC...

Page 102: ...s Components marked with gray background color Optional depending on the application Fig 8 5 Group Supply HCS Without Connection of the Groups When dimensioning the fuses in the supply feeder and in b...

Page 103: ...er A type current HMD01 Install 20 F per A type current HMS02 No additional capacitance required Arrangement of HCS02 Place HCS02 to the left of HMS01 HMS02 or HMD01 Place the accessory HAS04 at the l...

Page 104: ...inverters or supplied as in verters from another converter the drive controller must be parameterized for this purpose For information on configuration and parameterization of the drive control lers...

Page 105: ...p ply from the mains e g connect Bb contacts of HCS in series When controlling several mains contactors additionally make sure that the mains contactors are always controlled simultane ously and synch...

Page 106: ...wer PBD The sum is generated with reduced perform ance data The reduction takes place with the corresponding bal ancing factors for parallel operation For these data see Project Planning Manual Rexrot...

Page 107: ...Supply Unit With One Drive System Notes on Project Planning Only HMS01 HMD01 inverters as well as additional components HLB and HLC may be operated with third party supply units Requirements to the th...

Page 108: ...ns is influenced Supply units of other product ranges have no module bus With the drive firm ware as of version MPx 04VRS you can configure an inverter as module bus master Integrate the relay contact...

Page 109: ...s limited by the mains filter because the leakage current generated by the drive system loads the mains filter Max leakage capacitance Cab_g Due to the leakage capacitance capacitance of cables and mo...

Page 110: ...t the nominal current of the mains contactor does not exceed the nominal current of the mains filter Circuit for the mains connection Observe the chapter 9 Circuits for the Mains Connection page 141 M...

Page 111: ...l drive systems For such cases mains filters and mains choke can be selected too See chapter 15 3 1 Determining the Mains Choke on page 264 See chapter 15 3 2 Determining the Mains Filter on page 264...

Page 112: ...hoke to reduce line fre quency leakage currents Not specified Without Without Not allowed HMV01 1E W0075 HNL01 1E 0200 N0125 HNF01 1A F240 E0125 Standard combination for axis sys tems with Cy 2 1225 n...

Page 113: ...hout Without 1 axis 1 HMD01 A2 1 40 nF 40 m fs 8 kHz 40 m fs 12 kHz 1 In grounded mains Tab 8 6 Selection of Mains Connection HMV01 1E Mains Connection of HMV01 1R Supply Units Supply unit Mains choke...

Page 114: ...00 R0094 Standard combination for axis sys tems with Cy 2 2040 nF Number of axes 40 A2 2 1100 nF 1 050 m fs 8 kHz 270 m fs 12 kHz HNL01 1R 0540 C0094 with HNL01 1R 3000 S0094 Customer side Standard ma...

Page 115: ...ound at the DC bus 2 Maximum allowed motor cable length 5 m Tab 8 10 Additional Components in the Mains Connection of Converters Minimum value capacitance against housing at the DC bus When using HNF0...

Page 116: ...4 required with 1 HCS02 4 HMS02 the HAS04 would not be required 4 HAS04 is only required when an HNF01 1 mains filter is present in the drive system Tab 8 11 Cy Capacitances against Housing Mains Conn...

Page 117: ...0020 HNF01 1A F240 R0026 Central supply to axis systems Type current HMS W0054 Type current HMD W0020 Type current HCS W0054 Sum of type currents 198 without mains choke 120 2 330 nF Cy 2 1225 nF Moto...

Page 118: ...NF01 1A M900 E0051 Central supply to axis systems Type current HMS W0054 Type current HMD W0036 Type current HCS W0070 Sum of type currents 270 2 330 nF Cy Motor cable length 900 m fs 8 kHz A2 2 350 n...

Page 119: ...HMD W0036 Sum of type currents 270 2 330 nF Cy 2 600 nF Motor cable length 240 m fs 8 kHz HNL01 1E 0571 N0050 HNF01 1A M900 E0051 Central supply to axis systems Type current HMS W0054 Type current HM...

Page 120: ...HMD W0036 Sum of type currents 270 2 330 nF Cy 2 600 nF Motor cable length 240 m fs 8 kHz HNL01 1E 0362 N0080 HNF01 1A M900 E0125 Central supply to axis systems Type current HMS W0070 Type current HM...

Page 121: ...HMD W0036 Sum of type currents 270 2 330 nF Cy 2 600 nF Motor cable length 240 m fs 8 kHz HNL01 1E 0240 N0106 HNF01 1A M900 E0125 Central supply to axis systems Type current HMS W0070 Type current HM...

Page 122: ...HMD W0036 Sum of type currents 270 2 330 nF Cy 2 1225 nF Motor cable length 900 m fs 8 kHz HNL01 1E 0170 N0146 with HNL01 1E 3400 S0202 Customer side Standard mains choke connected in series with curr...

Page 123: ...h additional components are allowed at the DC bus of HMV supply units and HCS converters Project planning of HLC Take the charging ability CDC_ext of the used supply unit or con verter into account Su...

Page 124: ...raking resistor HLR Regenerative operation with great energy con tents e g Deceleration of great centrifugal masses at centrifuges Long braking processes for crane lifting gears Take energy absorption...

Page 125: ...the 24V control volt age Braking via ZKS then will only take place in cases of emergency Required type data To select an appropriate HLR braking resistor the following type data of the application are...

Page 126: ...e the selected braking resistor by setting bit 8 1 in parameter P 0 0860 Converter configuration Braking Resistors HLR01 for HCS02 Converter Braking resistor type1 Type of con struction 2 Type Dimensi...

Page 127: ...8R0 A 007 NNNN N B2 HCS03 1E W0100 A 05 xNBV HLR01 1N 09K5 N13R0 A 007 NNNN N B3 HCS03 1E W0150 A 05 xNBV HLR01 1N 15K0 N08R1 A 007 NNNN N B4 HCS03 1E W0210 A 05 xNBV HLR01 1N 23K0 N05R5 A 007 NNNN N...

Page 128: ...d operating conditions HMF01 Motor Filters Damage caused by too high switching fre quency NOTICE Only operate HMF01 motor filters up to their maximum allowed switching fre quency fs HMF01 motor filter...

Page 129: ...of 20 times If this number is exceeded the electrical data of the internal connection can be above the specified minimum requirements This can cause mal function of the drive controllers 8 5 3 Control...

Page 130: ...of firmware ver sion HMS01 1N W0020 A 07 NNNN MPH 02VRS MPB 02VRS W0036 A 07 NNNN MPH 02VRS MPB 02VRS W0054 A 07 NNNN MPH 02VRS MPB 02VRS W0070 A 07 NNNN MPH 02VRS MPB 02VRS W0110 A 07 NNNN MPH 02VRS...

Page 131: ...0012 A 07 NNNN MPD 02VRS W0020 A 07 NNNN MPD 02VRS W0036 A 07 NNNN MPD 02VRS Tab 8 21 Required Firmware Versions for Inverters DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02...

Page 132: ...x xx xx xx As of MPB 16VRS A CD EC xx xx xx xx As of MPC 17VRS W0005 A 03 E S3 EC xx xx xx xx As of MPE 16VRS B ET EC xx xx xx xx As of MPB 16VRS A CD EC xx xx xx xx As of MPC 17VRS W0008 A 03 E S3 EC...

Page 133: ...NNV MPH 02V11 MPB 02V11 W0070 A 05 NNBV MPH 02VRS MPB 02VRS W0070 A 05 NNNV MPH 02V11 MPB 02V11 W0070 A 15 PSPV MPH 02VRS MPB 02VRS W0100 A 05 LNBV MPH 02VRS MPB 02VRS W0100 A 05 LNNV MPH 02V11 MPB 02...

Page 134: ...1C MPB 04V20 061C 071C 076C Tab 8 25 Required Firmware Versions for KSM01 Near Motor Servo Drives KMS01 Product Series Features Supported as of firmware ver sion KMS01 B A018 P D7 SE ENH NN NN MPB 07V...

Page 135: ...ion The control sections of the Rexroth IndraDrive product range support differ ent encoder systems Evaluation of these encoder systems requires the men tioned encoder evaluations as optional modules...

Page 136: ...042 M1 Optical encoder multi turn absolute HIPERFACE 128 increments supply voltage 7 12 V ENS RKG4200 M2 Optical encoder multi turn absolute EnDat2 1 2048 increments supply voltage 12 V ENS RKG4200 M3...

Page 137: ...M2 ENS K See encoder system R1 EN1 Depending on motor type IKS0223 or IKS0226 V See encoder system R0 EN1 N See encoder system S0 EN1 P See encoder system M0 EN1 1 See following note 2 Without extens...

Page 138: ...ge provides the possibili ty of operating drive controllers of the ANAX and Diax 02 ranges with ana log command value input sercos Analog Converter The sercos analog converter is used to connect contr...

Page 139: ...motor cables of the RKL series for Rexroth IndraDrive systems For selecting the motor cables and other connections e g encoder ca bles use the documentation Rexroth Connection Cables 8 7 2 Motor cable...

Page 140: ...gher the switching frequency the shorter the allowed cable length to protect the drive control lers against overload Only set such switching frequencies which are supported by the involved components...

Page 141: ...a of 24V supply see Project Planning Manual Rexroth IndraDrive Supply Units and Power Sections Chapter of the respective de vice Technical Data Basic Data Data for Control Voltage Supply Mechanical Re...

Page 142: ...eveloped peak power of the motor is smaller than the peak power or sum of peak powers of the braking resistors at the DC bus Take into account that in particular during operation in the field weakenin...

Page 143: ...function when the 24V control voltage has not been applied and when there isn t any current flowing to the input This condition can occur in the following situations Failure of 24V control voltage Wir...

Page 144: ...See also firmware documentation Troubleshooting Guide which con tains the descriptions of the error messages diagnostic messages Bb Contact The mains contactor has to be controlled depending on the er...

Page 145: ...r to prevent the external mains contactor from being over loaded by the load current in the case of frequent switch off First switch off the drive e g via drive enable in the master communication Then...

Page 146: ...HMV supply units HCS drive controllers Place the additional mains contactor electrically before Mains filter Mains choke Mains contactor integrated or externally installed Mains input of supply unit o...

Page 147: ...e parameter P 0 0860 Converter configuration Behaves as converter if drive controller is to get supply voltage via mains connection e g for type of mains connection individual supply or central supply...

Page 148: ...at the DC bus Passive charging current limitation available via charg ing resistor in drive controller HCS02 1E W0012 0070 HCS03 1E W0070 0150 The 24V supply of the drive controllers e g HMS HMD oper...

Page 149: ...rol sections Compared to other control sections only the CSB01 1 FC control section has a Bb contact with higher allowed switching voltage of AC 250 V Until the internal supply voltages are built up a...

Page 150: ...ding to the machine design Install additional monitors and protective devices on the installation side Suggested Circuit Connect the Bb contact of HLB in series with the Bb contacts of the involved In...

Page 151: ...1 Drive enable via input at control section or via master communica tion depending on parameter P 0 4028 Device control word A20 Optional contact for drive enable DOK INDRV SYSTEM PR06 EN P Rexroth In...

Page 152: ...s contactor OFF delay must be smaller than td_on S1 Emergency stop S2 Axis end position S4 Power Off S5 Power On td_on Delay of input X32 8 X1 Module bus Fig 9 4 Control Circuit for Mains Connection o...

Page 153: ...l 1 Drive enable via input at control section or via master communica tion depending on parameter P 0 4028 Device control word A10 Emergency stop relay example of circuit optional design DOK INDRV SYS...

Page 154: ...OFF delay must be smaller than td_on S1 Emergency stop S2 Axis end position S4 Power Off S5 Power On td_on Delay of input X32 8 X1 Module bus Fig 9 5 Control Circuit for Mains Connection of HCS02 and...

Page 155: ...ely HNK01 1 Drive enable via input at control section or via master communica tion depending on parameter P 0 4028 Device control word A20 Optional contact for drive enable DOK INDRV SYSTEM PR06 EN P...

Page 156: ...the switch on sequence of the supply unit the supplying mains is loaded with the current IL_trans_max_on for the purpose of analysis During the unloading process voltage overshoot can occur at the ma...

Page 157: ...the electronic system of the drive is disturbed motors can coast in an un controlled way In these cases it is possible to short circuit the DC bus volt age as a measure in addition to shutdown with d...

Page 158: ...me into effect in the case of an emergency e g activation of an axis limit switch causes the mains supply to be cut off and simultaneously causes the 24V supply of the ZKS input to be interrupted Inst...

Page 159: ...the drive is disturbed In order to trigger a DC bus short circuit in such a case the Bb contacts of the drive controllers have to be connected in series with the con trol contact and wired in the eme...

Page 160: ...according to the error reaction set in the drive controller The mains contactor is switched off and the DC bus short circuit ZKS takes effect when the supply unit Bb1 contact outputs a drive error me...

Page 161: ...1E Supply Units With Integrated Mains Contactor e g HMV01 1E W0030 W0070 W0120 F1 Fuse of power supply F3 Fuse of 24V power supply unit 1 Control of K1 if A10 is not used DOK INDRV SYSTEM PR06 EN P Re...

Page 162: ...Integrated mains contactor K4 Control of drive enable S1 Emergency stop S2 Axis end position S4 Power Off S5 Power On S11 S12 Safety door monitor ZKS DC bus short circuit HNL HNF Optional depending on...

Page 163: ...upply Units With Integrated Mains Contactor e g HMV01 1R W0018 W0045 W0065 F1 Fuse of power supply F2 Fuse of synchronization connection X14 F3 Fuse of 24V power supply unit DOK INDRV SYSTEM PR06 EN P...

Page 164: ...he emergency stop pushbutton is actuated the mains contactor in the supply unit drops out The emergency stop relay or an auxiliary contact of the mains contactor switches off the drive enable signals...

Page 165: ...ted Mains Contactor e g HMV01 1R W0018 45 65 and HLB01 1D F1 Fuse of power supply F2 Fuse of synchronization connection X14 F3 Fuse of 24V power supply unit 1 Control of K1 if A10 is not used DOK INDR...

Page 166: ...unit K1 Integrated mains contactor K4 Control of drive enable S1 Emergency stop S2 Axis end position S4 Power Off S5 Power On S11 S12 Safety door monitor ZKS DC bus short circuit Fig 9 10 Control Cir...

Page 167: ...and HLB01 1D 1 Control of K1 if A10 is not used 2 Drive enable via input at control section or via master communica tion depending on parameter P 0 4028 Device control word A10 Emergency stop relay ex...

Page 168: ...he supply unit Circuits for overvoltage protection increase the Off delay Ob serve the data of the selected mains contactor Pick up delay K1 Select K1 mains contactors with a pick up delay of less tha...

Page 169: ...in the drive controller P 0 0117 bit 0 1 In the case of emergency stop or when the monitors of the supply unit trigger e g mains failure the drives are decelerated in a position controlled way by the...

Page 170: ...ns Contactor e g HMV01 1R W0018 W0045 W0065 F1 Fuse of power supply F2 Fuse of synchronization connection X14 F3 Fuse of 24V power supply unit 1 Control of K1 if A10 is not used Bosch Rexroth AG DOK I...

Page 171: ...supply unit If the end positions of the feed axes have been sufficiently cushioned If external braking devices are used Features The DC bus voltage is not short circuited In the case of emergency stop...

Page 172: ...th Integrated Mains Contactor e g HMV01 1E W0030 W0070 W0120 F1 Fuse of power supply F3 Fuse of 24V power supply unit 1 Control of K1 if A10 is not used Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rex...

Page 173: ...and X31 2 K1 Integrated mains contactor K4 Control of drive enable S1 Emergency stop S4 Power Off S5 Power On S11 S12 Safety door monitor ZKS DC bus short circuit HNL HNF Optional depending on the app...

Page 174: ...ontactor e g HMV01 1R W0018 W0045 W0065 F1 Fuse of power supply F2 Fuse of synchronization connection X14 F3 Fuse of 24V power supply unit 1 Control of K1 if A10 is not used Bosch Rexroth AG DOK INDRV...

Page 175: ...ontrol section X31 1 and X31 2 K1 Integrated mains contactor K4 Control of drive enable S1 Emergency stop S4 Power Off S5 Power On S11 S12 Safety door monitor ZKS DC bus short circuit Fig 9 14 Control...

Page 176: ...V01 1R W0120 F1 Fuse of power supply F2 Fuse of synchronization connection X14 see Project Planning Manual Rexroth IndraDrive Supply Units and Power Sections F3 Fuse of 24V power supply unit Bosch Rex...

Page 177: ...cuit Without DC Bus Short Circuit ZKS for HMV01 1R Supply Units Without Integrated Mains Contactor Observe Off delay and pick up delay of K1 Off delay K1 Select K1 mains contactors with an Off delay s...

Page 178: ...Mains Contactor e g HMV02 1R W0015 F1 Fuse of power supply F3 Fuse of 24V power supply unit F4 Fuse of synchronization connection X14 integrated in HNS02 mains filter Bosch Rexroth AG DOK INDRV SYSTEM...

Page 179: ...g HMV Supply Units ON and OFF Switching On Risk of damage to the supply units when they are switched on simultaneously NOTICE With 3 or more HMV supply units at common supply mains Switch on supply un...

Page 180: ...e DC bus is charged t5 Time depends on DC bus capacitance internal external and mains voltage t6 500 ms delay time until mains contactor closes t7 Maximum 200 ms depends on device ON delay of mains co...

Page 181: ...ow has been interrupted when the disconnection process starts You can make sure this order is observed by appropriate switch elements e g by a main switch of the control cabinet with leading auxiliary...

Page 182: ...Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 180 309...

Page 183: ...ficiently low noise emission of electric magnetic or electromagnetic noise of an electric installation or an electric device to other surrounding devices via lines or through air 10 1 2 Noise Immunity...

Page 184: ...mit Values Evaluation Criterion Explanation abbreviated form from EN 61800 3 A Deviations within allowed range B Automatic recovery after interference C Switched off without automatic recovery Device...

Page 185: ...limit values to use and operation on site User has to carry out and provide evidence of EMC planning None Category C3 2nd environment Class A Group 2 I 100 A Limit value in industrial areas to be com...

Page 186: ...n if source of interference in second environment class A group 1 4 1 Category C1 First environment unrestricted distribution QSP first environment even if source of interference in second environment...

Page 187: ...t of the mains For in dustrial companies for example such connection points are the interconnect ing stations from the power supply system Unrestricted Distribution Channel of distribution for which p...

Page 188: ...ring 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 p...

Page 189: ...a bles and lines the shield has to be grounded over a large surface area To connect the shield at the motor a suitable PG gland with shield connec tion can be used Make sure that the connection betwee...

Page 190: ...Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 188 309...

Page 191: ...22 mm For control cabinets with a depth of 400 mm The figure below contains a rough overview of the main dimensions For other data and required mounting dimensions see Project Planning Manual Rexroth...

Page 192: ...Dissipation Mounting Position Cooling Distances Distance Between the Devices Owing to power dissipation in the devices especially due to integrated brak ing resistors the temperatures of neighboring d...

Page 193: ...possible and corre sponds at least to the cross section dbot mounting depth The channel should lead with at least this cross section to the air in takes at the bottom and at the top of the devices If...

Page 194: ...causes the mains supply to be cut off and simultaneously causes the 24V supply of the ZKS input to be interrupted Install a 24V UPS if the sacrificing behavior of HLB is relevant to your drive system...

Page 195: ...1R does so particularly after power has been switched off Under rated load the escaping cooling air has cooled down in the minimum distance to below 105 C If the integrated braking resistor is not loa...

Page 196: ...Observe additional distance to lateral neighboring devices HCS02 1E W0054 55 378 25 13 7 Observe additional distance to lateral neighboring devices HCS02 1E W0070 55 378 25 13 7 Observe additional di...

Page 197: ...466 25 13 7 HMD01 1N W0020 0 466 25 13 7 HMD01 1N W0036 0 466 25 13 7 HNL02 1 100 378 20 13 7 HNS02 1 0 378 55 13 7 HLB01 1C 0 378 32 5 13 7 HLB01 1D 50 466 25 13 7 HLC01 1C 01M0 0 378 25 13 7 HLC01 1...

Page 198: ...pplying device as possible The HAS02 accessories in the figure require additional downward mounting clearance Dimension Z is significantly determined by the involved devices The table below contains t...

Page 199: ...MS01 1N W0110 HMS01 1N W0150 HMS01 1N W0210 HMS01 1N W0350 HMD01 1N W0012 HMD01 1N W0020 HMD01 1N W0036 HLC01 1D 05M0 HLB01 1D 50 HMV01 1E W0030 HMV01 1E W0075 HMV01 1E W0120 HMV01 1R W0018 HMV01 1R W...

Page 200: ...1 1C 01M0 HLC01 1C 02M4 HMV01 1E W0030 HMV01 1E W0075 HMV01 1E W0120 HMV01 1R W0018 HMV01 1R W0045 HMV01 1R W0065 HMV01 1R W0120 HMS01 1N W0020 HMS01 1N W0036 HMS01 1N W0070 HMS01 1N W0110 HMS01 1N W0...

Page 201: ...the drive controllers with high capacity as close to the supplying device as possible The HAS02 accessories in the figure require additional downward mounting clearance Dimension Z is significantly d...

Page 202: ...50 50 without a distance between the devi ces HCS03 1E W0210 HCS03 1E W0210 100 without a distance between the devi ces HCS03 1E W0070 HCS03 1E W0100 HCS03 1E W0150 HCS03 1E W0210 75 without a distanc...

Page 203: ...1N W0020 HMS01 1N W0036 HMS01 1N W0054 HMS01 1N W0070 HMD01 1N W0012 HMD01 1N W0020 HMD01 1N W0036 50 without a distance between the devi ces HCS03 1E W0210 HMS01 1N W0020 HMS01 1N W0036 HMS01 1N W00...

Page 204: ...imultaneously using DC bus resistor unit and DC bus capacitor unit in a drive system arrange the DC bus capacitor unit between sup ply unit and DC bus resistor unit Fig 11 7 Example of Arrangement Arr...

Page 205: ...res should not be routed freely in the cabinet but close to the cabinet housing or mounting pan els Separate the incoming and outgoing cables of the radio interference sup pression filter Interference...

Page 206: ...trol Cabinet Design According to Interference Areas Exemplary Arrangements page 205 We distinguish three areas 1 Interference free area of control cabinet area A This includes Supply feeder input term...

Page 207: ...s have good contact Control Cabinet Design According to Interference Areas Exemplary Arrangements Do not operate any additional loads at the mains filter Do not operate any other loads at the connecti...

Page 208: ...omponents K1 External mains contactor for supply units without integrated mains contactor Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS0...

Page 209: ...C If this is impossible there are two alternatives 1 Install lines in shielded form and connect the shield at several points at least at the beginning and at the end of the line to the mounting plate...

Page 210: ...within the control cabinet Mains Filters for AC Drives Ideally mount the mains filter on the parting line between the areas A and B Make sure the ground connection between filter housing and housing...

Page 211: ...he drive controller Influence of the Motor Power Ca ble The longer the motor power cable the greater its leakage capacitance To comply with a certain EMC limit value the allowed leakage capacitance of...

Page 212: ...Cables With Cable Duct B Area B C Area C 1 Cable duct for mains connection lines 2 Shield connection of motor power cable via clips at least at one point alternatively at the device or on mounting pl...

Page 213: ...ble shields devices with microprocessor and switching power supply units have to be well contacted over a large surface area This also applies to all screw con nections between mounting plate and cont...

Page 214: ...ded lines or lines routed along synthetic carriers because they are functioning like reception antennas noise immunity and like transmitting antennas emission of interference Exceptional cases are fle...

Page 215: ...uppression element arranged immediately at the in ductance does serve this purpose Otherwise the emitted noise level is too high which can affect the function of the electronic system and of the drive...

Page 216: ...Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 214 309...

Page 217: ...ith fan Requirements for Control Cabinets with Fan Risk of damage by unclean air in the control cabinet NOTICE Operating a control cabinet with a fan but without the corresponding filters can damage t...

Page 218: ...ntroller may only be operat ed up to a specified maximum ambient temperature A cooling unit might therefore be required Possible damage to the drive controller Op erational safety of the machine endan...

Page 219: ...of the control cabinet is not lower than the temperature of the surrounding air Set the temperature limitation to the maximum surrounding temperature Only use well sealed control cabinets so that moi...

Page 220: ...guides between the lines to protect the devices in the upper lines against the warm outlet air of the devices beneath and protect the devices beneath against penetration of liquids e g dripping conden...

Page 221: ...6 Air guide in control cabinet for liquid cooling this is also the drip pro tection for the devices beneath 7 Fan in control cabinet 8 Supply of cooled air from cooling unit Fig 12 2 Example of Arrang...

Page 222: ...Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 220 309...

Page 223: ...ommunication Within the Drive System Equipment grounding conductor connections PE to X3 or joint bars at the devices DC bus connections L with bars DC bus connections L with bars Control voltage conne...

Page 224: ...g points of the motor flanges charge acceptance and the ground connection of the drive system e g mounting surface of the drive controllers in the control cabinet Ground the housings of the devices 1...

Page 225: ...ip ment grounding system Involved devices Equipment Grounding Connections Between De vices Connection to equipment grounding system in control cabinet at devices HMV01 HCS03 HMS01 HMD01 HLB01 1D HLC01...

Page 226: ...each at all HNL02 HNS02 and one connection at connected drive system consisting of all HMV02 HMS02 Tab 13 1 Equipment Grounding Connections Equipment Grounding Connections Between Devices 1 Joint bar...

Page 227: ...Fig 13 3 Equipment Grounding Connections 1 Joint bar 2 Connection to equipment grounding system Fig 13 4 Equipment Grounding Connection in the Case of Supply via HMV01 HMV02 or HCS03 DOK INDRV SYSTEM...

Page 228: ...not smaller than the cross sections of the outer conduc tors of the mains supply feeder Additionally mount the housing of HCS02 1E to a bare met al mounting plate Connect the mounting plate too with...

Page 229: ...wed cable length between the components mains filter mains choke and mains choke supply unit X3 X14 At most 2 m for each cable unshielded twisted or run in groun ded metallic channel Shielded cables w...

Page 230: ...ction M6 thread at device terminal block Unit Min Max Tightening torque Nm 5 5 6 5 Short circuit protection Via fusing elements connected in the incoming circuit to the mains connection Overload prote...

Page 231: ...Strength The connection lines from the supply unit to the drive systems and between the drive systems must have a dielectric strength of at least 1000 V against each other 700 V against ground Line C...

Page 232: ...ength m From To HMV01 HMV02 HCS03 HCS02 HMS01 HMD01 HMS02 HLB01 HLC01 HMV01 0 5 21 0 35 0 35 HMV02 0 5 0 35 0 35 0 35 HCS03 0 5 21 0 35 HCS02 0 5 21 0 35 0 35 0 35 HMS01 HMD01 21 0 35 0 35 HMS02 21 0...

Page 233: ...onnection lines with a heat shrinkable sleeve Af terwards only strip the insulation of the contact surface of the ring terminal Make connections according to figure Fig 13 8 DC Bus Connections for Cab...

Page 234: ...ctions for 24V supply at the devices used see sections Terminal Block 24 0V 24V Supply and X13 Control Voltage in the Project Planning Manual Rexroth IndraDrive Supply Units and Power Sections Connect...

Page 235: ...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 13 5 Function Pin Assig...

Page 236: ...be correctly mounted and the required clearances and creepage distances can be complied with The cables must be twisted Cable Routing to the Left Fig 13 11 Control Voltage Connections for Cable Routi...

Page 237: ...e supplied ribbon cables Graphic Representation Fig 13 13 X1 When extension cables are used for the module bus they must be shielded Their total length mustn t exceed a maximum of 40 m To extend the m...

Page 238: ...xroth Connec tion Cables Minimum requirements for connecting the motor power cables to the drive controller Connect the shield of the motor power cable over the largest possible surface area with low...

Page 239: ...ithout Accessory HAS02 For shield connection without HAS02 accessory connect the cable shield with the lowest possible impedance to the drive controller The following paragraphs describe two basic alt...

Page 240: ...s of the two in ner pairs of wires are in contact with the overall shield With a cable 6 line cross section at least 10 mm2 connect ground bus 4 to ground connection at supplying device Rexroth IndraD...

Page 241: ...contact with the overall shield On level of ground bus in control cabinet remove a piece of cable sheath from motor power cable in order to lay bare the overall shield 5 Connect overall shield 5 to g...

Page 242: ...lded form or under metal between winding and terminal box if the terminal box is not directly mounted on the spindle case Shield Connection of Linear Mo tors For linear motors connect the shield of th...

Page 243: ...esigned and built in accordance with the present state of the art of standardization In order to comply with the machine directives regarding electromagnetic compatibility EMC a conformity test of the...

Page 244: ...ccurring in practical ap plication is mainly influenced by the following characteristics The output variables of the drive controller which is used feed the trans mission distance Cable parameters dep...

Page 245: ...y means of an inductance measuring bridge The measurement has to be made for a complete motor wired for normal operation but not yet connected During the measurement one motor terminal remains open Fo...

Page 246: ...ulation class has to correspond at least to that of the motor or has to be sized for higher temperatures The voltage load of the choke depends on the drive controller used Tab 14 2 Data for Possibly R...

Page 247: ...controller can evaluate measuring systems as a motor encoder if they are contained in P 0 0074 Encoder type 1 motor encoder see also Project Planning Manual Rexroth IndraDrive Drive Controllers Contro...

Page 248: ...14 4 2 Selecting the Connection Technique For the available power cables and encoder cables see documentation Rexroth Connection Cables 14 4 3 Notes on Commissioning For further information notes on...

Page 249: ...from the mechanical power tak ing the following aspects into consideration Motor and controller efficiency Simultaneity Factors Mechanical Power Pm Mechanical power M Torque Nm Angular velocity min 1...

Page 250: ...ontroller have been dimensioned for loading with continuous power If loaded with cyclic charging and discharging processes of high energy content the DC bus capacitors can be overloaded especially wit...

Page 251: ...tor speed min 1 Fig 15 7 Mechanical Power for Main Drives DC Bus Continuous Power for Servo Drives The drive controller or the group of drive controllers has to make available the DC bus power However...

Page 252: ...ous power will not restrict the short time op eration power of the main drives DC Bus Continuous Power for Main and Servo Drives When main and servo drives are operated at a drive controller the requi...

Page 253: ...1 4 Regenerative Power When all main and servo drives connected to a drive controller or combina tion of drive controllers brake simultaneously the generated regenerative power must not be greater th...

Page 254: ...aking resistor Tcycl Allowed cycle time Fig 15 16 Energy Absorption of Braking Resistor Energy absorption capacity with long cycle times For cycles with T 5 Tcycl the indicated maximum regenera tive p...

Page 255: ...rollers This provides the following advantages For drive controllers without mains regeneration function this prevents the braking resistor in the drive controller from being switched on when the driv...

Page 256: ...For additional external capacitors observe that the series connection of these units can require a balancing device Size additional capacitors at the DC bus for 10 overvoltage at the mains connection...

Page 257: ...Exact calculation is required for example for one of the following applica tions Applications with servo drives which are characterized by many acceler ation and deceleration processes e g nibbling m...

Page 258: ...ption because all involved components such as load gear motor cables absorb a part of the regenerative energy Only reduce the generated continuous regenerative power when the efficiency behavior is kn...

Page 259: ...ton 15 1 7 Peak Regenerative Power Usually peak regenerative power will occur when an E Stop signal is trig gered and all axes brake simultaneously Risk of damage due to extended braking times and dis...

Page 260: ...meters P 0 0833 Braking resistor threshold P 0 0858 Data of external braking resistor 15 1 8 Calculating the Control Factor The control factor of an inverter is the ratio of its output voltage to a re...

Page 261: ...acitors in the DC bus The required additional capacitance can be approx imately calculated with the following formula Applies to a a0 CDC_ext Required additional capacitance in DC bus in F a0 Minimum...

Page 262: ...wer Take power of drive controller motor combination from Rexroth Indra Size or calculate it PmHa Mechanical nominal power for main drives shaft output kW Mn Nominal motor torque Nm nn Nominal motor s...

Page 263: ...omponents with resistance charge the inrush current profile is accord ing to an exponential function After the delay td is over the charging process is completed Data for calculating the delay td See...

Page 264: ...ctor cos 1 DPF Power Factor cos or TPF The power factor cos or TPF is used for dimensioning mains components transformer fuse etc Pnetz Effective mains power SLN Apparent mains power Fig 15 36 Power F...

Page 265: ...king resistor continuous power that all devices at common DC bus can process in continuous operation in kW PBD HCS02 Braking resistor continuous power that the drive controller can proc ess in continu...

Page 266: ...How to proceed for selecting the mains filter 1 Determine the required EMC limit value class for the application 2 Determine the maximum applied mains voltage Observe that not all Rexroth IndraDrive m...

Page 267: ...1 mains filters at mains grounded via outer conductor install an isolating trans former between mains and mains filter How to Proceed for Selecting the Mains Transformer The selection of the mains tra...

Page 268: ...2005 7 2 8 such supply lines to short circuit protection devices branching off main lines do not need to be especially pro tected against short circuit when the following requirements have been fulfil...

Page 269: ...sin gle core lines stranded wire de sign class 2 3 3 4 5 0 6 8 6 10 10 3 16 13 5 16 18 3 20 2 5 22 25 4 28 32 6 31 40 6 35 40 10 44 50 10 59 63 16 77 80 25 96 100 35 117 125 50 149 160 70 180 200 95...

Page 270: ...5 0 6 8 5 10 10 1 16 1 0 13 1 16 1 5 17 4 20 2 5 23 25 4 28 32 6 30 40 6 35 40 10 40 50 10 54 63 16 70 80 25 86 100 35 103 125 50 130 160 70 156 200 95 179 200 120 195 224 150 221 250 185 258 315 240...

Page 271: ...0 10 4 16 12 4 16 1 16 1 20 1 5 22 25 2 5 28 32 4 30 40 4 37 40 6 44 50 10 52 63 10 70 80 16 88 100 25 110 125 35 133 160 50 171 200 70 207 250 95 240 315 120 277 355 150 316 400 185 374 425 240 432 5...

Page 272: ...420 450 600 kcmil Tab 15 5 Line Cross Sections and Fuses According to UL508A 2007 Table 28 1 Dimensioning variables of the table values 1 Ambient temperature TA of routed lines 40 C 2 Temperature TL...

Page 273: ...ristic gG fuses Circuit breakers in accordance with IEC 60898 1 2 type B or C Circuit breakers in accordance with IEC 60947 2 6 2 USA Canada Class J 600 V Correction factors For deviating dimensioning...

Page 274: ...es on open cable trays Fig 15 40 Installation methods compare IEC 60364 5 52 VDE0298 7 EN 60204 1 15 3 6 Determining the Leakage Capacitance The capacitances which generate so called leakage currents...

Page 275: ...al power cables For the individual capacitances per unit length see the technical data of the power cables For a list of selected values see Appen dix of this documentation under chapter 18 2 Leakage...

Page 276: ...operation at the nominal working point the filter having been installed By means of the measured values it is then pos sible to calculate the temperature rise To do this the limit values of the fol l...

Page 277: ...45 C Tamb Ambient temperature on site Fig 15 47 Current Reduction in the Case of Overtemperature DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 Bosc...

Page 278: ...time or control following processes via the status P 0 0115 Device control status word Delay td for HCS02 In HCS02 converters the DC bus is charged via the integrated braking resistor RDC_Bleeder The...

Page 279: ...s CDC see Project Planning Manual Rexroth IndraDrive Supply Units and Power Sections Chapter of the respective device Technical Data Basic Data table Data of Power Section DC bus 15 4 2 Calculating Sp...

Page 280: ...Velocity KM Torque constant motor Nm A see P 0 0051 Angular velocity motor s 1 R Transformed resistance L Winding inductance motor H see P 0 4016 zp Number of pole pairs motor see P 0 0018 Fig 15 55...

Page 281: ...asymptote tending to 0 The motor nevertheless comes to standstill because in practical application a friction torque takes ef fect in addition to the braking torque due to ZKS DC bus short circuit Ch...

Page 282: ...Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 280 309...

Page 283: ...ile to the following address Bosch Rexroth AG Electric Drives and Controls Buergermeister Dr Nebel Strasse 2 97816 Lohr am Main Germany Packaging The packaging materials consist of cardboard wood and...

Page 284: ...can contain flame retardants These plastic parts are labeled according to EN ISO 1043 They have to be recycled separately or disposed of according to the valid legal requirements Bosch Rexroth AG DOK...

Page 285: ...rvice repair e g delivery addresses and training can be found on our internet sites Service worldwide Outside Germany please contact your local service office first For hotline numbers refer to the sa...

Page 286: ...Bosch Rexroth AG DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 284 309...

Page 287: ...ng for control sections HAS01 Basic accessory Accessories for connecting the components contact bars fixing material HAS02 Shield connection Accessory for connecting shielded motor cables to power sec...

Page 288: ...U02 Drive connection box Additional component of IndraDrive Mi product range to connect KSM02 or KMS02 to HMV supply units or HCS converters KSM01 KSM02 Motor integrated servo drive Motor integrated s...

Page 289: ..._ ___ 0 7 MSM031B 0300 NN __ ___ 0 7 MSM031C 0300 NN __ ___ 1 4 MSM041B 0300 NN __ ___ 1 3 Last modification 2008 11 20 Tab 18 2 MSM019A 0300 NN MSM019B 0300 NN Type Leakage capacitance of the compone...

Page 290: ...NN __ ___ ____ 2 1 MSK103D 0300 NN __ ___ ____ 6 0 MSK131B 0200 NN __ ___ ____ 14 3 MSK131D 0200 NN __ ___ ____ 27 7 Last modification 2008 12 10 Tab 18 3 MSK Leakage Capacitance Excerpt See also Rex...

Page 291: ...t modification 2007 11 08 Tab 18 4 INK Technical Data Excerpt Data Sheet Excerpt Bulk Cables Type Cross section of power core Leakage capacitance CY_K_typ mm2 nF m REH0800 2 5 0 2 Tab 18 5 REH Technic...

Page 292: ...L Mains choke With mains choke of higher in ductance 1 7 x LN of HNL IL_cont 5 50 100 5 50 100 5 50 100 k f Ik I1 Ik I1 Ik I1 Ik I1 Ik I1 Ik I1 Ik I1 Ik I1 Ik I1 Hz 1 50 100 100 100 100 100 100 100 10...

Page 293: ...5 0 5 0 5 0 5 0 5 0 5 0 5 34 1700 1 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 35 1750 3 1 0 5 0 5 0 5 0 5 0 5 0 5 0 5 36 1800 1 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 37 1850 2 1 0 5 0 5 0 5 0 5 0 5 0 5 0 5 38 1900 0...

Page 294: ...Supply Units Re generative HMV R In the end application the harmonics values are within the mini mum and maximum values listed below The harmonics values depend on Load distribution Conditions in the...

Page 295: ...0 0 5 1 1 29 1450 0 5 1 1 30 1500 0 5 0 5 1 31 1550 0 5 0 5 1 32 1600 0 5 0 5 1 33 1650 0 5 0 5 0 5 34 1700 0 5 0 5 0 5 35 1750 0 5 0 5 0 5 36 1800 0 5 0 5 0 5 37 1850 0 5 0 5 0 5 38 1900 0 5 0 5 0 5...

Page 296: ...monics content of the mains voltage when ope rating drives generally is below 10 Short time drops in mains voltage are below 20 More precise values can only be calculated with exact knowledge of the m...

Page 297: ...18 1 Impulse Withstand Voltage 1 2 50 s and 8 20 s According to EN 61000 DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 Bosch Rexroth AG 295 309 Appe...

Page 298: ...within the indicated discharge time these devi ces discharge the voltage below the allowed 50 V Due to the operating principle the discharge time is the longer the bigger the energy store the capacit...

Page 299: ...is connected to the DC bus voltage by the brake chopper Cable A cable is a combination of several strands which is kept together by the ca ble jacket A typical type of cable is the cable for the motor...

Page 300: ...ich is plugged into the power section The control section processes the signals of the connected compo nents field bus encoder system control panel etc Control sections differ with regard to their per...

Page 301: ...enerates three phase alternating voltage with variable ampli tude and frequency from the DC bus direct voltage Leakage capacitance The capacitances which generate so called leakage currents against gr...

Page 302: ...primary circuit by means of double or reinforced insulation Power section The power section is a separate component which contains all the important power elements of the drive controller Power secti...

Page 303: ...Cables Capacitance 288 Connection cables to motor 137 Documentation 31 Leakage capacitance 288 Calculations 247 Additional external capacitors 252 Charging the DC bus 276 Continuous power in the comm...

Page 304: ...lines Minimum requirements 229 Connections In the drive system 221 Contactor Selecting 265 Contained substances see Significant components 281 Continuous powers in the common DC bus Calculations 263 C...

Page 305: ...C bus resistor unit HLB01 brief description 51 DC bus short circuit ZKS Calculating speed characteristic and braking time 277 DC bus short circuit ZKS 155 Deceleration In the case of disturbed electro...

Page 306: ...uipment grounding conductor Connection 89 223 Connections 223 Cross section 225 External wiring 271 F Fan unit HAB01 Brief description 52 Field wiring 271 Fields of application Drive system Rexroth In...

Page 307: ...ription 47 Housing for control sections HAC01 Brief description 52 I Impulse withstand voltage 294 Inappropriate use 36 Consequences exclusion of liability 35 IndraDyn H 140 Inductance per unit length...

Page 308: ...ection 264 Mains harmonics 74 Calculations 261 Emitted 290 Mains overvoltages Maximum allowed 75 Mains short circuit Mains short circuit ratio 82 Mains short circuit current 80 Mains short circuit pow...

Page 309: ...rative power Calculations 257 PELV 41 Phase current Calculating 260 Power consumption Maximum 69 Typical 69 Power dissipation Calculations 252 Power factor cos Calculations 262 Power factor cos 1 Calc...

Page 310: ...tion 222 System elements Product overview 285 Short designations 285 System impedance 80 System platform 11 System presentation 11 T Test Factory side 64 Insulation resistance 64 Voltage test 64 THD 8...

Page 311: ...Notes DOK INDRV SYSTEM PR06 EN P Rexroth IndraDrive Drive Systems with HMV01 02 HMS01 02 HMD01 HCS02 03 Bosch Rexroth AG 309 309...

Page 312: ...DRV SYSTEM PR06 EN P Bosch Rexroth AG Electric Drives and Controls P O Box 13 57 97803 Lohr Germany Bgm Dr Nebel Str 2 97816 Lohr Germany Tel 49 9352 18 0 Fax 49 9352 18 8400 www boschrexroth com elec...

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