Related Manuals for Bosch Rexroth IndraDrive HMV01.1E-W0030
Summary of Contents for Bosch Rexroth IndraDrive HMV01.1E-W0030
- Page 1 Industrial Electric Drives Linear Motion and Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth IndraDrive R911299229 Supply Units Edition 01 Project Planning Manual...
- Page 2 DOK-INDRV*-HMV-*******-PR01-EN-P 01.2004 Project Planning Manual; first edition 2004 Bosch Rexroth AG Copyright Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).
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Page 3: Table Of Contents
Rexroth IndraDrive Contents Contents Introduction About this Documentation ......................1-1 Purpose of Documentation ...................... 1-1 Introducing the Devices......................... 1-1 Features and Fields of Application ..................1-1 Main Features .......................... 1-1 Basic Structure......................... 1-2 Drive System..........................1-3 Tests and Certifications ......................1-4 Important Directions for Use Appropriate Use .......................... - Page 4 Contents Rexroth IndraDrive Type Plates on the Unit......................4-2 Device Types ..........................4-3 Type Code..........................4-3 Transport and Storage Transporting the Devices ......................5-1 Conditions ..........................5-1 Storing the Devices ........................5-1 Conditions ..........................5-1 In Case of Long Storage Periods..................... 5-1 Mechanical Mounting Mounting Conditions ........................
- Page 5 Rexroth IndraDrive Contents X14, Mains Voltage Synchronization ..................7-30 Touch Guard ..........................7-31 Cutouts........................... 7-31 Mounting ..........................7-32 Determination of Appropriate Power Supply Units Introduction ........................... 8-1 DC Bus Continuous Power ......................8-1 DC Bus Peak Power ........................8-4 Regenerated Energy ........................8-5 Continuous Regenerated Power....................
- Page 6 Contents Rexroth IndraDrive 13 Appendix 13-1 13.1 Connection of Supply Unit by Wires ................... 13-1 Supply Unit to the Left of the Drive Controller ............... 13-1 Supply Unit to the Right of the Drive Controller ..............13-2 13.2 Stacked Devices ......................... 13-3 Counterclockwise Cable Routing ...................
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Page 7: Introduction
Rexroth IndraDrive Introduction Introduction About this Documentation Purpose of Documentation This documentation describes • planning the mechanical control cabinet construction • planning the electrical control cabinet construction • logistical handling of the equipment Introducing the Devices Features and Fields of Application The supply unit …... -
Page 8: Basic Structure
Introduction Rexroth IndraDrive Basic Structure Supply Unit hmv_aufbau.fh7 Signal processing Control panel (Display) Power connections and control voltage connection Fig. 1-1: Basic structure Control Panel The control panel is a separate part which is plugged on the supply unit. The supply unit is supplied ex works complete with control panel. 01.F4002 Enter Fig. -
Page 9: Drive System
Rexroth IndraDrive Introduction Drive System The following figure shows the components of the drive system. firmware drive controller DC bus resistor unit supply unit DC bus capacitor unit 24 V supply unit RKS - ready-made encoder cable battery RKG - ready-made power cable motor mains supply Fa5147f1.fh7... -
Page 10: Tests And Certifications
Introduction Rexroth IndraDrive Tests and Certifications CE Mark CEf1.fh7 Fig. 1-4: CE mark In preparation C-UL-US Listing Tests Insulation-high-voltage test in Routine testing with DC 2230 V, 1 min accordance with EN50178 resp. Routine testing with AC 1575 V, 1 min; Power supply with 0,1 A short-circuit current Separation between control and... -
Page 11: Important Directions For Use
Rexroth IndraDrive Important Directions for Use Important Directions for Use Appropriate Use Introduction Rexroth products represent state-of-the-art developments manufacturing. They are tested prior to delivery to ensure operating safety and reliability. The products may only be used in the manner that is defined as appropriate. -
Page 12: Areas Of Use And Application
Important Directions for Use Rexroth IndraDrive Areas of Use and Application Supply units of Rexroth are designed to supply the Rexroth IndraDrive M drive controllers. Control and monitoring of the motors may require additional sensors and actors. Note: The supply units may only be used with the accessories and parts specified in this document. -
Page 13: Safety Instructions For Electric Drives And Controls
Rexroth IndraDrive Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls Introduction Read these instructions before the initial startup of the equipment in order to eliminate the risk of bodily harm or material damage. Follow these safety instructions at all times. -
Page 14: Hazards By Improper Use
Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Hazards by Improper Use High voltage and high discharge current! Danger to life or severe bodily harm by electric shock! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! DANGER High electrical voltage due to wrong... -
Page 15: General Information
Rexroth IndraDrive Safety Instructions for Electric Drives and Controls General Information • Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. • Read the operating, maintenance and safety instructions in your language before starting up the machine. - Page 16 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive • Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the documentation "EMC in Drive and Control Systems".
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Page 17: Protection Against Contact With Electrical Parts
Rexroth IndraDrive Safety Instructions for Electric Drives and Controls Protection Against Contact with Electrical Parts Note: This section refers to equipment and drive components with voltages above 50 Volts. Touching live parts with voltages of 50 Volts and more with bare hands or conductive tools or touching ungrounded housings can be dangerous and cause electric shock. -
Page 18: Protection Against Electric Shock By Protective Low Voltage (Pelv)
Safety Instructions for Electric Drives and Controls Rexroth IndraDrive To be observed with electrical drive and filter components: High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! ⇒ Connect the electrical equipment, the housings of all DANGER electrical units and motors permanently with the safety conductor at the ground points before power is... -
Page 19: Protection Against Dangerous Movements
Rexroth IndraDrive Safety Instructions for Electric Drives and Controls Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of the connected motors. Some common examples are: • improper or wrong wiring of cable connections • incorrect operation of the equipment components •... - Page 20 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! ⇒ Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures DANGER integrated in the installation. Unintended machine motion is possible if monitoring devices are disabled, bypassed or not activated.
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Page 21: Protection Against Magnetic And Electromagnetic Fields During Operation And Mounting
Rexroth IndraDrive Safety Instructions for Electric Drives and Controls ⇒ Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: - maintenance and repair work - cleaning of equipment - long periods of discontinued equipment use ⇒... -
Page 22: Protection Against Contact With Hot Parts
3-10 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Protection Against Contact with Hot Parts Housing surfaces could be extremely hot! Danger of injury! Danger of burns! ⇒ Do not touch housing surfaces near sources of heat! Danger of burns! CAUTION ⇒... -
Page 23: Battery Safety
3-11 Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3.11 Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or material damage. Risk of injury by incorrect handling! ⇒ Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and cauterization). - Page 24 3-12 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Notes DOK-INDRV*-HMV-*******-PR01-EN-P...
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Page 25: Identifying And Checking The Delivered Components
Rexroth IndraDrive Identifying and Checking the Delivered Components Identifying and Checking the Delivered Components Delivery of Components Packaging The components are supplied in separate packaging units. Packaging Units The content of the packed components and the order number may be Packaging Labels identified using the adhesive barcode label on the packaging. -
Page 26: Component Designation
Identifying and Checking the Delivered Components Rexroth IndraDrive Component Designation Each drive component is identified by a type designation. A type plate is attached to all units, including the motor. A label (cable marker) is wrapped round the ready-made cable. The type designation and length are indicated on this label. -
Page 27: Device Types
Rexroth IndraDrive Identifying and Checking the Delivered Components Device Types Type Code Note: The following figure illustrates the basic structure of the type code. Your sales representative will help with the current status of available versions. Abbrev. Column 1 2 3 4 6 7 8 9 1 2 3 4 6 7 8 9... - Page 28 Identifying and Checking the Delivered Components Rexroth IndraDrive Notes DOK-INDRV*-HMV-*******-PR01-EN-P...
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Page 29: Transport And Storage
Rexroth IndraDrive Transport and Storage Transport and Storage Transporting the Devices Conditions temperature -25 ... 70 °C relative humidity 5 ... 95%; climatic category 2K3 absolute humidity 1 ... 60 g/m climatic category 2K3 moisture condensation not allowed icing not allowed Shock check not in operation Halve sine in 3 axis: according to EN 60068-2-27... - Page 30 Transport and Storage Rexroth IndraDrive Notes DOK-INDRV*-HMV-*******-PR01-EN-P...
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Page 31: Mechanical Mounting
Rexroth IndraDrive Mechanical Mounting Mechanical Mounting Mounting Conditions Ambient and Operating Conditions Note: The supply units and their additional components are designed to be built into control cabinets. Note: The user must check that the ambient conditions, and in particular the temperature of the control cabinet, are complied with by calculating the heat levels in the control cabinet. - Page 32 (e.g. lubricants in machine tools) which may interact with our controls and drives, it cannot be completely ruled out that any reactions with the materials used by Bosch Rexroth might occur. For this reason, before using the respective material a compatibility test has to be carried out for new lubricants, cleaning agents etc.
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Page 33: Duty Capacity
Rexroth IndraDrive Mechanical Mounting Duty Capacity Where conditions differ, the following performance data diminish in accordance with the diagrams (see “Fig. 6-2: Duty capacity at higher ambient temperature” and “Fig. 6-3: Duty capacity at higher mounting altitude”): • Permitted DC bus continuous output •... -
Page 34: Mechanical Technical Data
Mechanical Mounting Rexroth IndraDrive Mechanical Technical Data Dimensions Dimensional Drawing for HMV01.1E-W0*** and HMV01.1R-W00** maszblatt_hmv.fh7 minimum mounting clearance Fig. 6-4: Dimensional drawing for HMV01.1E-W0*** and HMV01.1R-W00** Device L [mm] L1 [mm] HMV01.1E-W0030 HMV01.1E-W0075 HMV01.1E-W0120 HMV01.1R-W0018 HMV01.1R-W0045 HMV01.1R-W0065 Fig. 6-5: L and L1 dimensions DOK-INDRV*-HMV-*******-PR01-EN-P... -
Page 35: Installation Orientation
Rexroth IndraDrive Mechanical Mounting Installation Orientation Install supply units in such a way that their longitudinal axis corresponds to the natural direction of convection (connections for motor and power downwards). In this way the natural convection supports the forced cooling air current. This avoids the generation of pockets of heat. - Page 36 Mechanical Mounting Rexroth IndraDrive Control Cabinet with Multiple Line Structure Note: Particular attention should be paid to the maximum permissible air intake temperature of components when they are arranged in multiple lines in the control cabinet. Where necessary, cooling air guides are to be allowed for with ventilators specially inserted for this purpose.
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Page 37: Cooling And Cooling Units
Rexroth IndraDrive Mechanical Mounting Cooling and Cooling Units Power Dissipation The power dissipation of a drive system radiated to the control cabinet is calculated from the sum of the power dissipation of the supply unit, the power dissipation of the mains connecting unit, the power dissipation of each drive controller, and the power dissipation of additional units (e.g. -
Page 38: Mounting Cooling Units
Mechanical Mounting Rexroth IndraDrive Mounting Cooling Units Unless the ratings are reduced the drive controller may only be operated up to an specified ambient temperature (see chapter 6.1). It is therefore possible that a cooling unit will be required. Possible damage to the drive controller Operational safety of the machine endangered ⇒... - Page 39 Rexroth IndraDrive Mechanical Mounting incorrect correct control cabinet control cabinet air inflow air inflow air outflow duct cooling cooling unit unit electronic electronic equip. equip. Eb0002f1.fh7 Fig. 6-10: Arrangement of the cooling unit on the front of the control cabinet Condensation occurs when the temperature of the unit is lower than the Avoiding Condensation ambient temperature.
- Page 40 6-10 Mechanical Mounting Rexroth IndraDrive Notes DOK-INDRV*-HMV-*******-PR01-EN-P...
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Page 41: Electrical Installation
Rexroth IndraDrive Electrical Installation Electrical Installation General Information Damage can be caused to the supply unit or circuit boards if electrostatic charging present in people and/or tools is discharged across them. Therefore, please note the following information: Electrostatic charges can cause damage to electronic components and interfere with their operational safety! ⇒... -
Page 42: Interference Elimination And Emc
Electrical Installation Rexroth IndraDrive Interference Elimination and EMC Interference Elimination Note: The subject interference elimination and electromagnetic compatibility (EMC) is described in detail in a separate documentation. It is absolutely necessary to read this documentation for the proper operation of AC-drives! The document is titled "Electromagnetic compatibility (EMC) in drive and control systems". -
Page 43: Rules For Emc-Correct Installation Of Drives
Rexroth IndraDrive Electrical Installation 10 Rules for EMC-Correct Installation of Drives The following 10 rules are the basics for designing drive systems in compliance with EMC. Rules 1 to 7 are generally valid. Rules 8 to 10 are especially important to limit noise emission. - Page 44 Electrical Installation Rexroth IndraDrive All variable-speed motors should be connected using shielded cables, Rule 9 whereby the shield is connected at both ends to the housings through the largest possible surface area to minimize the inductance. The motor feeder cables should also be shielded outside the cabinet, or at least screened using barriers.
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Page 45: Optimal Emc Installation
Rexroth IndraDrive Electrical Installation Optimal EMC Installation With regard to an optimal EMC installation, a spatial separation of the interference-free area (mains connection) interference susceptible area (drive components) is advisable. See the next figure in this respect. HMV01.1E-Wxxxx shielded control cabinet compartment or intermediate mains panel... - Page 46 Electrical Installation Rexroth IndraDrive HMV01.1R-Wxxxx mains ground connection control cabinet filter connecting clamps main switch distributor clamps fuse mains choke shielded cable power connection to the motors earth rail shielded control cabinet compartment or intermediate panel HMVR_emv.fh7 Fig. 7-2: HMV01.1R - Separation of interference-free and interference susceptible areas DOK-INDRV*-HMV-*******-PR01-EN-P...
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Page 47: Electrical Data
Rexroth IndraDrive Electrical Installation Electrical Data HMV01.1E-W0030, -W0075, -W0120 Designation Symbol Unit HMV01.1E-W0030 HMV01.1E-W0075 HMV01.1E-W0120 kind of connection (mode of operation at 3-phase the mains) mains input voltage (rated voltage) 380 -10% to 480 +10% transient overvoltage limit values 1200 L trans max mains frequency 48 to 62... -
Page 48: Hmv01.1R-W0018, -W0045, -W0065
Electrical Installation Rexroth IndraDrive HMV01.1R-W0018, -W0045, -W0065 Designation Symbol Unit HMV01.1R- HMV01.1R- HMV01.1R- W0018 W0045 W0065 kind of connection (mode of operation at 3-phase the mains) mains input voltage (rated voltage) 380 -10% to 480 +10% transient overvoltage limit values 1200 L trans max mains frequency... -
Page 49: Control Voltage
Rexroth IndraDrive Electrical Installation Control Voltage (Information at ambient temperature of 25 °C) Designation Symbol Unit Value 24 ±5% Control voltage Max. ripple content controlled Max. allowed overvoltage 24 +20% N3max Max. charging current HMV01.1E-W0030: 7 A EIN3 HMV01.1E-W0075: 16 A HMV01.1E-W0120: 15 A HMV01.1R-W0018: 6 A HMV01.1R-W0045: 8 A... -
Page 50: Complete Connection Diagram
7-10 Electrical Installation Rexroth IndraDrive Complete Connection Diagram mains contactor acknowledgment power ON mains contactor acknowledgment power OFF 24V for interface DC bus short circuit 24V mains OFF mains ON braking resistor threshold fixed/variable ** 0V for interface module bus ready for operation DC bus ok prewarning temp./bleeder... -
Page 51: Connecting Cables And Rails
7-11 Rexroth IndraDrive Electrical Installation Connecting Cables and Rails Connections (Power Section) Overview installation_hmv_system.fh7 Designation UPS (uninterruptible power system) 24 V control voltage supply Supply unit Drive controller PE connection of mains supply Mains connection PE connection to drive controller; If cables are used for ground connection they must have a cross section of at least 10 mm Module bus X1 Control voltage connection (+24V, 0V);... - Page 52 7-12 Electrical Installation Rexroth IndraDrive HMV01.1E-W0030 and HMV01.1E-W0075 control panel +24 V control voltage DC bus mains hmv_e30_front.fh7 Fig. 7-8: HMV01.1E-W0030 and HMV01.1E-W0075 Description of connections: Connection See page control voltage 7-15 DC bus 7-17 mains voltage (X5) 7-22 PE connection power supply unit resp. neighboring device 7-20 7-21 7-21...
- Page 53 7-13 Rexroth IndraDrive Electrical Installation HMV01.1E-W0120 control panel +24 V control voltage DC bus PE connection to drive controller PE connection to drive controller mains hmv_e120_front.fh7 Fig. 7-9: HMV01.1E-W0120 Description of connections: Connection See page control voltage 7-15 DC bus 7-17 mains voltage (X5) 7-22...
- Page 54 7-14 Electrical Installation Rexroth IndraDrive HMV01.1R-W0018, -W0045, -W0065 control panel +24 V control voltage DC bus mains hmv_r18_front.fh7 Fig. 7-10: HMV01.1R-W0018, -W0045, -W0065 Description of connections: Connection See page control voltage 7-15 DC bus 7-17 mains voltage (X5) 7-22 PE connection power supply unit resp. neighboring device 7-20 7-21 7-21...
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Page 55: Control Voltage (+24 V, 0 V)
7-15 Rexroth IndraDrive Electrical Installation Control Voltage (+24 V, 0 V) The control voltage is supplied by an external 24-V power supply unit. • Technical data: see page 7-9 Note: • Falling short of the permissible control voltage leads to a corresponding error message (=>... - Page 56 7-16 Electrical Installation Rexroth IndraDrive schienen_steuerspg cables (to the source of control voltage) contact rails Fig. 7-11: Contact rails 6 Nm Tightening Torque DOK-INDRV*-HMV-*******-PR01-EN-P...
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Page 57: Dc Bus (L+, L-)
7-17 Rexroth IndraDrive Electrical Installation DC Bus (L+, L-) The DC bus connection connects • the supply unit to the drive controller • the supply unit to additional components in order to • increase the stored power by means of DC bus capacitor unit •... - Page 58 7-18 Electrical Installation Rexroth IndraDrive Risk of voltage arcing! ⇒ If devices are stacked in the control cabinet, the connections for the DC buses between the drive controllers have to be correctly made. There is CAUTION otherwise a risk of voltage arcing (see page 13-3 onward).
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Page 59: Pe Connection Of Power Supply
7-19 Rexroth IndraDrive Electrical Installation PE Connection of Power Supply HMV01.1E-W0030, -W0075 HMV01.1E-W0120 HMV01.1R-W0018, -W0045, -W0065 hmv_erdanschluss_netz_30.fh7 hmv_erdanschluss_netz_120.fh7 Abb. 7-13: PE connection of power supply The ground wire is fixed to the supply unit with screws: Design HMV01.1E-W0030, -W0075 HMV01.1E-W0120 HMV01.1R-W0018, -W0045, -W0065 M6 x 25 Tightening Torque... -
Page 60: Pe Connection, Power Supply Unit And Neighboring Device
7-20 Electrical Installation Rexroth IndraDrive PE Connection, Power Supply Unit and Neighboring Device The PE connection (grounding) to the drive controller can be provided in duplicate in the case of the drive controllers through: • a grounding bracket on the front (see figure below) •... -
Page 61: X1, Bus Module
7-21 Rexroth IndraDrive Electrical Installation X1, Bus Module The bus module permits data exchange between the supply unit and the drive controllers. Graphic Representation X1_hmv Fig. 7-15: Design Type Number of Type of design poles Flat line connector Connector on device Fig. -
Page 62: X2, Rs232
7-22 Electrical Installation Rexroth IndraDrive X2, RS232 RS232 Interface The RS232 interface is required for diagnosis during commissioning and servicing. Graphic Representation PS2_stecker_hmv.fh7 Fig. 7-17: Design Type Number of poles Type of design MiniDIN socket on device Fig. 7-18: Design Connection cross section Cross section Cross section... -
Page 63: X3, Mains Connection
7-23 Rexroth IndraDrive Electrical Installation X3, Mains Connection Graphic Representation hmv_X3 Fig. 7-20: Design HMV01.1E- Type Number Type of design of poles Terminal block Threaded terminal end W0030 Terminal block Threaded terminal end W0075 Terminal block Threaded terminal end W0120 HMV01.1R- Type Number... - Page 64 7-24 Electrical Installation Rexroth IndraDrive Tightening Torque HMV01.1E- Torque W0030 W0075 W0120 HMV01.1R- Torque W0018 W0045 W0065 Fig. 7-23: Tightening torques Note: See chapter 13.3 onward for further information on mains connection. DOK-INDRV*-HMV-*******-PR01-EN-P...
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Page 65: X31, Connection For Messages
7-25 Rexroth IndraDrive Electrical Installation X31, Connection for Messages The X31 interface is used as a connection for messages: Description • supply unit ready for operation (Bb1) • power supply ok (UD) • warning signal for bleeder overload and overtemperature (WARN) Graphic Representation hmv_X31 Fig. - Page 66 7-26 Electrical Installation Rexroth IndraDrive Connection ready for operation DC bus warning overtemperature/ WARN bleeder overload hmv_X31_schalt Name Pin no. Description Level Notes Bb1_1 supply unit ready for contact load DC 30V / 1A operation inrush current max. 5A Bb1_2 contact closes: if no error is present contact opens:...
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Page 67: X32, Mains Contactor Control, Dc Bus Short Circuit, Braking Resistor Threshold
7-27 Rexroth IndraDrive Electrical Installation X32, Mains Contactor Control, DC Bus Short Circuit, Braking Resistor Threshold The X32 interface is used to connect Description • the mains contactor control • the DC bus short circuit • the switching signal for braking resistor threshold Note: See chapter 9 onward for further information on mains contactor control. - Page 68 7-28 Electrical Installation Rexroth IndraDrive Connection 24V for interface DC bus short circuit 24V mains OFF mains ON braking resistor threshold fixed/variable * 0V for interface * only for HMV01.1E-Wxxxx hmv_X32_schalt Name Description Level Notes 24V ±5% 24V_IF 24V supply for interface (input) 24V supply for interface, because interface inputs are isolated DC bus s.c.
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Page 69: X33, Acknowledge Messages Of Internal Mains Contactor
7-29 Rexroth IndraDrive Electrical Installation X33, Acknowledge Messages of Internal Mains Contactor The X33 interface is used as a connection for acknowledge messages of Description the internal mains contactor. Graphic Representation hmv_X33 Fig. 7-32: Design Type Number of poles Type of design LK04-1M WIN R3,5 Bushing on device series 0734... -
Page 70: X14, Mains Voltage Synchronization
7-30 Electrical Installation Rexroth IndraDrive X14, Mains Voltage Synchronization The X14 interface is only available for regenerative supply units Description (HMV01.1R). It is used to connect the mains voltage synchronization. Graphic Representation hmv_X14 Fig. 7-36: Design Type Number of poles Type of design LE 7,62 M PC 4,0 / 3G Connector on device... -
Page 71: Touch Guard
7-31 Rexroth IndraDrive Electrical Installation Touch Guard Lethal electric shock caused by live parts with more than 50 V! ⇒ The appropriate touch guard must be mounted for each supply unit following connection work. WARNING ⇒ Never mount a damaged touch guard. ⇒... -
Page 72: Mounting
7-32 Electrical Installation Rexroth IndraDrive • At the first and last drive controller in a line of devices connected to each other there mustn’t any cutout be broken off at the outer side of the touch guard. Mounting The touch guard must always be mounted following connection work. hmv_beruehrschutz Fig. -
Page 73: Determination Of Appropriate Power Supply Units
Rexroth IndraDrive Determination of Appropriate Power Supply Units Determination of Appropriate Power Supply Units Introduction The mains supply for an AC drive system of the IndraDrive M product family mainly consists of the power supply unit. Depending on the tasks and design of the supply unit and the conditions of its use, it may be necessary to add link reactors, auxiliary capacitors, bleeder modules and transformers as needed. - Page 74 Determination of Appropriate Power Supply Units Rexroth IndraDrive If the duration over which the drive is operated at constant speed is considerably greater than the accel and decel time, then it applies: Average speed without accel and decel time average motor speed [min ...
- Page 75 Rexroth IndraDrive Determination of Appropriate Power Supply Units Mechanical power for servo drives 9550 continuous mech. power for servo drives [kW] effective motor torque [Nm] average motor speed [min Fig. 8-6: Mechanical power for servo drives Main drives are primarily used with constant power over a specific speed Mechanical power for main range.
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Page 76: Dc Bus Peak Power
Determination of Appropriate Power Supply Units Rexroth IndraDrive If main and servo drives are operated on a power supply unit, the required DC bus continuous power for DC bus continuous power needs to be added. main and servo drives It is the spindle drive in a NC machine tool that primarily determines the DC bus power needed. -
Page 77: Regenerated Energy
Rexroth IndraDrive Determination of Appropriate Power Supply Units Regenerated Energy The energy content of all main and servo drives that brake simultaneously under unfavorable conditions may not be greater than the maximum regenerated energy of the power supply unit as specified in the data sheet. -
Page 78: Continuous Regenerated Power
Determination of Appropriate Power Supply Units Rexroth IndraDrive The auxiliary capacitor must be designed so that it is capable of storing rotary drive energy: ≥ − 1000 HMV01.1Ein tern − bleeder actuation threshold (approx. 820 V) DC bus nominal voltage rotatory energy [Ws] auxiliary capacitor [mF]... -
Page 79: Peak Regenerated Power
Rexroth IndraDrive Determination of Appropriate Power Supply Units potential energy [Ws] load mass [kg] gravity constant = 9,81 m/s² drop height [m] number of drops per cycle Fig. 8-20: Potential energy of non-compensated masses potg rotg ≤ continuous regenerated power [kW] continuous bleeder power [kW] cycle time [s] sum of potential energy [kWs]... -
Page 80: Connected Load Of The Supply Unit
Determination of Appropriate Power Supply Units Rexroth IndraDrive Connected Load of the Supply Unit The connected load is calculated to be able to determine mains fuses, line cross sections and, if needed, commutation chokes and transformers. The connected load is dependent on the continuous power of the drives and the functional principle of the power supply unit. -
Page 81: Control Mains Contactor
Rexroth IndraDrive Control Mains Contactor Control Mains Contactor Control Possibilities The controls of the mains contactor and of the DC bus dynamic brake in the supply unit, that are suggested in this documentation, explain the function principles. In this chapter, several control options are discussed and explained. - Page 82 Control Mains Contactor Rexroth IndraDrive You should use this mode, if Applications • only motors with permanent magnetic excitation have been mounted, • or if motors with permanent magnetic excitation and asynchronous motors (induction machines) have been mounted, • or if the E-Stop circuit must be duplicated or if e.g. a protection door monitor is required, •...
- Page 83 Rexroth IndraDrive Control Mains Contactor 24 V +/-5% X32/1 X32/9 X31/5 X31/6 bleeder control X32/8 >1 X32/7 signal processing X32/6 DC bus enable dynamic X32/5 converter brake X32/4 & ON delay ready-to- approx. 1.5 seconds ... 4 minutes 3) operate Power supply unit +24V Control voltage...
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Page 84: Without Dc Bus Dynamic Brake
Control Mains Contactor Rexroth IndraDrive Without DC Bus Dynamic Brake • If an uncontrolled running out of the drives cannot damage the Application installation. • If only asynchronous drives are connected to the supply unit. • If the end positions of the feed axes are sufficiently attenuated. The DC bus voltage is not short-circuited. - Page 85 Rexroth IndraDrive Control Mains Contactor 24 V +/-5% X32/1 X31/5 for diagnostics X32/9 X31/6 bleeder control X32/8 >1 X32/7 signal processing X32/6 DC bus enable dynamic X32/5 converter brake X32/4 & ON delay ready-to- approx. 1.5 seconds ... 4 minutes 3) operate Power supply unit +24V...
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Page 86: Control Via Nc Controller
Control Mains Contactor Rexroth IndraDrive Control via NC Controller If the mains contactor is controlled via NC controller, it is possible to provide a position controlled shutdown of the drive via the NC controller in the event of an emergency stop or as reaction of the internal monitoring of the drive. - Page 87 Rexroth IndraDrive Control Mains Contactor 24 V +/-5% X32/1 X31/5 for diagnostics X32/9 X31/6 braking resistor control X32/8 >1 X32/7 signal processing X32/6 DC bus enable dynamic X32/5 converter brake X32/4 & ON delay ready-to- approx. 1.5 seconds ... 4 minutes 3) operate Power supply unit Control voltage...
- Page 88 Control Mains Contactor Rexroth IndraDrive Notes DOK-INDRV*-HMV-*******-PR01-EN-P...
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Page 89: Troubleshooting
10-1 Rexroth IndraDrive Troubleshooting Troubleshooting 10.1 General Extensive searches for faults and repair of drive components on the machine are not acceptable due to the production downtime involved. The modular concept of Rexroth drives makes it possible to completely exchange drive components. Service thus means localizing problems either on the motor, drive controller or power supply unit and replacing the part. -
Page 90: Checking And Repairing The Unit
10-2 Troubleshooting Rexroth IndraDrive 10.3 Checking and Repairing the Unit When contacting our service personnel we would like to ask you to provide the following information so that a quick and precise assistance can be assured: • type designations and serial numbers of units and motors, •... -
Page 91: Replacing The Unit
10-3 Rexroth IndraDrive Troubleshooting 10.4 Replacing the Unit Note: Replacing the unit requires, depending upon unit weight, a lifting device and an identical replacement unit. Electrical shock due to voltage-containing parts of more than 50 V! ⇒ The unit may only be replaced by qualified personnel, which have been trained to perform the DANGER work on or with electrical devices. -
Page 92: Diagnostic Display
10-4 Troubleshooting Rexroth IndraDrive 10.5 Diagnostic Display Concerning error diagnoses displayed on the control panel see Troubleshooting Guide of firmware documentation. DOK-INDRV*-HMV-*******-PR01-EN-P... -
Page 93: Disposal And Environmental Protection
In addition, when returned the products mustn’t contain any undue foreign matter or foreign component. Please send the products free domicile to the following address: Bosch Rexroth AG Electric Drives and Controls Bürgermeister-Dr.-Nebel-Straße 2 D-97816 Lohr am Main Packaging Materials The packaging materials consist of cardboard, wood and polystyrene. -
Page 94: Recycling
11-2 Disposal and Environmental Protection Rexroth IndraDrive Recycling Due to their high content of metal most of the product components can be recycled. In order to recycle the metal in the best possible way it is necessary to disassemble the products into individual modules. The metals contained in the electric and electronic modules can also be recycled by means of specific separation processes. -
Page 95: Service & Support
12-1 Rexroth IndraDrive Service & Support Service & Support 12.1 Helpdesk Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries. Sie erreichen uns Contact us 49 (0) 9352 40 50 60... -
Page 96: Kundenbetreuungsstellen - Sales & Service Facilities
Tel. +49 (0) 9352 40 42 22 Tel.: +49 (0)171 333 88 26 Vertriebsgebiet Süd Vertriebsgebiet West Gebiet Südwest Germany South Germany West Germany South-West Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG Landshuter Allee 8-10 Regionalzentrum West Service-Regionalzentrum Süd-West 80637 München Borsigstrasse 15 Siemensstr.1... - Page 97 - Italien Netherlands - Niederlande/Holland Netherlands – Niederlande/Holland Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth Services B.V. Bosch Rexroth B.V. Via del Progresso, 16 (Zona Ind.) Via Isonzo, 61 Technical Services Kruisbroeksestraat 1 35020 Padova 40033 Casalecchio di Reno (Bo) Kruisbroeksestraat 1 (P.O.
- Page 98 - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland – Polen DEL a.s. Bosch -Rexroth, spol.s.r.o. Bosch Rexroth Kft. Bosch Rexroth Sp.zo.o. Strojírenská 38 Hviezdoslavova 5 Angol utca 34 ul. Staszica 1 591 01 Zdar nad Sázavou 627 00 Brno 1149 Budapest 05-800 Pruszków...
- Page 99 Australia - Australien Australia - Australien China China AIMS - Australian Industrial Bosch Rexroth Pty. Ltd. Shanghai Bosch Rexroth Shanghai Bosch Rexroth Machinery Services Pty. Ltd. No. 7, Endeavour Way Hydraulics & Automation Ltd. Hydraulics & Automation Ltd. 28 Westside Drive...
- Page 100 Canada West - Kanada West Mexico Mexico Bosch Rexroth Canada Corporation Bosch Rexroth Canada Corporation Bosch Rexroth Mexico S.A. de C.V. Bosch Rexroth S.A. de C.V. Burlington Division 5345 Goring St. Calle Neptuno 72 Calle Argentina No 3913 3426 Mainway Drive Burnaby, British Columbia Unidad Ind.
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Page 101: Appendix
13-1 Rexroth IndraDrive Appendix Appendix 13.1 Connection of Supply Unit by Wires Risk of voltage arcing! ⇒ If wires are used to connect the supply unit, the connections have to be correctly made. CAUTION If the contact rails supplied for connecting the supply unit cannot be used you can use wires, too. -
Page 102: Supply Unit To The Right Of The Drive Controller
13-2 Appendix Rexroth IndraDrive Supply Unit to the Right of the Drive Controller drive controller supply unit (DC bus connection) correct incorrect DC bus nach rechts zum versorger Fig. 13-2: Connection of supply unit by wires to the DC bus connection of the drive controller DOK-INDRV*-HMV-*******-PR01-EN-P... -
Page 103: Stacked Devices
13-3 Rexroth IndraDrive Appendix 13.2 Stacked Devices Risk of voltage arcing! ⇒ If devices are stacked in the control cabinet, the connections for the DC buses between the devices have to be correctly made. CAUTION connection depends cable routing (clockwise counterclockwise). -
Page 104: Clockwise Cable Routing
13-4 Appendix Rexroth IndraDrive Clockwise Cable Routing device 1 (DC bus connection) device 2 (DC bus connection) device 1 (DC bus connection) device 2 (DC bus connection) correct incorrect DC bus nach rechts_hmv Fig. 13-4: DC bus connection for clockwise cable routing DOK-INDRV*-HMV-*******-PR01-EN-P... -
Page 105: Mains Connection
13-5 Rexroth IndraDrive Appendix 13.3 Mains Connection General High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! ⇒ Connect the electrical equipment, the housings of all DANGER electrical units and motors permanently with the safety conductor at the ground points before power is switched on. -
Page 106: Mains Supply Requirements
13-6 Appendix Rexroth IndraDrive Mains Supply Requirements Depending on the connected load there must be certain necessary short- Connected load circuit power of the mains supply present to use HMV01.1x devices. Connected load Required short-circuit Examples of application [kVA] power S [MVA] 6 ... -
Page 107: Hmv01.1E
13-7 Rexroth IndraDrive Appendix HMV01.1E Power Supply Direct mains connection [with In case of mains voltages with 3 x AC 380 ... 480 V (±10 %) the power 3 x AC 380 ... 480 V (±10 %)] supply unit can be connected directly to the mains; no other components are necessary. - Page 108 13-8 Appendix Rexroth IndraDrive If mains voltages are smaller than 3 AC x 380 V respectively greater than Connecting the mains via 3 AC x 480 V, it is necessary to use a transformer. autotransformer (with mains voltages < 3 AC x 380 V e.g. >...
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Page 109: Hmv01.1R
13-9 Rexroth IndraDrive Appendix HMV01.1R Power Supply As the power part of the HMV01.1R power supply units consists of a Mains connection with 3 x AC 380 ... 480 V (±10 %) clocked 3-phase IGBT bridge, a mains choke KDxx will always be needed for the mains connection. - Page 110 13-10 Appendix Rexroth IndraDrive • to ensure a sufficient interference suppression. The combining filters are exclusively provided for the operation with HMV01.1R/E supply modules. On the filter outlet side no other devices may be connected. If other components in the control cabinet are to be suppressed, it is necessary to employ an appropriate interference suppression which should preferably be installed at the control cabinet entry...
- Page 111 13-11 Rexroth IndraDrive Appendix do this, the limit values of the following diagram are read at the respective frequency and used in the formula together with the measured value. Dg5027f1.fh7 Fig. 13-11: Derating If the total of the temperature values is greater than 10 K, the harmonics have to be reduced by means of appropriate measures.
- Page 112 13-12 Appendix Rexroth IndraDrive Synchronizing to the Mains A separate connection is necessary that the HMV01.1R may be operated synchronously to the mains. The synchronizing voltage must be tapped before the mains choke KDxx but after the mains filter. Power and synchronizing voltage connection must be in phase (see figure below).
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Page 113: Fusing With Direct Mains Supply
13-13 Rexroth IndraDrive Appendix Fusing with Direct Mains Supply Fusing the mains supply can implement, with power circuit breakers or slow-blow fuses of the gL/gG type: HMV01.1E- Fusing Power Circuit Breaker Wire cross Setting [A] section [mm²] W0030 W0075 W0120 HMV01.1R- Fusing Power Circuit Breaker... -
Page 114: Fault Current Protective Device
13-14 Appendix Rexroth IndraDrive 13.5 Fault Current Protective Device High electrical voltage! Danger to life, severe bodily harm by electric shock! ⇒ A residual-current-operated protective device (RCD) must not be used on electric drives! Indirect contact DANGER must be prevented by other means, for example, by an overcurrent protective device. -
Page 115: Chronological Sequence When Switching On And Off
13-15 Rexroth IndraDrive Appendix 13.7 Chronological Sequence when Switching ON and OFF When Switching On Control voltage Bb1 contact closes Power Internal test routine DC bus loading Mains contactor UD contact closes hmv_einschalt_verlauf.fh7 5,2 s; time for internal booting until Bb1 contact closes time can be set by the user 400 ms;... -
Page 116: When Switching Off
13-16 Appendix Rexroth IndraDrive When Switching Off Power Acknowledge Power OFF UD contact opens Control voltage Bb1 contact opens hmv_ausschalt_verlauf.FH7 max. 200 ms; depends on device (OFF delay of mains contactor) time can be set by the user Fig. 13-15: Chronological sequence when shutting down the unit DOK-INDRV*-HMV-*******-PR01-EN-P... -
Page 117: Auxiliary Components
13-17 Rexroth IndraDrive Appendix 13.8 Auxiliary Components Mains Choke For Supply Units HMV01.1E circuit diagramm: ϑ long hole in "B" direction MB_KD.fh7 Mains choke Dimensions [mm] Weight [kg] KD 31 7 x 15 13,5 KD 35 8 x 12 KD 33 15 x 11 Fig. - Page 118 13-18 Appendix Rexroth IndraDrive For Supply Units HMV01.1R circuit diagramm: long hole in "B" direction MB_KD32.fh7 Mains choke Dimensions [mm] Weight [kg] KD 34 C 8 x 12 KD 32 C 11 x 15 KD 36 C 11 x 15 Fig.
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Page 119: Mains Filter Hfd
13-19 Rexroth IndraDrive Appendix Mains Filter HFD Risk of damage! ⇒ Only use Rexroth filters. These filters have been adjusted to the Rexroth supply units, inverters and motors in the best possible way. If you use different CAUTION filters, the limit values possibly cannot be complied with. Moreover the filters and other components of the drive system might be destroyed. - Page 120 13-20 Appendix Rexroth IndraDrive Versions Filter Type Supply Unit/ Mains current Limit Values Frequency Converter EN61800-3 HFD01.2-480-0026 HMV01.1R-W0018 class A, group 2 (curve 2.1/2.2) HFD01.2-480-0065 HMV01.1R-W0045; HMV01.1E- class A, group 2 (curve 2.1/2.2) W0030 HFD01.2-480-0098 HMV01.1R-W0065 class A, group 2 (curve 2.1/2.2) HFD01.2-480-0125 HMV01.1E-W0075 class A, group 2 (curve 1.1/1.2)
- Page 121 13-21 Rexroth IndraDrive Appendix Dimensions Fig. 13-24: HFD0x.2-480-0065 DOK-INDRV*-HMV-*******-PR01-EN-P...
- Page 122 13-22 Appendix Rexroth IndraDrive Fig. 13-25: HFD01.2-480-0026 DOK-INDRV*-HMV-*******-PR01-EN-P...
- Page 123 13-23 Rexroth IndraDrive Appendix Fig. 13-26: HFD02.2-480-0026 DOK-INDRV*-HMV-*******-PR01-EN-P...
- Page 124 13-24 Appendix Rexroth IndraDrive Last Load 4x45° Beschriftung 6,5 12 Netz Line hfd02_2_480_0202.fh7 Fig. 13-27: HFD02.2-480-0202 DOK-INDRV*-HMV-*******-PR01-EN-P...
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Page 125: Index
14-1 Rexroth IndraDrive Index Index Accompanying documents 4-1 Acknowledge messages internal mains contactor: 7-29 Ambient Conditions 6-1 Appropriate use 2-1 Arrangement power-dependent 6-5 Auxiliary capacitance calculation 8-5 Auxiliary components 13-17 Battery safety 3-11 Bb1 7-26 Braking resistor threshold switching signal 7-27 value 7-7 Bus module 7-21 CE mark 1-4... - Page 126 14-2 Index Rexroth IndraDrive DC bus dynamic brake 9-2 DC bus peak power calculation 8-4 DC bus short circuit 7-27 Delivery scope 4-1 Device types 4-3 Diagnostic Display 10-4 Dimensional drawing 6-4 Display 1-2 Dissipation power 6-7 Drawing dimensional drawing 6-4 Dripping or sprayed water 6-8 Drive system 1-3 Duty Capacity 6-3...
- Page 127 14-3 Rexroth IndraDrive Index acknowledge messages 7-29 KD 31 13-17 KD 32 C 13-18 KD 33 13-17 KD 34 C 13-18 KD 35 13-17 KD 36 C 13-18 L+, L- 7-17 Mains connection 13-5 connection 7-23 synchronizing 13-12 Mains chokes 13-17 Mains contactor control (X32) 7-27 Mains contactor control possibilities 9-1 Mains filters HFD 13-19...
- Page 128 14-4 Index Rexroth IndraDrive Regenerated energy 8-5 Regenerated power continuous 8-6 peak 8-7 Repairing 10-2 Replacing 10-3 RS232 7-22 Safety Instructions for electric drives and controls 3-1 Scope of delivery 4-1 Stacked devices 13-3 Standard control panel 1-2 Storing 5-1 Supply unit appropriate use 2-1 basic structure 1-2...
- Page 129 14-5 Rexroth IndraDrive Index X14 7-30 X2 7-22 X3 7-23 X31 7-25 X32 7-27 X33 7-29 DOK-INDRV*-HMV-*******-PR01-EN-P...
- Page 130 14-6 Index Rexroth IndraDrive Notes DOK-INDRV*-HMV-*******-PR01-EN-P...
- Page 132 Bosch Rexroth AG Electric Drives and Controls Postfach 13 57 97803 Lohr, Deutschland Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Deutschland Tel. +49 (0)93 52-40-50 60 Fax +49 (0)93 52-40-49 4 1 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany R911299229 DOK-INDRV*-HMV-*******-PR01-EN-P...