Page 1 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Project Planning Manual Edition 04 R911335703...
Page 2 RS-447a9cdbb5102eb30a6846a001f6e846-4-en-US-4 Record of Revisions chapter 1.4.1 "Editions" on page Copyright © Bosch Rexroth AG 2019 All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. The specified data is intended for product description purposes only and shall...
Page 3: Table Of Contents
KLC03 DC bus capacitor unit......................23 KLC03 type code..........................23 1.3.9 Firmware............................23 About this documentation........................24 1.4.1 Editions.............................. 24 1.4.2 Documentations..........................27 Drive systems, system components....................27 Motors............................. 28 Cables............................28 Firmware............................28 1.4.3 Your comments..........................31 R911335703_Edition 04 Bosch Rexroth AG...
Page 4 Technical data of the components................61 Explanation of terms and definitions..................... 61 KSM02 motor-integrated servo drive....................65 5.2.1 KSM02 without motor holding brake, data sheet................65 5.2.2 KSM02 with motor holding brake, data sheet..................67 5.2.3 KSM02 characteristics........................70 Bosch Rexroth AG R911335703_Edition 04...
Page 5 Selecting RKH hybrid cable incl. communication................118 5.9.4 Selecting RKH hybrid cable without communication............... 121 5.9.5 Interconnection diagrams for ready-made hybrid cables incl. communication........ 123 KCU - KSM/KMS.......................... 123 KSM/KMS - KSM/KMS......................... 124 Flexible cable tracks........................126 R911335703_Edition 04 Bosch Rexroth AG...
Page 6 X141, safety technology and service input "release brake"............. 173 X141, safety technology "Safe Torque Off".................. 174 X141, safety technology "Safe Motion" (S3, SD options)............. 176 X141, without safety technology....................177 6.3.8 Second connection point of equipment grounding conductor............178 KMS02 connection points........................180 Bosch Rexroth AG R911335703_Edition 04...
Page 7 XG14, mains voltage synchronization..................... 204 6.6.12 XG34, mains contactor control and feedback contacts (KNK03)............ 205 6.6.13 Connection cover: Mounting options....................206 6.6.14 Two-piece connection cover......................206 KNK03 connection points........................207 6.7.1 Positions of the connection points....................207 R911335703_Edition 04 Bosch Rexroth AG...
Page 8 Motor fan for KSM02........................242 7.1.12 Evaluating motor encoders at KMS....................242 7.1.13 Length of motor cables and encoder cables at KMS............... 243 7.1.14 Operation with standard motors...................... 243 Notes on electrical project planning....................245 Bosch Rexroth AG R911335703_Edition 04...
Page 9 8.2.1 KSM type plate..........................261 Arrangement..........................261 Design............................262 System type plate......................... 262 8.2.2 KMS02 type plate..........................263 Arrangement..........................263 Design............................264 System type plate......................... 264 8.2.3 KMS03 type plate..........................265 Arrangement..........................265 Design............................266 R911335703_Edition 04 Bosch Rexroth AG...
Page 10 Mounting KMS..........................282 KCU02..............................283 9.4.1 Mounting depths..........................283 9.4.2 Touch guard............................ 283 9.4.3 KCU02 connection diagram......................285 KNK03, KMV03, KLC03........................286 9.5.1 Arranging the devices........................286 9.5.2 Mounting............................286 Electrical connection........................... 286 9.6.1 General information......................... 286 Bosch Rexroth AG R911335703_Edition 04...
Page 11 RKB0044, Communication Cable....................... 329 10.17 RKB0054, fan cable..........................330 10.18 RKS0010, Interface Cable........................331 10.19 RBS0023, connector for safety zone node..................332 10.20 RLS0725, KMS03 motor power cable connector................333 10.21 RGS0725, KMS03 encoder cable connector..................334 R911335703_Edition 04 Bosch Rexroth AG...
Page 12 Replacing the component........................ 359 11.4.5 "Release holding brake" service function..................359 11.4.6 Saving Parameters.......................... 360 11.4.7 Firmware Update..........................360 11.4.8 Replacing the programming module....................360 11.5 Maintenance............................361 11.5.1 Maintenance of the Motor Component.................... 361 General Information........................361 Bosch Rexroth AG R911335703_Edition 04...
Page 13 Digital inputs (safety technology S options)..................370 14.2 Digital outputs............................. 371 14.2.1 Digital outputs (safety technology L options)................... 371 14.2.2 Digital outputs (safety technology S options).................. 372 14.3 Two-piece connection cover....................... 374 14.4 Sizing mains filters (drive system)...................... 375 Index.......................... 395 R911335703_Edition 04 Bosch Rexroth AG...
Page 14 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Bosch Rexroth AG R911335703_Edition 04...
Page 15: System Presentation
⇒ Component used to buffer the DC bus voltage Components of the IndraDrive Mi product range allow a drive system to be designed without a control cabinet. Supplying the drives with HMV supply units or HCS drive controllers requires a control cabinet. R911335703_Edition 04 Bosch Rexroth AG...
Page 16: Features
KMS02/03, KMV03, KNK03, KLC03 System presentation 1.1.2 Features KSM02 motor-integrated servo drive Power is supplied to the drives via HMV or HCS (alternative power supply: KMV); HMS, HMD: optional Fig. 1-1: IndraDrive Mi with KSM02 – Features Bosch Rexroth AG R911335703_Edition 04...
Page 17: Kms02 Near Motor Servo Drive
KMS02/03, KMV03, KNK03, KLC03 System presentation KMS02 near motor servo drive Power is supplied to the drives via HMV or HCS (alternative power supply: KMV); HMS, HMD: optional Fig. 1-2: IndraDrive Mi with KMS02 – Features R911335703_Edition 04 Bosch Rexroth AG...
Page 18: Knk03 Mains Filter, Kmv03 Supply Unit, Klc03 Dc Bus Capacitor Unit, Kms03 Near Motor Servo Drive
4 digital inputs and outputs, two thereof can be used as fast probe inputs ● Multi-Ethernet communication ● External Multi-Ethernet communication (optional) ● Multi-Ethernet communication output coupling (optional) ● Safe Torque Off or Safe Motion safety technology (optional) ● Integrated Motion Logic in accordance with IEC 61131-3 Bosch Rexroth AG R911335703_Edition 04...
Page 19: Cooling Types
(ES option) use separate cables for communication). Tab. 1-1: IndraDrive Mi with KMS03 – Features Cooling types Thermal interface Forced cooling Natural convection (cold plate, insulated mounting) Tab. 1-2: Cooling types (example: KMV03) R911335703_Edition 04 Bosch Rexroth AG...
Page 20: Maximum Number Of Drives Per Drive Line
DC bus power, power requirement of control voltage, Y‑capacitance and leakage capacitance of axes, cable lengths. The module bus always limits the maximum number to Tab. 1-3: Maximum number of drives per drive line Bosch Rexroth AG R911335703_Edition 04...
Page 21: Indradrive Mi Drive System
The KMS near motor servo drive consists of control section and power section. ⇒ chapter "KMS02 near motor servo drive" on page 3 RKH hybrid cable The RKH hybrid cable replaces the following individual cables: R911335703_Edition 04 Bosch Rexroth AG...
Page 22: Series
KCU02 drive connection box ● KSM02 motor-integrated servo drive ● KMS02 near motor servo drive ● KMS03 near motor servo drive ● KMV03 supply unit ● KNK03 mains filter ● KLC03 DC bus capacitor unit Bosch Rexroth AG R911335703_Edition 04...
Page 23: Firmware
Rexroth IndraDrive KMV03.1R supply unit The IndraDrive Mi drive system in the figure below contains KSM motor-integrated servo drives. This system structure also applies to IndraDrive Mi drive systems with KMS near motor servo drives. R911335703_Edition 04 Bosch Rexroth AG...
Page 24 Ethernet cable of defined length (max. 0.55 m) Encoder cable (optional) Hybrid cable Motor cable (optional) Mains synchronization (only with regenerative HMVs) X103.1 Connection of RKH hybrid cable at first KSM02 Fig. 1-3: IndraDrive Mi drive system with HMV01 Bosch Rexroth AG R911335703_Edition 04...
Page 25 9-5 "IndraDrive Mi drive system with HCS02" on page ● HCS03: fig. 9-6 "IndraDrive Mi drive system with HCS03" on page ● KMV03: fig. 9-9 "IndraDrive Mi drive system with KNK03, KMV03, KMS03" on page 294 R911335703_Edition 04 Bosch Rexroth AG...
Page 26: Overview Of Functions
Hardware-related functional restrictions as compared to drive controllers with separate control sections: ● Safety technology: not all safety functions available ● No analog inputs or outputs ● No digital and analog I/O extensions ● No additional encoder evaluations or encoder emulations Bosch Rexroth AG R911335703_Edition 04...
Page 27: Type Code
Before placing a purchase order, have our sales representative check whether individual options are available The figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of available versions. R911335703_Edition 04 Bosch Rexroth AG...
Page 28: Ksm02 Motor-Integrated Servo Drive
M3 = Capacitive encoder, Hiperface multi-turn absolute, 16 signal periods ⑩ Electrical connection: H = Connector, hybrid ⑪ Shaft: G = Plain shaft with shaft sealing ring P = Shaft with keyway according to DIN 6885-1 with shaft sealing ring Bosch Rexroth AG R911335703_Edition 04...
Page 29 FW = Firmware has to be ordered as a separate subposition Tab. 1-5: KSM02 type code Size Length Winding – – ✓ – – ✓ – ✓ ✓ ✓ – – – ✓ – – Tab. 1-6: Winding R911335703_Edition 04 Bosch Rexroth AG...
Page 30 – – ✓ ✓ ✓ – – – Tab. 1-7: Other design Encoder Safety option ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ – – ✓ ✓ – – Tab. 1-8: Safety option Bosch Rexroth AG R911335703_Edition 04...
Page 31: Kms02 Near Motor Servo Drive
ENH = Encoder Hiperface® NNN = Without 3) 4) ENA = Encoder ACURO®link ⑪ Safety option: L3 = Safe Torque Off (STO) S3 = Safe Motion (without SBC) 1) 3) SD = Safe Motion NN = Without R911335703_Edition 04 Bosch Rexroth AG...
Page 32 FW = Firmware has to be ordered as a separate subposition Only if encoder interface = ENH, ENA Only if encoder interface = ENH Only if other design ≠ WN, WT, WE Only if safety option = L3, NN Tab. 1-9: KMS02 type code Bosch Rexroth AG R911335703_Edition 04...
Page 33: Kms03 Near Motor Servo Drive
ES = External master communication Multi-Ethernet (2 × M12) NN = Without TO = Multi-Ethernet output coupling (2 × M12) ⑬ Firmware: FW = Firmware is required to operate the device Tab. 1-10: Type code KMS03 R911335703_Edition 04 Bosch Rexroth AG...
Page 34: Kcu02 Drive Connection Box
N = Without ⑩ Other design: NN = None ⑪ Firmware: NW = Without firmware Tab. 1-11: Type code KCU02.2 KCU02.2 vs. KCU02.1 KCU02.2 is fully downward compatible with version KCU02.1 and completely replaces this type. Bosch Rexroth AG R911335703_Edition 04...
Page 35: Kmv03 Supply Unit
Rated power "0007" only with cooling type "B" Rated power "01K5" only with cooling type "I" Rated power "05K0" only with cooling type "A" Rated power "06K0" only with cooling type "W" Tab. 1-12: KMV03 type code R911335703_Edition 04 Bosch Rexroth AG...
Page 36: Knk03 Mains Filter
Nominal current "0002" with cooling type "I" only Nominal current "0012" with cooling type "B" only Nominal current "0008" with cooling type "A" only Nominal current "0010" with cooling type "W" only Tab. 1-13: KNK03 type code Bosch Rexroth AG R911335703_Edition 04...
Page 37: Klc03 Dc Bus Capacitor Unit
Degree of protection: P = IP65 ⑧ Nominal DC bus voltage: D7 = DC 750 V ⑨ Other design: NNNN = None Tab. 1-14: KLC03 type code 1.3.9 Firmware Type code: see Functional Description of firmware R911335703_Edition 04 Bosch Rexroth AG...
Page 38: About This Documentation
Included information on locking pins at connectors and connection points of hybrid cables ● Included conductor colors of hybrid cable for connection points X52, X53 and X54 ● Included internal design of digital inputs/outputs (X37, X38) Bosch Rexroth AG R911335703_Edition 04...
Page 39 Hybrid cable without communication lines (REH0803) ● Drive systems with HCS01.1E-W0054 supply unit Modified contents ● KSM02 type code ● KMS02 type code ● Allowed maximum number of KCU02 + KMS02/KSM02 devices per drive line increased from 20 to 30 R911335703_Edition 04 Bosch Rexroth AG...
Page 40 KSM02 type code ● KMS02 type code ● KMS03 type code ● KMV03 type code ● KNK03 type code ● RKB0011 replaced by RKB0021 ● External communication (X118, X119) described in greater detail Tab. 1-15: Editions Bosch Rexroth AG R911335703_Edition 04...
Page 41: Documentations
Rexroth Inline Product Range In the document typecodes, "xx" is a placeholder for the current edition of the documentation (e.g.: AW01 is the first edition of an Application Manual) Tab. 1-17: Documentations – overview R911335703_Edition 04 Bosch Rexroth AG...
Page 42: Motors
Application Manual MP*-20VRS**-APxx-EN-P 345608 MPx-20 Functions IndraDrive Release Notes MP*-20VRS**-RNxx-EN-P 345606 MPx-20 Version Notes IndraDrive Application Manual PSB-21VRS**-APxx-EN-P 385754 Power Supply Basic PSB‑21 Functions IndraDrive Release Notes PSB-21VRS**-RNxx-EN-P 385752 Power Supply Basic PSB‑21 Version Notes Bosch Rexroth AG R911335703_Edition 04...
Page 43 SI3*SMO-VRS-APxx-EN-P 338920 Integrated Safety Technology "Safe Motion" (as of MPx-18) Rexroth IndraDrive Reference Book MLD-SYSLIB2-RExx-EN-P 332627 Rexroth IndraMotion MLD Libraries as of MPx-17 IndraDrive Reference Book MLD-SYSLIB3-RExx-EN-P 338916 Rexroth IndraMotion MLD Libraries as of MPx-18 R911335703_Edition 04 Bosch Rexroth AG...
Page 44 IndraMotion MLD as of MPx-18 In the document typecodes, "xx" is a placeholder for the current edition of the documentation (e.g.: RE02 is the second edition of a Reference Book) Tab. 1-20: Documentations – firmware Bosch Rexroth AG R911335703_Edition 04...
Page 45: Your Comments
If you find any mistakes in this documentation or have suggestions for changes, please send your feedback to the following address: Bosch Rexroth AG Dept. DC-AE/EPI5 Bürgermeister-Dr.-Nebel-Str. 2 97816 Lohr am Main, Germany Email: dokusupport@boschrexroth.de R911335703_Edition 04 Bosch Rexroth AG...
Page 46 32/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Bosch Rexroth AG R911335703_Edition 04...
Page 47: Important Directions For Use
Drive controllers have to be programmed before commissioning to ensure that the motor executes the functions specific to the application. Drive controllers of the IndraDrive Mi series have been developed for use in single- and multi-axis drive and control tasks. R911335703_Edition 04 Bosch Rexroth AG...
Page 48: Unintended Use
These components are not provided for use in a public low- voltage mains supplying residential areas. If these components are used in such a mains, high-frequency interference is to be expected. This can require additional measures of interference suppression. Bosch Rexroth AG R911335703_Edition 04...
Page 49: Safety Instructions For Electric Drives And Controls
R911335703_Edition 04 Bosch Rexroth AG...
Page 50: General Information
● Only qualified persons may work with components of the electric drive and control system or within its proximity. ● Only use accessories and spare parts approved by Rexroth. Bosch Rexroth AG R911335703_Edition 04...
Page 51 National Electrical Manufacturers Association (NEMA), as well as local engineering regulations – Regulations of the National Fire Protection Association (NFPA) ● Canada: Canadian Standards Association (CSA) ● Other countries: – International Organization for Standardization (ISO) – International Electrotechnical Commission (IEC) R911335703_Edition 04 Bosch Rexroth AG...
Page 52: Hazards By Improper Use
Always wait 30 minutes after switching off power to allow live capacitors to discharge before accessing an electric component. Measure the electrical voltage of live parts before beginning to work to make sure that the equipment is safe to touch. Bosch Rexroth AG R911335703_Edition 04...
Page 53 (4 AWG) 16 mm (6 AWG) 35 mm (2 AWG) 50 mm (1/0 AWG) 25 mm (4 AWG) 70 mm (2/0 AWG) 35 mm (2 AWG) Tab. 3-1: Minimum cross section of the equipment grounding connection R911335703_Edition 04 Bosch Rexroth AG...
Page 54: Protective Extra-Low Voltage As Protection Against Electric Shock
The safety regulations applicable to the installation or machine must be taken into consideration. Unintended machine movements or other malfunctions are possible if safety devices are disabled, bypassed or not activated. To avoid accidents, injury and/or property damage: Bosch Rexroth AG R911335703_Edition 04...
Page 55: Protection Against Electromagnetic And Magnetic Fields During Operation And Mounting
Health hazard for persons with active implantable medical devices (AIMD) such as pacemakers or passive metallic implants. ● Hazards for the above-mentioned groups of persons by electromagnetic and magnetic fields in the immediate vicinity of drive controllers and the associated current-carrying conductors. R911335703_Edition 04 Bosch Rexroth AG...
Page 56: Protection Against Contact With Hot Parts
Immediately clean up any spilled liquids from the floor due to the risk of falling! 3.3.7 Battery safety Batteries consist of active chemicals in a solid housing. Therefore, improper handling can cause injury or property damage. Risk of injury by improper handling! Bosch Rexroth AG R911335703_Edition 04...
Page 57: Protection Against Pressurized Systems
Environmental protection and disposal! The agents (e.g., fluids) used to operate the product might not be environmentally friendly. Dispose of agents harmful to the environment separately from other waste. Observe the national regulations of your country. R911335703_Edition 04 Bosch Rexroth AG...
Page 58: Explanation Of Signal Words And The Safety Alert Symbol
In case of non-compliance with this safety instruction, death or serious injury could occur. CAUTION In case of non-compliance with this safety instruction, minor or moderate injury could occur. NOTICE In case of non-compliance with this safety instruction, property damage could occur. Bosch Rexroth AG R911335703_Edition 04...
Page 59: General Data And Specifications
UL wiring material In the scope of CSA / UL, use copper 60/75 °C only; class 1 or equivalent only. R911335703_Edition 04 Bosch Rexroth AG...
Page 60 ● UL standard: UL 1004-1 ● CSA standard: C22.2 No. 100 Company Name BOSCH REXROTH ELECTRIC DRIVES & CONTROLS GMBH Category Name: Servo and Stepper Motors - Component File numbers MSK, MSM motors: E335445 Tab.
Page 61: Transport And Storage
The KMV supply unit contains electrolytic capacitors which may deteriorate during storage. When storing the KMV supply unit for a longer period of time, run it once a year for at least 1 hour at mains voltage U R911335703_Edition 04 Bosch Rexroth AG...
Page 62 Measure insulation resistance. Dry the winding at a value of < ■ ■ 1kohm per volt rated voltage. ■ Replace bearing ■ Replace encoder Tab. 4-6: Measures before commissioning motors that have been stored over a prolonged period of time Bosch Rexroth AG R911335703_Edition 04...
Page 63 Visually inspect the cable jacket. Do not use the cable if you ■ detect any abnormalities (squeezed or kinked spots, color deviations, ...). Tab. 4-7: Measure before commissioning cables and connectors that have been stored over a prolonged period of time R911335703_Edition 04 Bosch Rexroth AG...
Page 64: Installation Conditions
4.2.1 "Transporting the components" on page 47 Allowed mounting position Definition of mounting positions: See chapter "Mounting positions of components" on page Installation altitude 1000 nenn Ambient temperature range °C 0 … 40 a_work Bosch Rexroth AG R911335703_Edition 04...
Page 65 Some components can be operated in mounting positions oth‐ er than G1. The allowed mounting positions are specified in the technical data of the components. Tab. 4-8: Ambient and operating conditions (HCS, HMV, HMS, HMD, HCQ, HCT, KCU, HLC, HNF) R911335703_Edition 04 Bosch Rexroth AG...
Page 66 F (f × F Relative humidity 5 … 95 Absolute humidity 1 … 29 Climatic category (IEC721) Allowed pollution degree (IEC 60664‑1) 3 (only with connectors plugged in) Bosch Rexroth AG R911335703_Edition 04...
Page 67 G2, G4, G5) KMV, KNK, KLC Cooling types B and I: G1, G2, G3, G4 Cooling types A and W: G1 Installation altitude 1000 nenn Ambient temperature range °C 0 … 40 a_work R911335703_Edition 04 Bosch Rexroth AG...
Page 68 KMV, KNK, KLC Vibration sine: radial With HAS10.1-001-001-NN KMS: acceleration at 10 … 2000 Hz accessories: KMV/KNK/KLC: acceleration at 5 … 200 Hz KMV, KNK, KLC Overvoltage category III (according to IEC 60664-1) According to EN 60068-2-6 Bosch Rexroth AG R911335703_Edition 04...
Page 69 IndraDrive Mi Drive Systems with KCU02, KSM02, 55/407 KMS02/03, KMV03, KNK03, KLC03 General data and specifications According to EN 60721‑3‑3 Tab. 4-10: Ambient and operating conditions (KMS, KMV, KNK, KLC) R911335703_Edition 04 Bosch Rexroth AG...
Page 70: Control Cabinet Design And Cooling
Service the filters at regular intervals according to the dust loading in the environment. ● Only replace the filters when the fan has been switched off, because otherwise the fan sucks in the dirt coming off the filter and the dirt gets into the control cabinet. Bosch Rexroth AG R911335703_Edition 04...
Page 71 The control cabinet fan behind the air intake opening conveys the air into the control cabinet and generates overpressure in the control cabinet. The overpressure prevents unclean air from getting into the control cabinet through possibly existing leaky points (leaky cable ducts, damaged seals, etc.). R911335703_Edition 04 Bosch Rexroth AG...
Page 72: Mounting Position
Fan within the component (forces the cooling air current) Cooling air 180° to normal mounting position 90° to normal mounting position bottom mounting; mounting surface on the bottom top mounting; mounting surface at the top Tab. 4-12: Mounting positions Bosch Rexroth AG R911335703_Edition 04...
Page 73: Mounting Positions Of Motor-Integrated Servo Drives
Voltage testing and insulation resistance testing According to standard, the components of the IndraDrive Mi range are tested with voltage. Testing Test rate Voltage testing 100% (EN 61800-5-1) Insulation resistance testing 100% (EN 60204-1) Tab. 4-14: Applied standards R911335703_Edition 04 Bosch Rexroth AG...
Page 74: Control Voltage (24V Supply)
Applies to all devices except HCS01 and HMV02: Insulation monitoring impossible The input 0 V is connected in conductive form to the housing potential. Insulation monitoring at +24 V and 0 V against housing is impossible. Protective Extra Low Voltage Bosch Rexroth AG R911335703_Edition 04...
Page 75: Technical Data Of The Components
Maximum torque that can be delivered for approx. 400 ms at maximum current I (manufacturing tolerances +5% / ‑20%). Maximum current Maximum, temporarily allowed phase current (rms value) in the max(rms) motor winding without damaging effect on the permanent- magnet circuit of the motor. R911335703_Edition 04 Bosch Rexroth AG...
Page 76 According to DIN EN ISO 11205; comparative value at 1 m dis‐ tance, out of cabinet KCU02: DC bus input L+/L- Also depending on firmware and control section; see parame‐ ter description "P–0–0001, Switching frequency of the power output stage"; see "P-0-4058, Amplifier type data" Bosch Rexroth AG R911335703_Edition 04...
Page 77 Relative duty cycle in % Δt Operating time with constant load Fig. 5-2: Relative duty cycle The values specified in the documentation have been determined on the basis of the following parameters: Cycle duration: 1 min R911335703_Edition 04 Bosch Rexroth AG...
Page 78 EN 60034-1; 1998) and max. duty cycle 1 min. , controlled supply DC 750 V (2)(3)(4) , uncontrolled supply 3 × AC 400 V; the voltage drop on the supply line has not been taken into account Fig. 5-4: Sample characteristic Bosch Rexroth AG R911335703_Edition 04...
Page 79: Ksm02 Motor-Integrated Servo Drive
DC bus Diss_cont power respectively 540...750 Rated input voltage, power LN_nenn Capacitance in DC bus 0.012 0.024 50 + 100 Capacitance against housing 4; 8 Allowed switching frequencies Motor stage data Latest amendment: 2017-01-24* R911335703_Edition 04 Bosch Rexroth AG...
Page 80 50 nF: L+ against ground; 100 nF: L- against ground Tab. 5-2: KSM without motor holding brake - Technical data Rated power consumption control voltage input at U Plus power consumption of externally connected inputs/outputs, plus safety option Bosch Rexroth AG R911335703_Edition 04...
Page 81: Ksm02 With Motor Holding Brake, Data Sheet
Rated power (t > 10 min) 1320 1285 1200 LN_nenn Power dissipation at continuous current and continuous DC bus Diss_cont power respectively 540...750 Rated input voltage, power LN_nenn Capacitance in DC bus 0.012 0.024 Latest amendment: 2017-01-24* R911335703_Edition 04 Bosch Rexroth AG...
Page 82 "P-0-4058, Amplifier type data"; for supply units the switching frequency is 4.2 kHz Manufacturing tolerance ±5% 50 nF: L+ against ground; 100 nF: L- against ground Tab. 5-3: KSM with motor holding brake - Technical data Bosch Rexroth AG R911335703_Edition 04...
Page 83 IndraDrive Mi Drive Systems with KCU02, KSM02, 69/407 KMS02/03, KMV03, KNK03, KLC03 Technical data of the components Rated power consumption control voltage input at U Including motor holding brake, plus power consumption of externally connected inputs/outputs, plus safety option R911335703_Edition 04 Bosch Rexroth AG...
Page 84: Ksm02 Characteristics
, controlled supply (1) 3 × AC 400 V (2)(3)(4) , uncontrolled supply (2) 3 × AC 480 V, (3) 3 × AC 440 V, (4) 3 × AC 400 V Fig. 5-6: KSM02.1B-061C-35 characteristics Bosch Rexroth AG R911335703_Edition 04...
Page 85 , controlled supply (1) 3 × AC 400 V (2)(3)(4) , uncontrolled supply (2) 3 × AC 480 V, (3) 3 × AC 440 V, (4) 3 × AC 400 V Fig. 5-8: KSM02.1B-071C-24 characteristics R911335703_Edition 04 Bosch Rexroth AG...
Page 86 , controlled supply (1) 3 × AC 400 V (2)(3)(4) , uncontrolled supply (2) 3 × AC 480 V, (3) 3 × AC 440 V, (4) 3 × AC 400 V Fig. 5-10: KSM02.1B-076C-35 characteristics Bosch Rexroth AG R911335703_Edition 04...
Page 87: Dimensions And Technical Design
HAS10 accessory with a screwdriver. The exact dimension of the mounting clearance is not specified, since the required mounting clearance depends on the length of the screwdriver used. Fig. 5-11: KSM02.1B-041C dimensions R911335703_Edition 04 Bosch Rexroth AG...
Page 88 HAS10 accessory with a screwdriver. The exact dimension of the mounting clearance is not specified, since the required mounting clearance depends on the length of the screwdriver used. Fig. 5-12: KSM02.1B-041C dimensions (ATEX design) Bosch Rexroth AG R911335703_Edition 04...
Page 89 HAS10 accessory with a screwdriver. The exact dimension of the mounting clearance is not specified, since the required mounting clearance depends on the length of the screwdriver used. Fig. 5-13: KSM02.1B-061C dimensions R911335703_Edition 04 Bosch Rexroth AG...
Page 90 HAS10 accessory with a screwdriver. The exact dimension of the mounting clearance is not specified, since the required mounting clearance depends on the length of the screwdriver used. Fig. 5-14: KSM02.1B-071C dimensions Bosch Rexroth AG R911335703_Edition 04...
Page 91 HAS10 accessory with a screwdriver. The exact dimension of the mounting clearance is not specified, since the required mounting clearance depends on the length of the screwdriver used. Fig. 5-15: KSM02.1B-076C dimensions R911335703_Edition 04 Bosch Rexroth AG...
Page 92: Technical Design
5 × 5 × 20 DS M5 KSM02.1B-061 6 × 6 × 32 DS M6 KSM02.1B-071 10 × 8 × 45 DS M10 KSM02.1B-076 8 × 7 × 40 DS M8 Tab. 5-5: Key and centering hole Bosch Rexroth AG R911335703_Edition 04...
Page 93: Bearing Load And Shaft Load
Bearings Radial force F radial Fig. 5-16: KSM02.1B-041: Allowed radial force (shaft and bearing load) Fig. 5-17: KSM02.1B-061: Allowed radial force (shaft and bearing load) Fig. 5-18: KSM02.1B-071: Allowed radial force (shaft and bearing load) R911335703_Edition 04 Bosch Rexroth AG...
Page 94 Technical data of the components Fig. 5-19: KSM02.1B-076: Allowed radial force (shaft and bearing load) Axial force F Type Maximum allowed axial force in [N] axial KSM02.1B-041 KSM02.1B-061 KSM02.1B-071 KSM02.1B-076 Tab. 5-6: Allowed axial force Bosch Rexroth AG R911335703_Edition 04...
Page 95: Kms02 Near Motor Servo Drive
* 0.71 out_eff V/Hz (U/f) control Output voltage, fundamental wave in out_eff closed-loop operation Rise of voltage at output with U LN_nenn 7.5 m motor cable length phase-phase dv/dt kV/µs 5.00 (10‑90%) Latest amendment: 2018-02-22* R911335703_Edition 04 Bosch Rexroth AG...
Page 96 Guide value "Rise of voltage at output" Observe that the voltage load at the motor is almost independent of the power section used. Especially when using standard motors, make sure that they comply with the occurring voltage load. Bosch Rexroth AG R911335703_Edition 04...
Page 97 Depending on the electric output frequency, the output current is reduced for thermal protection of the power section. The output current is reduced, when the electric output frequency has fallen below the threshold to detect motor standstill. R911335703_Edition 04 Bosch Rexroth AG...
Page 98: Kms02 Dimensional Drawing
HAS10 accessory with a screwdriver. The exact dimension of the mounting clearance is not specified, since the required mounting clearance depends on the length of the screwdriver used. Boring dimensions Fig. 5-20: Dimensions Bosch Rexroth AG R911335703_Edition 04...
Page 99 Boring dimensions Fig. 5-21: Dimensions (with angular connector for motor and encoder connec‐ tion) R911335703_Edition 04 Bosch Rexroth AG...
Page 100: Kcu02 Drive Connection Box
42V control voltage ● with integrated fuses protects the RKH hybrid cable against electric overload ● allows the higher-level control unit to communicate with the KSM motor- integrated servo drives and KMS near motor servo drives Bosch Rexroth AG R911335703_Edition 04...
Page 101: Kcu02 Data Sheet
Max. inrush current at 24 V supply 10.00 EIN3_max Pulse width of I < 1000 EIN3 EIN3Lade Input capacitance 11.00 Maximum allowed voltage 33.00 N3_max 1 ms Control voltage data - output Nominal voltage 42.0 Nominal power 588.0 Latest amendment: 2017-01-20* R911335703_Edition 04 Bosch Rexroth AG...
Page 102 Property damage due to temperatures higher NOTICE than 105 °C! Comply with specified minimum distances! Air intake Air outlet Mounting surface in control cabinet Distance top Distance bottom Distance horizontal Fig. 5-22: Air intake and air outlet at device Bosch Rexroth AG R911335703_Edition 04...
Page 103: Kcu02 Dimensional Drawing
IndraDrive Mi Drive Systems with KCU02, KSM02, 89/407 KMS02/03, KMV03, KNK03, KLC03 Technical data of the components 5.4.3 KCU02 dimensional drawing Minimum mounting clearance Fig. 5-23: Dimensions R911335703_Edition 04 Bosch Rexroth AG...
Page 104: Kmv03 Supply Unit
Output voltage DC 750 Output current 10.0 Latest amendment: 2019-08-08* Mains input L1, L2, L3; For use on a solidly grounded wye source only. Tab. 5-9: KMV - Ambient and operating conditions - UL ratings Bosch Rexroth AG R911335703_Edition 04...
Page 105: Mechanics And Mounting
IndraDrive Mi Drive Systems with KCU02, KSM02, 91/407 KMS02/03, KMV03, KNK03, KLC03 Technical data of the components 5.5.2 Mechanics and mounting KMV03.1R-B/Ixxxx dimensional drawing (thermal interface) Minimum mounting clearance Boring dimensions Fig. 5-24: KMV03.1R-B/Ixxxx (thermal interface), dimensions R911335703_Edition 04 Bosch Rexroth AG...
Page 106: Kmv03.1R-Axxxx Dimensional Drawing (Natural Convection)
92/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Technical data of the components KMV03.1R-Axxxx dimensional drawing (natural convection) Minimum mounting clearance Boring dimensions Fig. 5-25: KMV03.1R-Axxxx (natural convection), dimensions Bosch Rexroth AG R911335703_Edition 04...
Page 107: Kmv03.1R-Wxxxx Dimensional Drawing (Forced Cooling)
IndraDrive Mi Drive Systems with KCU02, KSM02, 93/407 KMS02/03, KMV03, KNK03, KLC03 Technical data of the components KMV03.1R-Wxxxx dimensional drawing (forced cooling) Minimum mounting clearance Boring dimensions Fig. 5-26: KMV03.1R-Wxxxx (forced cooling), dimensions R911335703_Edition 04 Bosch Rexroth AG...
Page 108: Dimensions, Mass, Insulation, Sound Pressure Level
According to DIN EN ISO 11205; comparative value at 1 m dis‐ tance 150 nF: L+ against ground; 200 nF: L- against ground Tab. 5-10: KMV - Data for mass, dimensions, sound pressure level, insulation Bosch Rexroth AG R911335703_Edition 04...
Page 109: Power Dissipation, Mounting Position, Cooling, Distances
Latest amendment: 2019-08-08 Plus dissipation of braking resistor and control section See information on "Rated power consumption control voltage input at U " Tab. 5-11: KMV - Cooling and power dissipation data R911335703_Edition 04 Bosch Rexroth AG...
Page 110: Basic Data
< 1000 EIN3 EIN3Lade Input capacitance 11.00 Rated power consumption control voltage input at U Latest amendment: 2019-08-08* 1) 2) 3) Observe supply voltage for motor holding brake Tab. 5-12: KMV - Control voltage supply data Bosch Rexroth AG R911335703_Edition 04...
Page 111: Mains Voltage
DC_cont 0.99 with mains choke; U LN_nenn Power factor fundam. component DPF at P with cosφ 0.99 DC_cont mains choke Mains connection power with mains choke DC_cont LN_nenn Rated input current 12.0 Latest amendment: 2019-08-08* R911335703_Edition 04 Bosch Rexroth AG...
Page 112 DC bus Copper wire; PVC-insulation (conductor temperature 90 °C; ≤ 40 °C) in accordance with NFPA 79 chapter 12 and UL 508A chapter 28 Tab. 5-13: KMV - Mains voltage supply data Bosch Rexroth AG R911335703_Edition 04...
Page 113: Dc Bus
Charging time maximum lade_DC_Ce external capacitance 0.70 at U DCext LN_nenn Latest amendment: 2019-09-04* Only devices with regulated DC bus voltage Use assigned mains choke Tab. 5-14: KMV - Supply unit data - DC bus R911335703_Edition 04 Bosch Rexroth AG...
Page 114: Braking Resistor
- independent of mains R_DC_On_f voltage Regenerative power 7.50 R_max absorbed Cooling integrated braking Heat sink Base plate (Coldplate) Heat sink resistor Latest amendment: 2019-08-08 Factory setting Tab. 5-15: KMV - Integrated braking resistor data Bosch Rexroth AG R911335703_Edition 04...
Page 115: Klc03 Dc Bus Capacitor Unit
DC bus power respectively Maximum discharge time from entl_ZK to DC 50 V R_DC_On Allowed input current at L+ L- max(rms) Insulation resistance (at DC 500 V) Mohm > 50 Tab. 5-16: KLC03 - technical data R911335703_Edition 04 Bosch Rexroth AG...
Page 116: Klc03.1N-B04M7 Dimensional Drawing (Thermal Interface)
102/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Technical data of the components 5.6.2 KLC03.1N-B04M7 dimensional drawing (thermal interface) Minimum mounting clearance Boring dimensions Fig. 5-27: KLC03.1N-B04M7 (thermal interface), dimensions Bosch Rexroth AG R911335703_Edition 04...
Page 117: Klc03.1N-A04M7 Dimensional Drawing (Natural Convection)
IndraDrive Mi Drive Systems with KCU02, KSM02, 103/407 KMS02/03, KMV03, KNK03, KLC03 Technical data of the components 5.6.3 KLC03.1N-A04M7 dimensional drawing (natural convection) Minimum mounting clearance Boring dimensions Fig. 5-28: KLC03.1N-A04M7 (natural convection), dimensions R911335703_Edition 04 Bosch Rexroth AG...
Page 118: Klc03.1N-W04M7 Dimensional Drawing (Forced Cooling)
104/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Technical data of the components 5.6.4 KLC03.1N-W04M7 dimensional drawing (forced cooling) Minimum mounting clearance Boring dimensions Fig. 5-29: KLC03.1N-W04M7 (forced cooling), dimensions Bosch Rexroth AG R911335703_Edition 04...
Page 119: Knk03 Mains Filter
Plus dissipation of braking resistor and control section Copper wire; PVC-insulation (conductor temperature 90 °C; ≤ 40 °C) in accordance with NFPA 79 chapter 12 and UL 508A chapter 28 Tab. 5-17: KNK - Technical data - currents, voltages, power R911335703_Edition 04 Bosch Rexroth AG...
Page 120: Knk03.1A-Nr-B/Ixxxx Dimensional Drawing (Thermal Interface)
106/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Technical data of the components 5.7.2 KNK03.1A-NR-B/Ixxxx dimensional drawing (thermal interface) Minimum mounting clearance Boring dimensions Fig. 5-30: KNK03.1A-NR-B/Ixxxx (thermal interface), dimensions Bosch Rexroth AG R911335703_Edition 04...
Page 121: Knk03.1A-Nr-Axxxx Dimensional Drawing (Natural Convection)
IndraDrive Mi Drive Systems with KCU02, KSM02, 107/407 KMS02/03, KMV03, KNK03, KLC03 Technical data of the components 5.7.3 KNK03.1A-NR-Axxxx dimensional drawing (natural convection) Minimum mounting clearance Boring dimensions Fig. 5-31: KNK03.1A-NR-Axxxx (natural convection), dimensions R911335703_Edition 04 Bosch Rexroth AG...
Page 122: Knk03.1A-Nr-Wxxxx Dimensional Drawing (Forced Cooling)
108/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Technical data of the components 5.7.4 KNK03.1A-NR-Wxxxx dimensional drawing (forced cooling) Minimum mounting clearance Boring dimensions Fig. 5-32: KNK03.1A-NR-Wxxxx (forced cooling), dimensions Bosch Rexroth AG R911335703_Edition 04...
Page 123: Kms03 Near Motor Servo Drive
DC bus 127.00 222.00 Diss_cont power respectively Power section data - output Output voltage, fundamental wave × 0.71 out_eff in V/Hz (U/f) control Output voltage, fundamental wave × 0.71 out_eff in closed-loop operation Latest amendment: 2018-02-22* R911335703_Edition 04 Bosch Rexroth AG...
Page 124 See following note regarding output current reduction Tab. 5-18: KMS - Technical data Rated power consumption control voltage input at U Plus motor holding brake, plus power consumption of externally connected inputs/outputs, plus safety option Bosch Rexroth AG R911335703_Edition 04...
Page 125 Depending on the electric output frequency, the output current is reduced for thermal protection of the power section. The output current is reduced, when the electric output frequency has fallen below the threshold to detect motor standstill. R911335703_Edition 04 Bosch Rexroth AG...
Page 126: Kms03 Dimensional Drawing
Mounting clearance with optional master communication output coupling More mounting clearance with HAS10 accessory (fixing clip for hybrid cable connectors). More mounting clearance is required to install the HAS10 accessory with a screwdriver. Fig. 5-33: KMS03.1B-A, dimensions Bosch Rexroth AG R911335703_Edition 04...
Page 127 More mounting clearance with HAS10 accessory (fixing clip for hybrid cable connectors). More mounting clearance is required to install the HAS10 accessory with a screwdriver. Mounting clearance with cable outlet away from housing Drilling pattern Fig. 5-34: KMS03.1B-B, dimensions R911335703_Edition 04 Bosch Rexroth AG...
Page 128: Rkh Hybrid Cable
±30 Max. horizontal travel distance Maximum travel velocity m/s² Maximum acceleration UL approval cURus UL AWM Style AWM20234 RoHS (EU) compliant with Directive 2002/95/EC Halogens halogen-free according to VDE 0472, Part 815 Latest amendment: 2019-06-17 Bosch Rexroth AG R911335703_Edition 04...
Page 129 The hybrid cable contains both power lines and control lines. Route hybrid cables in accordance with EN 61800‑5‑1 and EN 61800‑5‑2, protected against external damage. Select the types of protective measures according to the respective application. R911335703_Edition 04 Bosch Rexroth AG...
Page 130: Rkh Hybrid Cable Without Communication, Technical Data
Directive 2011/65/EC Halogens halogen-free according to VDE 0472, Part 815 Oil resistance HD22.10 S1 and VDE0282 IEC 60332-1-2; UL 1581, Sec. 1061; UL 2556, Flammability Sec. 9.3 Latest amendment: 2019-06-17 According to EN 50363-10-2 Bosch Rexroth AG R911335703_Edition 04...
Page 131 The hybrid cable contains both power lines and control lines. Route hybrid cables in accordance with EN 61800‑5‑1 and EN 61800‑5‑2, protected against external damage. Select the types of protective measures according to the respective application. R911335703_Edition 04 Bosch Rexroth AG...
Page 132: Selecting Rkh Hybrid Cable Incl. Communication
RKH0907 RKH0900 connector Outgoing direction "A" Outgoing direction "B" Outgoing direction "V" To interconnect two RKH0700 cables, use a short RKH0610 cable as an intermediate piece HCS01.1E-W0054 with HAS05.1-023 accessories Tab. 5-21: RKH hybrid cable Bosch Rexroth AG R911335703_Edition 04...
Page 133 "Length of hybrid cable incl. communication " on page 227). Identifying the hybrid cables Hybrid cables are labeled according to the following example: RKH0111/030,5 The cable designation is made up of: ● Cable number: e.g. RKH0111 ● Cable length: e.g. 30.5 m R911335703_Edition 04 Bosch Rexroth AG...
Page 134 Otherwise, the signals for E- Stop and safety technology would not be valid. When mounting hybrid cables in cable ducts or flexible cable tracks, make sure that the direction of the hybrid cables is correct. Bosch Rexroth AG R911335703_Edition 04...
Page 135: Selecting Rkh Hybrid Cable Without Communication
A: horizontal (towards the housing) ● B: horizontal (away from the housing) ● V: vertical Tab. 5-24: Hybrid cable outgoing directions Identifying the hybrid cables Hybrid cables are marked according to the following example: RKH0121/030,5 R911335703_Edition 04 Bosch Rexroth AG...
Page 136 Otherwise, the signals for E- Stop and safety technology would not be valid. When mounting hybrid cables in cable ducts or flexible cable tracks, make sure that the direction of the hybrid cables is correct. Bosch Rexroth AG R911335703_Edition 04...
Page 137: Interconnection Diagrams For Ready-Made Hybrid Cables Incl. Communication
R-End plug-in connector for RKH0511 Picture shows coding with view to mating side The coding profile ensures the downward compatibility of the hybrid cable for KSM01/KMS01 Tab. 5-25: Parts of ready-made hybrid cables from KCU to KSM/KMS R911335703_Edition 04 Bosch Rexroth AG...
Page 138: Ksm/Kms - Ksm/Kms
RKH0212, RKH0213, RKH0214, RKH0215, RKH0610, RKH0611 KSM/KMS plug-in Bulk cable KSM/KMS plug-in connector connector RHS0011/C03 REH0800 RHS0011/C03 RHS0016/C03 RHS0016/C03 Interconnection diagram Coding at KSM/KMS plug-in connector Cable type L-End (X103.1) R-End (X103.2) RKH0011 RKH0110 RKH0210 RKH0212 RKH0214 RKH0610 Bosch Rexroth AG R911335703_Edition 04...
Page 139 Locking pin Coding profile Picture shows coding with view to mating side The coding profile ensures the downward compatibility of the hybrid cable for KSM01/KMS01 Tab. 5-26: Parts of ready-made hybrid cables from KSM/KMS to KSM/KMS R911335703_Edition 04 Bosch Rexroth AG...
Page 140: Flexible Cable Tracks
Bulk cable KSM/KMS plug-in connector connector RHS0007/C03 REH0800 RHS0007/C03 Interconnection diagram Coding at KSM/KMS plug-in connector Cable type L-End R-End RKH0700 Not coded Not coded Tab. 5-27: Parts of ready-made hybrid cable for flexible cable tracks Bosch Rexroth AG R911335703_Edition 04...
Page 141: Hybrid Cable With Circular Connector
Plug-in connector, circular Bulk cable Plug-in connector, circular connector connector RHS2321/C03 REH0800 RHS2322/C03 RHS0011/C03 RHS0016/C03 Interconnection diagram (RHS2321 - RHS2322) Interconnection diagram (RHS2321 - RHS0011/RHS0016) RKH0900 RKH0901, RKH0904 RKH0906 Tab. 5-28: RKH0900, RKH0901, RKH0904, RKH0906 R911335703_Edition 04 Bosch Rexroth AG...
Page 142 Applies to: RKH0900, RKH0902, RKH0905, RKH0907 Plug-in connector, circular Bulk cable Plug-in connector, circular connector connector/KSM/KMS REH0800 RHS2322/C03 RHS2321/C03 RHS0011/C03 RHS0016/C03 Interconnection diagram (RHS2322 - RHS2321) Interconnection diagram (RHS2322 -RHS0011/RHS0016) RKH0900 RKH0902, RKH0905 RKH0907 Tab. 5-29: RKH0900, RKH0902, RKH0905, RKH0907 Bosch Rexroth AG R911335703_Edition 04...
Page 143 KMS02/03, KMV03, KNK03, KLC03 Technical data of the components Applies to: RKH0903 KCU plug-in connector Bulk cable Plug-in connector, circular connector RHS0005/C03 REH0800 RHS2321/C03 Interconnection diagram Tab. 5-30: Parts of ready-made hybrid cables from KCU to circular connector R911335703_Edition 04 Bosch Rexroth AG...
Page 144 KMS02/03, KMV03, KNK03, KLC03 Technical data of the components Applies to: RKH0909 HAS05.1-023 plug-in Bulk cable Plug-in connector, circular connector connector RHS0015/CM03 REH0800 RHS2321/CM03 Interconnection diagram Tab. 5-31: Parts of ready-made hybrid cables from HAS05.1-023 to circular connector Bosch Rexroth AG R911335703_Edition 04...
Page 145 For RKH09xx hybrid cables, a metallic flange can be fitted to the circular connector. This allows hybrid cable housing ducts to be implemented with a pluggable connection at the housing (control cabinet, machine). chapter 10.24 "Metallic flange for circular connectors" on page 337. R911335703_Edition 04 Bosch Rexroth AG...
Page 146: Has05.1-023 - Ksm/Kms
Picture shows coding with view to mating side The coding profile ensures the downward compatibility of the hybrid cable for KSM01/KMS01 Tab. 5-33: Parts of ready-made hybrid cables from HAS05.1-023 to KSM/KMS HAS05.1-023 chapter 10.9 "HAS05.1-023, HCS01 adapter" on page 310 Bosch Rexroth AG R911335703_Edition 04...
Page 147: Rhs0014 Terminal Connector
Internal M12 socket wiring If it is difficult to access the M12 socket in your drive system: Connect a cable (e.g. RKB0043) to the M12 socket and position the end of the cable at an easily accessible point. R911335703_Edition 04 Bosch Rexroth AG...
Page 148: Interconnection Diagrams For Ready-Made Hybrid Cables Without Communication
X103.1 RKH0421 RHS0008 X103.1 RKH0521 RHS0008 X103.1 R-End plug-in connector for RKH0321, RKH0421 R-End plug-in connector for RKH0521 View to mating side Tab. 5-35: Parts of ready-made hybrid cables without communication from KCU to KSM02/KMS Bosch Rexroth AG R911335703_Edition 04...
Page 149: Ksm/Kms - Ksm/Kms
Applies to: RKH0021, RKH0120, RKH0121, RKH0220, RKH0222 KSM/KMS plug-in Bulk cable KSM/KMS plug-in connector connector RHS0021/CM02 REH0803 RHS0021/CM02 RHS0022/CM02 Interconnection diagram KSM/KMS plug-in connector Cable type L-End R-End RKH0021 X103.1 X103.2 RKH0120 X103.1 X103.2 RKH0121 X103.2 X103.1 R911335703_Edition 04 Bosch Rexroth AG...
Page 150 X103.1 X103.2 RKH0222 X103.1 X103.2 R-End plug-in connector for RKH0021, RKH0120, RKH0121, RKH0220 R-End plug-in connector for RKH0222 View to mating side Tab. 5-36: Parts of ready-made hybrid cables without communication from KSM/KMS to KSM/KMS Bosch Rexroth AG R911335703_Edition 04...
Page 151: Flexible Cable Tracks
Bulk cable KSM/KMS plug-in connector connector RHS0023/CM02 REH0803 RHS0023/CM02 Interconnection diagram Coding at KSM/KMS plug-in connector Cable type L-End R-End RKH0710 Not coded Not coded Tab. 5-37: Parts of ready-made hybrid cable for flexible cable tracks R911335703_Edition 04 Bosch Rexroth AG...
Page 152: Interconnection Diagrams For Ready-Made Hybrid Cables Used For Mains Connection
KMV03 plug-in connector RHS0017/K03 REH0803 RHS0018/K03 Interconnection diagram KNK03/KMV03 plug-in connector Cable type L-End R-End RKH0800 XD1 connector XD1 connector XG34 connector XG34 connector Tab. 5-38: Parts of ready-made hybrid cables used for mains connection Bosch Rexroth AG R911335703_Edition 04...
Page 153: Knk03 - Kmv03 (Rkh0801)
KMV03 plug-in connector RHS0019/K03 REH0803 RHS0020/K03 Interconnection diagram KNK03/KMV03 plug-in connector Cable type L-End R-End RKH0801 XG14 connector XG14 connector XG3 connector XG3 connector Tab. 5-39: Parts of ready-made hybrid cables used for mains connection R911335703_Edition 04 Bosch Rexroth AG...
Page 154: Interconnection Diagrams For Ready-Made Hybrid Cables Used For Dc Bus Connection
KLC03 plug-in connector Bulk cable KLC03 plug-in connector RHS0009/KM04 REL0015 RHS0009/KM04 Interconnection diagram KLC03/KLC03 plug-in connector Cable type L-End R-End RKH0803 XG9 connector XG9 connector Tab. 5-41: Parts of ready-made hybrid cables used for DC bus connection Bosch Rexroth AG R911335703_Edition 04...
Page 155: Connection Points
Make sure that these charges can be directly discharged against ground at their point of origin. Therefore, connect the second connection point of equipment grounding conductor of the devices to the equipment grounding system of the installation. R911335703_Edition 04 Bosch Rexroth AG...
Page 156: Cabinet Free Drive Systems
Make sure that these charges can be directly discharged against ground at their point of origin. Therefore, connect the second connection point of equipment grounding conductor of the devices to the equipment grounding system of the installation. Bosch Rexroth AG R911335703_Edition 04...
Page 157: Ground Connection
2. Connect the mounting surface of the control cabinet in conductive form to the equipment grounding system. 2 drive lines If you connect 2 drive lines from terminal connector to terminal connector, provide equipotential bonding (ground connection) between the drive lines. R911335703_Edition 04 Bosch Rexroth AG...
Page 158: Kcu02 Connection Points
L3 (Safe Torque Off) E-Stop E-Stop input Status messages For exchanging status messages 42 V, 0 V 42 V output; control voltage supply DC bus, equipment DC bus output; power supply grounding conductor Tab. 6-2: Connection Points KCU02 Bosch Rexroth AG R911335703_Edition 04...
Page 159: X1, Module Bus
RKB0001. ● When using DC bus capacitor units: Do not establish this connection at the DC bus capacitor unit, if the DC bus capacitor unit is the last device in the drive system. R911335703_Edition 04 Bosch Rexroth AG...
Page 160: X29.1, X29.2, Multi-Ethernet
Short cables to connect devices arranged side by side in the control cabinet. 4 lengths available: 0.19 m; 0.25 m; 0.35 m; 0.55 m Order code for a 0.55 m long cable: RKB0013/00,55 Minimum bending radius: 30.75 mm Tab. 6-4: Function, pin assignment, properties Bosch Rexroth AG R911335703_Edition 04...
Page 161 KCU02 to a neighboring drive controller. Tab. 6-5: RKB0013/00,55 netSWITCH sercos III With sercos III and for the Engineering of the drive system, you can connect "netSWITCH sercos III" accessory into the sercos III ring. R911335703_Edition 04 Bosch Rexroth AG...
Page 162: X49, L3 - Safe Torque Off
X50 (E‑Stop input) must not be used for power supply of X49! Tab. 6-7: Pin Assignment, Function When the dynamization outputs do not work, check the power supply connection. The polarity might possibly have been reversed. Bosch Rexroth AG R911335703_Edition 04...
Page 163: X50, E-Stop Input
Exclusively use the 0 V output for the E-Stop input in conjunc‐ tion with the jumper from X50.1 to X50.2. Maximum rating: 15 mA. Tab. 6-8: Function, Pin Assignment, Properties See also description of the E-Stop function: chapter "E-Stop function" on page 240 R911335703_Edition 04 Bosch Rexroth AG...
Page 164: X52, Status Messages
Connection cable stranded wire n.s. Connection cable Voltage range 24 +10% Voltage level "H" n.s. Voltage level "L" n.s. Output current n.s. Conductor color of the ready-made cable RKH Tab. 6-9: Function, Pin Assignment, Properties Bosch Rexroth AG R911335703_Edition 04...
Page 165: X53, Control Voltage Output
LED H53 emits red light. Thereafter, the motors are coasting down because a return movement is no longer possible. Notes on Operation Do not remove connectors when the component has been powered. Do not plug in connectors when the component has been powered. R911335703_Edition 04 Bosch Rexroth AG...
Page 166: X54, Dc Bus, Equipment Grounding Conductor Output Ksm02/Kms02
Connection via hybrid cable RKH Connection cable Short circuit protection L+, L- Fuses F4, F5 Voltage L+, L- (see technical data of KCU02) Conductor color of the ready-made cable RKH Tab. 6-11: Function, Pin Assignment, Properties Bosch Rexroth AG R911335703_Edition 04...
Page 167: Dc Bus Connection L+, L
Current carrying capacity "looping through" from L+ to L+, L- to L- (contact bars in scope of supply of accessory HAS01) With contact bars -072 Additionally with contact bars ‑042 and end piece Tab. 6-12: Function, Pin Assignment, Properties R911335703_Edition 04 Bosch Rexroth AG...
Page 168 Line protection By means of fuses in the mains connection Dielectric strength of single ≥ 750 V (e.g.: strand type – H07) strand against ground Tab. 6-13: DC Bus Line Bosch Rexroth AG R911335703_Edition 04...
Page 169 HMV01 and HCS03 devices have greater mounting depths than the drive connection box KCU. For connecting the drive connection box KCU to an HMV01 or HCS03 device, you must therefore use the control cabinet adapter HAS03.1-002 which compensates the different mounting depths. R911335703_Edition 04 Bosch Rexroth AG...
Page 170: Control Voltage Supply +24V, 0V
KSM02/KMS02 devices is switched off and LED H53 emits red light. Thereafter, the motors are coasting down because a return movement is no longer possible. Protective Extra Low Voltage Bosch Rexroth AG R911335703_Edition 04...
Page 171 KCU with contact For HCS02 devices, the 24V supply is connected to the bars. drive connection box KCU with cables (cross section: min. 6 mm (AWG 10)). Tab. 6-16: Connecting the 24V supply R911335703_Edition 04 Bosch Rexroth AG...
Page 172: Ksm02 Connection Points
X103.2 X107 Programming module X1x8 Communication (optional) X1x9 ● X108, X109: Communication output coupling ● X118, X119: External communication X141 Safety technology (optional) Second connection point of equipment grounding conductor Tab. 6-17: KSM02 connection points Bosch Rexroth AG R911335703_Edition 04...
Page 173: X37, X38, Digital Inputs/Outputs
5-pin M12 connectors (X37 and X38). The configuration is carried out with the parameter "P-0-0300, Digital I/Os, assignment list". ● The inputs I_1 (X37.4) and I_2 (X38.4) can be used as probe inputs. R911335703_Edition 04 Bosch Rexroth AG...
Page 174 I Digital input dig. O Digital output 24 V Voltage from internal power supply 24 V Voltage from external power supply Shld Shield Fig. 6-4: Internal design of the digital inputs and digital outputs Bosch Rexroth AG R911335703_Edition 04...
Page 175 At the pins 1 and 3 of the connectors X37 and X38, you can connect an external 24 V power supply to increase the maximum output current of the digital outputs. The external 24 V supply has to comply with a voltage tolerance of ±20%. R911335703_Edition 04 Bosch Rexroth AG...
Page 176 This means that these outputs only can actively supply current. The energy absorption capacity of the outputs is used to limit voltage peaks caused when inductive loads are switched off. Limit voltage peaks by using free-wheeling diodes directly at the relay coil. Bosch Rexroth AG R911335703_Edition 04...
Page 177: X103.1, X103.2, Hybrid Cable Connection Point
Risk of damage from frequently plugging in NOTICE the hybrid cable. Allowed number of plugging cycles: ≤ 50 Codings of the connection points to prevent the hybrid cables from being incorrectly connected Fig. 6-6: X103.1 and X103.2 R911335703_Edition 04 Bosch Rexroth AG...
Page 178 Do not remove connectors when the component has been powered. Do not plug in connectors when the component has been powered. ● Avoid removing and plugging in the hybrid cable unless it is necessary. Allowed number of plugging cycles: ≤ 50 Bosch Rexroth AG R911335703_Edition 04...
Page 179: X107, Programming Module
Clean the device housing before removing the programming module cover. Make sure that neither dirt nor moisture penetrate the housing. Cover; is fixed to the device with 4 screws (tightening torque: 1 Nm) Programming module X107 Fig. 6-8: Removing the programming module R911335703_Edition 04 Bosch Rexroth AG...
Page 180 Before placing the cover back onto the housing and tightening the screws: Ensure that the circuit board with the connection points is still correctly plugged in under the cover. Tab. 6-22: Cover with connection points Bosch Rexroth AG R911335703_Edition 04...
Page 181: X108, X109, Communication Output Coupling
Female connector M12 (5‑pin, D‑coded) Ready-made connection cable ● RKB0043 (M12 → M12) ● RKB0044 (M12 → RJ-45) Tab. 6-24: X108, X109; function, pin assignment, properties Do not use angled connectors at the connection points. R911335703_Edition 04 Bosch Rexroth AG...
Page 182 Internal circuit board for communication output coupling X_serc Internal communication interface Fig. 6-10: Devices with communication output coupling In the case of devices without communication output coupling, the communication signals are directly transmitted via a circuit board (see figure: LK_B). Bosch Rexroth AG R911335703_Edition 04...
Page 183 The figure shows how the parts are correctly arranged, in case you have to reassemble the parts. Protective caps (2×) Seals (O-rings; 2×) Screws (4×; the screws are locked and cannot fall out of the cover) Cover Circuit board Tab. 6-25: Parts R911335703_Edition 04 Bosch Rexroth AG...
Page 184: X118, X119, External Communication
Female connector M12 (5‑pin, D‑coded) Ready-made connection cable ● RKB0043 (M12 → M12) ● RKB0044 (M12 → RJ-45) Tab. 6-26: X118, X119; function, pin assignment, properties Bosch Rexroth AG R911335703_Edition 04...
Page 185 RKB0044 connection cable at the RHS0014 terminal connector or at connection point X118 (X119 cannot be used), and it is transmitted to KCU via the hy‐ brid cable. The unused connection points X118 and X119 are deactivated. R911335703_Edition 04 Bosch Rexroth AG...
Page 186 RKB0044 connection cables. RKB0043 Connection cable (M12 → M12) RKB0044 Connection cable (M12 → RJ-45) RHS0014 Terminal connector Internal signal processing LK_C Internal circuit board for communication X_serc Internal communication interface Tab. 6-27: Connection Bosch Rexroth AG R911335703_Edition 04...
Page 187: X141, Safety Technology And Service Input "Release Brake
"X141, safety technology Safe Motion (S3, SD options)" on page 176 – chapter "X141, without safety technology" on page 177 ● Distributed supply unit: – chapter 6.6.5 "X141, safety technology (KMV03)" on page 200 R911335703_Edition 04 Bosch Rexroth AG...
Page 188: X141, Safety Technology "Safe Torque Off
(connected to X103.1.8) Dyn_Ch1 Channel 1 dynamization output 24V_ZBr Internal interface only; 24 V for "release brake" function Inputs and outputs power supply (connected to X103.2.9) GND_Zone For "safety zone node" function Dyn_Ch2 Channel 2 dynamization output Bosch Rexroth AG R911335703_Edition 04...
Page 189 14.2.1 "Digital outputs (safety technology L options)" on page 371 Channel 2 dynamization output Dyn_Ch2 Power supply of isolated inputs and outputs +24V DC 19.2 … 30 V max. 700 mA Tab. 6-29: Technical data R911335703_Edition 04 Bosch Rexroth AG...
Page 190: X141, Safety Technology "Safe Motion" (S3, Sd Options)
Can be used for "releasing the brake". Tab. 6-30: Function, pin assignment, properties Technical data chapter 14.1.3 "Digital inputs (safety technology S options)" on page 370 chapter 14.2.2 "Digital outputs (safety technology S options)" on page 372 Bosch Rexroth AG R911335703_Edition 04...
Page 191: X141, Without Safety Technology
D‑coded) n.c. n. c. n. c. 24V_Br Internal interface only; 24 V for "release brake" function n.c. n. c. Ready-made connection cable RKB0033 Can be used to "release brake". Tab. 6-31: Function, pin assignment, properties R911335703_Edition 04 Bosch Rexroth AG...
Page 192: Second Connection Point Of Equipment Grounding Conductor
The first equipment grounding conductor is routed via the hybrid cable from X103.1 / X103.2 (KSM0x/KMS0x) to the connection point X54 (KCU02) and connected to the equipment grounding system of the installation via KCU02. Bosch Rexroth AG R911335703_Edition 04...
Page 193 Thread M5 (for ring cable lug) Unit min. max. Tightening torque Cable cross section stranded wire Tab. 6-32: Second connection point of equipment grounding conductor, proper‐ ties R911335703_Edition 04 Bosch Rexroth AG...
Page 194: Kms02 Connection Points
Communication output coupling ● X118, X119: External communication X141 Safety technology (optional) X156 Motor KMS02.1B-xxxx-x-xx-xx- ENA-xx-xx-xx: Motor, motor encoder KMS02.1B-xxxx-x-xx-xx-xxx- xx-WN/WT/WE-xx: Angular connector Second connection point of equipment grounding conductor Tab. 6-33: KMS02 connection points Bosch Rexroth AG R911335703_Edition 04...
Page 195: X37, X38, Digital Inputs/Outputs
X37, X38, digital inputs/outputs See description KSM02 (chapter 6.3.2 "X37, X38, digital inputs/outputs" on page 159). 6.4.3 X103.1, X103.2, hybrid cable connection point See description KSM02 (chapter 6.3.3 "X103.1, X103.2, hybrid cable connection point" on page 163). R911335703_Edition 04 Bosch Rexroth AG...
Page 196: X104, Motor Encoder Connection
6.3.5 "X108, X109, communication output coupling" on page 6.4.7 X118, X119, external communication chapter 6.3.6 "X118, X119, external communication" on page 170. 6.4.8 X141, safety technology chapter 6.3.7 "X141, safety technology and service input release brake" on page 173. Bosch Rexroth AG R911335703_Edition 04...
Page 197: X156, Motor Connection
Output for controlling the motor holding brake (X156.7/8) Output current (A) 0.15 Continuous power overvoltage protection (B) n.s. Energy absorption (B) n.s. Cable RKL4305 Allowed length n.s. With deactivated brake current monitoring: 0 A Tab. 6-35: X156, motor R911335703_Edition 04 Bosch Rexroth AG...
Page 198: X156, Motor/Motor Encoder Connection (Single-Cable Connection)
Output for controlling the motor holding brake (X156.4/5) Output current (A) 0.15 Continuous power overvoltage protection (B) n.s. Energy absorption (B) n.s. Cable RH2-030DB Allowed length n.s. With deactivated brake current monitoring: 0 A Tab. 6-36: X156, motor/motor encoder (single-cable connection) Bosch Rexroth AG R911335703_Edition 04...
Page 199: Second Equipment Grounding Conductor Connection Point
IndraDrive Mi Drive Systems with KCU02, KSM02, 185/407 KMS02/03, KMV03, KNK03, KLC03 Connection points 6.4.11 Second equipment grounding conductor connection point chapter 6.3.8 "Second connection point of equipment grounding conductor" on page 178 R911335703_Edition 04 Bosch Rexroth AG...
Page 200: Kms03 Connection Points
● X108, X109: Communication output coupling ● X118, X119: External communication X141 Safety technology (optional) Motor Brake/temperature Motor encoder, digital Motor encoder, analog Second connection point of equipment grounding conductor Tab. 6-37: KMS03 connection points Bosch Rexroth AG R911335703_Edition 04...
Page 201: Motor Cable And Encoder Cable Connection
IndraDrive Mi Drive Systems with KCU02, KSM02, 187/407 KMS02/03, KMV03, KNK03, KLC03 Connection points 6.5.2 Motor cable and encoder cable connection Condition as supplied Connection cover Protective covering Screws (M4, 2.5 Nm) Fig. 6-14: Connection cover with protective covering R911335703_Edition 04 Bosch Rexroth AG...
Page 202: Connection Cover: Mounting Options
KMS02/03, KMV03, KNK03, KLC03 Connection points Connection cover: Mounting options Cable outlet toward the housing Cable outlet away from the housing Fig. 6-15: Connection cover: Mounting options Two-piece connection cover chapter 14.3 "Two-piece connection cover" on page 374. Bosch Rexroth AG R911335703_Edition 04...
Page 203: Connecting The Cables
4. Put encoder cable connector (RGS0725) through small opening and plug connector (XG4, XG8) into device. 5. Screw on cable plate at connection cover with 2.5 Nm. 6. Screw on connection cover with 2.5 Nm. R911335703_Edition 04 Bosch Rexroth AG...
Page 204 190/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Connection points Motor Brake/temperature Motor encoder, digital Motor encoder, analog Cable plate Fig. 6-16: Motor cable and encoder cable Bosch Rexroth AG R911335703_Edition 04...
Page 205: Xd3, Motor Connection
Tab. 6-40: Electrical data Cables Description Value Order type See description of connectors: RLS0725 RHS0725 Maximum allowed length 7.5 m (Maximum allowed length of all motor cables when using KNK03/KMV03: 50 m) Tab. 6-41: Cables R911335703_Edition 04 Bosch Rexroth AG...
Page 206: Xg3, Motor Temperature Monitoring And Motor Holding Brake
24 V supply to the output for controlling the motor holding brake. View Connection Signal name Function MotTemp+ Motor temperature evaluation input MotTemp- +24VBr Output for controlling the motor holding brake 0VBr Tab. 6-42: Pin assignment Bosch Rexroth AG R911335703_Edition 04...
Page 207 XG3. Make sure to comply with the required minimum current consumption of 100 mA when using an external contact element. Otherwise, the brake current monitor will signal an error. R911335703_Edition 04 Bosch Rexroth AG...
Page 208 194/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Connection points Connection diagram Fig. 6-17: Connection of motor temperature monitoring and motor holding brake Bosch Rexroth AG R911335703_Edition 04...
Page 209: Xg4, Digital Motor Encoder Connection
Tab. 6-47: Mechanical data Cables Description Value Order type See description of connectors: RGS0725 RHS0725 Maximum allowed length 7.5 m (Maximum allowed length of all encoder cables when using KNK03/ KMV03: 50 m) Tab. 6-48: Cables R911335703_Edition 04 Bosch Rexroth AG...
Page 210: Xg8, Analog Motor Encoder Connection
Tab. 6-50: Mechanical data Cables Description Value See description of connectors: Order type RGS0725 7.5 m Maximum allowed length (Maximum allowed length of all encoder cables when using KNK03/ KMV03: 50 m) Tab. 6-51: Cables Bosch Rexroth AG R911335703_Edition 04...
Page 211: X37, X38, Digital Inputs/Outputs
X141, safety technology chapter 6.3.7 "X141, safety technology and service input release brake" on page 173. 6.5.13 Second equipment grounding conductor connection point chapter 6.3.8 "Second connection point of equipment grounding conductor" on page 178. R911335703_Edition 04 Bosch Rexroth AG...
Page 212: Kmv03 Connection Points
Mains contactor control and XG34 feedback contacts (KNK03) Second connection point of equipment grounding conductor RKH0800 cable connects KMV to KNK RKH0801 cable connects KMV to KNK RKB0054 cable Tab. 6-52: KMV03 connection points Bosch Rexroth AG R911335703_Edition 04...
Page 213: X37, X38, Digital Inputs/Outputs
6.6.3 X103.1, X103.2, hybrid cable connection point See description KSM02 (chapter 6.3.3 "X103.1, X103.2, hybrid cable connection point" on page 163). 6.6.4 X118, X119, external communication chapter 6.3.6 "X118, X119, external communication" on page 170 R911335703_Edition 04 Bosch Rexroth AG...
Page 214: X141, Safety Technology (Kmv03)
14.1.2 "Digital inputs (safety technology L options)" on page 369 Channel 2 selection SI_Ch2 Tab. 6-54: Technical data 6.6.6 Second equipment grounding conductor connection point chapter 6.3.8 "Second connection point of equipment grounding conductor" on page 178 Bosch Rexroth AG R911335703_Edition 04...
Page 215: Xd1, Mains Voltage
Occurring current load and minimum required See technical data (I and A L_cont L_max connection cross section Occurring voltage load See technical data (U Tab. 6-57: Electrical data Cables Description Value Order type RKH0800 Maximum allowed length Tab. 6-58: Cables R911335703_Edition 04 Bosch Rexroth AG...
Page 216: Xd10, Control Voltage
Value Order type Cable cannot be ordered. Customer assembles the cable (HAS05.1-020 accessories required). Tab. 6-61: Cables 6.6.9 XD13, fan power supply Connection point for RKB0054 cable. chapter 10.17 "RKB0054, fan cable" on page 330. Bosch Rexroth AG R911335703_Edition 04...
Page 217: Xg3, Mains Choke Temperature Contact
XG3.1/2) Tab. 6-62: Pin assignment Mechanical data Spring terminal (connector) Unit max. Connection cable Stranded wire Stripped length Tab. 6-63: Mechanical data Cables Description Value Order type RKH0801 Maximum allowed length Tab. 6-64: Cables R911335703_Edition 04 Bosch Rexroth AG...
Page 218: Xg14, Mains Voltage Synchronization
Tab. 6-65: Pin assignment Mechanical data Screw terminal (connector) Unit max. Connection cable Stranded wire Stripped length Tightening torque Tab. 6-66: Mechanical data Cables Description Value Order type RKH0801 Maximum allowed length Tab. 6-67: Cables Bosch Rexroth AG R911335703_Edition 04...
Page 219: Xg34, Mains Contactor Control And Feedback Contacts (Knk03)
Connection to mains filter (XG34.3/4) Tab. 6-68: Pin assignment Mechanical data Spring terminal (connector) Unit max. Connection cable Stranded wire Stripped length Tab. 6-69: Mechanical data Cables Description Value Order type RKH0800 Maximum allowed length Tab. 6-70: Cables R911335703_Edition 04 Bosch Rexroth AG...
Page 220: Connection Cover: Mounting Options
KMS02/03, KMV03, KNK03, KLC03 Connection points 6.6.13 Connection cover: Mounting options Fig. 6-18: Connection cover: Mounting options Tightening torque of the mounting screws: 2.5 Nm 6.6.14 Two-piece connection cover chapter 14.3 "Two-piece connection cover" on page 374. Bosch Rexroth AG R911335703_Edition 04...
Page 221: Knk03 Connection Points
KMV to KNK RKH0801 cable connects KMV to KNK RKB0054 cable Tab. 6-71: KNK03 connection points 6.7.2 Second equipment grounding conductor connection point chapter 6.3.8 "Second connection point of equipment grounding conductor" on page 178 R911335703_Edition 04 Bosch Rexroth AG...
Page 222: Xd1, Mains Voltage
L_cont L_max connection cross section Occurring voltage load See technical data (U Tab. 6-74: Electrical data Cables Description Value Order type Cable cannot be ordered. Customer assembles the cable (HAS05.1-019 accessories required). Tab. 6-75: Cables Bosch Rexroth AG R911335703_Edition 04...
Page 223: Xd1.2, Supply Unit
See technical data (U Tab. 6-78: Electrical data Cables Description Value Order type RKH0800 Maximum allowed length Tab. 6-79: Cables 6.7.5 XD13, fan power supply Connection point for RKB0054 cable. chapter 10.17 "RKB0054, fan cable" on page 330. R911335703_Edition 04 Bosch Rexroth AG...
Page 224: Xg14, Mains Voltage Synchronization
Stripped length Tightening torque Tab. 6-81: Mechanical data Electrical data Screw terminal (connector) Unit Value Nominal current Rated voltage 1000 Tab. 6-82: Electrical data Cables Description Value Order type RKH0801 Maximum allowed length Tab. 6-83: Cables Bosch Rexroth AG R911335703_Edition 04...
Page 225: Xg3, Mains Choke Temperature Contact
Stranded wire Stripped length Tab. 6-85: Mechanical data Electrical data Screw terminal (connector) Unit Value Nominal current Nominal voltage Tab. 6-86: Electrical data Cables Description Value Order type RKH0801 Maximum allowed length Tab. 6-87: Cables R911335703_Edition 04 Bosch Rexroth AG...
Page 226: Xg34, Mains Contactor Control And Feedback Contacts
Stranded wire Stripped length Tab. 6-89: Mechanical data Electrical data Screw terminal (connector) Unit Value Nominal current Rated voltage Tab. 6-90: Electrical data Cables Description Value Order type RKH0800 Maximum allowed length Tab. 6-91: Cables Bosch Rexroth AG R911335703_Edition 04...
Page 227: Connection Cover: Mounting Options
KMS02/03, KMV03, KNK03, KLC03 Connection points 6.7.9 Connection cover: Mounting options Fig. 6-19: Connection cover: Mounting options Tightening torque of the mounting screws: 2.5 Nm 6.7.10 Two-piece connection cover chapter 14.3 "Two-piece connection cover" on page 374. R911335703_Edition 04 Bosch Rexroth AG...
Page 228: Klc03 Connection Points
Second equipment grounding conductor connection point chapter 6.3.8 "Second connection point of equipment grounding conductor" on page 178 6.8.3 XD13, fan power supply Connection point for RKB0054 cable. chapter 10.17 "RKB0054, fan cable" on page 330. Bosch Rexroth AG R911335703_Edition 04...
Page 229: X54.1, X54.2; Dc Bus
Occurring voltage load See technical data (U Tab. 6-95: Electrical data Cables Description Value Order type RKH0802 (KMV03 ↔ KLC03) RKH0803 (KLC03 ↔ KLC03) Maximum allowed length tbd m Tab. 6-96: Cables R911335703_Edition 04 Bosch Rexroth AG...
Page 230: Connection Cover: Mounting Options
IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Connection points 6.8.5 Connection cover: Mounting options chapter 6.7.9 "Connection cover: Mounting options" on page 213. 6.8.6 Two-piece connection cover chapter 14.3 "Two-piece connection cover" on page 374. Bosch Rexroth AG R911335703_Edition 04...
Page 231: Notes On Project Planning
DC_max(HMV, HCS) Fig. 7-2: Peak power of supply unit Notes on project planning with The HCS02.1E-W0054 and -W0070 types are allowed as supply units for HCS02 as supply unit for KCU02 KCU02 and KSM02/KMS02. and KSM/KMS R911335703_Edition 04 Bosch Rexroth AG...
Page 232: Power Supply By Hcs01
Power supply by KMV03 and KNK03 KMV03 supply unit, KNK03 mains filter KMV03 supply units can be used together with KNK03 mains filters to supply power to KSM0x motor-integrated servo drives or KMS0x near motor servo drives. Bosch Rexroth AG R911335703_Edition 04...
Page 233: Control Voltage Power Requirement 42 V
See specification of motor holding brake of the connected motor Tab. 7-1: Control voltage power requirement Control voltage power requirement N3_42V Basic S3/SD of one component Control voltage power requirement = ΣP total N3_42V of multiple components of a drive line R911335703_Edition 04 Bosch Rexroth AG...
Page 234: Kcu02 Drive Connection Box
X53 should not exceed the value of P (see technical data of KCU). In operation under rated conditions, the sum of P and P is generated Diss_cont at the "control voltage supply +24V, 0V" input of KCU as load for the 24V Bosch Rexroth AG R911335703_Edition 04...
Page 235 ≤ 288 W N3(KCU) Inrush current I = 10 A N3_EIN ● 288 W < P N3(KCU) Inrush current I N3_EIN N3(KCU) The holding brakes integrated in KSM have no effect on the inrush current of KCU. R911335703_Edition 04 Bosch Rexroth AG...
Page 236: Power Supply To Ksm/Kms (Kcu)
, it is allowed to use the actually occurring LN_nenn continuous power of the KSM/KMS. Taking the average speed and simultaneity factor into account, the sum of the installed rated motor powers therefore can be significantly higher with servo operation. Bosch Rexroth AG R911335703_Edition 04...
Page 237 KSM/KMS. Observe the following diagrams and the sections ● "Peak power when accelerating" on page 224 ● " Peak Power when Decelerating" on page 225 DC 500 V DC 565 V R911335703_Edition 04 Bosch Rexroth AG...
Page 238 With 18 kW, a maximum speed of ● With 32 kW, a maximum speed of approx. 90% of the corner speed approx. 90% of the corner speed can be reached. can be reached in motive form. Tab. 7-3: Examples Bosch Rexroth AG R911335703_Edition 04...
Page 239 80 m, due to the voltage limitation taking effect in KSM/KMS. The critical case is when all motors decelerate at the same time with peak torque out of maximum speed (e.g., in the case of E‑Stop). R911335703_Edition 04 Bosch Rexroth AG...
Page 240: Klc03 Dc Bus Capacitor Unit
(The DC bus power profile has to be available as an ASCII file with the time values and the corresponding power values.) ● Supply unit (selection list) ● Mains voltage (selection list) ● Voltage offset to the mains peak as safety reserve (it is necessary to enter a value) Bosch Rexroth AG R911335703_Edition 04...
Page 241: Hybrid Cable Length
Segment length with communication output coupling: seg_out_1 D1_X108 ↔ external component Segment length with communication output coupling: seg_out_2 [external component ↔ D1_X109] + [D1_X103.2 ↔ D2_X103.1] Flexible cable track length schlepp Fig. 7-11: Definition of the lengths R911335703_Edition 04 Bosch Rexroth AG...
Page 242 Tab. 7-4: Cable length limit values For routing in the flexible cable track, determine the "maximum allowed length in the flexible cable track" l within the maximum segment max_schlepp length l using the figure below. Bosch Rexroth AG R911335703_Edition 04...
Page 243 Technical justification of the specified lengths: Only within the specified lengths is it ensured that the properties of the Ethernet communication (attenuation, crosstalk) remain in the allowed range during the service life of the cable. R911335703_Edition 04 Bosch Rexroth AG...
Page 244: Length Of Hybrid Cable Without Communication
(e.g., KCU) to last KSM/KMS of a drive line For electric decoupling at rated current Segment length: Cable length between two KSM/KMS For thermal decoupling of the connection points at rated cur‐ rent Tab. 7-5: Cable length limit values Bosch Rexroth AG R911335703_Edition 04...
Page 245: Hybrid Cable Length Vs. Kcu Performance
After this, the servo drives are evenly distributed up to the end of the drive line. The figure below shows the maximum allowed hybrid cable length of a drive line depending on P = KCU output X53 load). R911335703_Edition 04 Bosch Rexroth AG...
Page 246 For exact calculations of the allowed hybrid cable lengths in limit cases, please contact our sales representative. The figure below shows P (KCU power consumption from 24V supply) N3(KCU) depending on P (KCU output X53 load). Bosch Rexroth AG R911335703_Edition 04...
Page 247 It is impossible to deduce thermal losses in the control cabinet from the difference between the power P and P . The N3(KCU) typical losses of KCU are approx. 40% less than the maximum calculated values. R911335703_Edition 04 Bosch Rexroth AG...
Page 248: Hybrid Cable Length Vs. Kmv03 Performance
After this, the servo drives are evenly distributed up to the end of the drive line. The figure below shows the maximum allowed hybrid cable length of a drive line depending on P = KMV output XD10 load). Bosch Rexroth AG R911335703_Edition 04...
Page 249 For exact calculations of the allowed hybrid cable lengths in limit cases, please contact our sales representative. The figure below shows P (KMV power consumption from 24V supply) N3(KMV) depending on P (KMV output XD10 load). R911335703_Edition 04 Bosch Rexroth AG...
Page 250 Servo drives evenly distributed at the end of the drive line Servo drives evenly distributed starting at 20% of the drive line KMV output XD10 load (without cable losses) Maximum KMV power consumption from 24V supply N3(KMV) Fig. 7-17: vs. P N3(KMV) Bosch Rexroth AG R911335703_Edition 04...
Page 251: Zone Setup
Cable for transmitting the safety-related signals S 1, S 2 Signals of the individual safety zones SI Zone 1, SI Zone 2 Safety zones X49, X141 Connection points of safety technology Fig. 7-18: Safety zones R911335703_Edition 04 Bosch Rexroth AG...
Page 252 Connection point of the safety zone beginner Tab. 7-6: Signal input Safety zone node When a KSM/KMS with optional safety technology is to be a safety zone node within a safety zone, X141 has to be equipped with the connector RBS0023. Bosch Rexroth AG R911335703_Edition 04...
Page 253 The subject of safety technology is very complex so that it is not explained in Documentation detail in this Project Planning Manual. For detailed information on safety technology, see the documentation "Rexroth IndraDrive Integrated Safety Technology as of MPx‑1x" (mat. no.: R911332634). R911335703_Edition 04 Bosch Rexroth AG...
Page 254: E-Stop Function
If a KSM/KMS/KMV has been configured as a safety zone beginner (X141.3 = n. c., P‑0‑0249 = 2) and no E‑Stop signal has been assigned to this KSM/KMS/KMV, the E‑Stop signal of the preceding safety zone is transmitted. Bosch Rexroth AG R911335703_Edition 04...
Page 255 Position of switch if X141 equipped with RBS0023 connector; P‑0‑0249 = 1 (zone node) Fig. 7-20: E‑Stop zone setup The E‑Stop zone setup is independent of whether a safety technology option L3 is available or not. R911335703_Edition 04 Bosch Rexroth AG...
Page 256: Motor Fan For Ksm02
Evaluating motor encoders at KMS KMS02 chapter 6.4.4 "X104, motor encoder connection" on page 182 KMS03 chapter 6.5.5 "XG4, digital motor encoder connection" on page 195 chapter 6.5.6 "XG8, analog motor encoder connection" on page 196 Bosch Rexroth AG R911335703_Edition 04...
Page 257: Length Of Motor Cables And Encoder Cables At Kms
T = 20 s; K = 2.0; f = 4 kHz Latest amendment: 2016-02-11* 1) 2) 3) 4) See UEL_P_e profile definition Tab. 7-7: KMS - Selecting standard motors 3 AC 400 V - exemplary profiles R911335703_Edition 04 Bosch Rexroth AG...
Page 258 Profile Explanation Performance profile "UEL_P_e" Characteristic of the selection of standard motors and servo drives. Tab. 7-8: Definition of Performance Profiles, Infeeding Supply Units and Con‐ verters Bosch Rexroth AG R911335703_Edition 04...
Page 259: Notes On Electrical Project Planning
H×10 + L See also documentation Parameter Description: ● "S‑0‑1040, Drive address of master communication" ● "S‑0‑1046, List of slave addresses in device" ● "P‑0‑4089.0.3, Device Address" Tab. 7-9: Setting the Drive Address at H and L R911335703_Edition 04 Bosch Rexroth AG...
Page 260: Ip Configuration
IP address be assigned automatically again, e.g. via the address selector switches. 7.2.3 Current limitation The current limitation makes sure that neither drive controller nor motor are damaged by overload, as long as the motor temperature remains below Bosch Rexroth AG R911335703_Edition 04...
Page 261: Motor Temperature
It is slightly higher than the housing temperature and should not exceed 100 °C. Operation under rated conditions causes temperature rise of 60 K. The product of the square of the current and the time results in a constant R911335703_Edition 04 Bosch Rexroth AG...
Page 262: Switching Frequency
Output shaft with key The optional key according to DIN 6885, sheet 1, edition 08‑1968, permits keyed transmission of torques with constant direction, with low requirements on the shaft-hub connection. Bosch Rexroth AG R911335703_Edition 04...
Page 263: Output Shaft With Shaft Sealing Ring
Rexroth does not provide any warranty for modified keys or motor shafts. Output shaft with shaft sealing ring The motors have been designed with radial shaft sealing rings according to DIN 3760 ‑ design A. R911335703_Edition 04 Bosch Rexroth AG...
Page 264: Bearings And Shaft Load
The design of the machine, the selected motor type and driving elements attached on the shaft side have to be adapted to one another to ensure that the specified load limits are not exceeded. Bosch Rexroth AG R911335703_Edition 04...
Page 265: Radial Load, Axial Load
In the exact calculation of the average speed according to the following example, the run-up and braking times are taken into account. R911335703_Edition 04 Bosch Rexroth AG...
Page 266: Bearing Service Life
Fig. 7-28: Calculating the bearing service life L10h if the allowed radial force is exceeded radial Under no circumstances may the actually acting radial force be higher than the maximum allowed radial force radial_act radial_max Bosch Rexroth AG R911335703_Edition 04...
Page 267: Holding Brakes
In normal operation, use the brake only in standstill and for performing the drive-integrated brake test. The holding brake is required for holding the axis when the machine is in a de-energized state. Observe the safety requirements for system design: R911335703_Edition 04 Bosch Rexroth AG...
Page 268: Sizing Holding Brakes
Do not use the holding brake as a service brake for moving axes. Sizing holding brakes The physical conditions of holding brakes require two states to be considered. In addition to normal operation, failures have to be considered. The effective braking torques are physically different: Bosch Rexroth AG R911335703_Edition 04...
Page 269: Mechanically Attaching Driving Elements
If redundant attachment cannot be avoided, it is absolutely necessary that you consult Rexroth. R911335703_Edition 04 Bosch Rexroth AG...
Page 270: Gearbox Attachment
Owing to thermal effects, the flange-side end of the output shaft may offset by up to 0.6 mm in relation to the motor housing. If helical driving pinions or bevel gear pinions directly attached to the output shaft are used, this change in position will lead to Bosch Rexroth AG R911335703_Edition 04...
Page 271 In such cases, you should therefore preferably use drive elements with their own bearings which are connected to the motor shaft via axially compensating couplings. R911335703_Edition 04 Bosch Rexroth AG...
Page 272 258/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Bosch Rexroth AG R911335703_Edition 04...
Page 273: Identification
System type plate Cable for communication (M12-D ↔ M12-D) ● RKB0044 Cable for communication (M12-D ↔ RJ-45) ● RKS0010 Interface cable (M12-A ↔ open ends) ● HAS10 Fixing clip for hybrid cables Tab. 8-2: Scope of supply R911335703_Edition 04 Bosch Rexroth AG...
Page 274: Kms03
8.1.5 KNK03 Standard Optional ● KNK03 ● HAS05.1-019 ● System type plate KNK03 mains voltage Tab. 8-5: Scope of supply 8.1.6 KLC03 Standard Optional ● KLC03 ● System type plate Tab. 8-6: Scope of supply Bosch Rexroth AG R911335703_Edition 04...
Page 275: Identifying And Checking The Delivered Components
IndraDrive Mi Drive Systems with KCU02, KSM02, 261/407 KMS02/03, KMV03, KNK03, KLC03 Identification Identifying and checking the delivered components 8.2.1 KSM type plate Arrangement Fig. 8-1: Type plate arrangement R911335703_Edition 04 Bosch Rexroth AG...
Page 276: Design
Rated power consumption control voltage input at U (UL) Rated control voltage input (UL) Parts number Production date Fig. 8-2: Type Plate KSM02 System type plate chapter 8.2.7 "System type plate (module of configured variants)" on page Bosch Rexroth AG R911335703_Edition 04...
Page 277: Kms02 Type Plate
IndraDrive Mi Drive Systems with KCU02, KSM02, 263/407 KMS02/03, KMV03, KNK03, KLC03 Identification 8.2.2 KMS02 type plate Arrangement Fig. 8-3: Type plate arrangement R911335703_Edition 04 Bosch Rexroth AG...
Page 278: Design
Rated power consumption control voltage input at U (UL) Rated control voltage input (UL) Parts number Production date Fig. 8-4: Type Plate KMS02 System type plate chapter 8.2.7 "System type plate (module of configured variants)" on page Bosch Rexroth AG R911335703_Edition 04...
Page 279: Kms03 Type Plate
IndraDrive Mi Drive Systems with KCU02, KSM02, 265/407 KMS02/03, KMV03, KNK03, KLC03 Identification 8.2.3 KMS03 type plate Arrangement Fig. 8-5: Type plate arrangement R911335703_Edition 04 Bosch Rexroth AG...
Page 280: Design
Rated power consumption control voltage input at U Rated control voltage input Material number Production date Fig. 8-6: KMS03 type plate System type plate chapter 8.2.7 "System type plate (module of configured variants)" on page Bosch Rexroth AG R911335703_Edition 04...
Page 281: Kmv03 Type Plate
IndraDrive Mi Drive Systems with KCU02, KSM02, 267/407 KMS02/03, KMV03, KNK03, KLC03 Identification 8.2.4 KMV03 type plate Arrangement Fig. 8-7: Type plate arrangement R911335703_Edition 04 Bosch Rexroth AG...
Page 282: Design
Allowed ambient temperature Cooling type Control current input Rated control voltage input Material number Production date Fig. 8-8: KMV03 type plate System type plate chapter 8.2.7 "System type plate (module of configured variants)" on page Bosch Rexroth AG R911335703_Edition 04...
Page 283: Knk03 Type Plate
IndraDrive Mi Drive Systems with KCU02, KSM02, 269/407 KMS02/03, KMV03, KNK03, KLC03 Identification 8.2.5 KNK03 type plate Arrangement Fig. 8-9: Type plate arrangement A second type plate is enclosed with the product. R911335703_Edition 04 Bosch Rexroth AG...
Page 284: Design
Hardware revision index Degree of protection in accordance with IEC 60529 Serial number Mass Rated input current Rated input voltage Company address Allowed ambient temperature Cooling type Material number Production date Fig. 8-10: KNK03 type plate Bosch Rexroth AG R911335703_Edition 04...
Page 285: Klc03 Type Plate
IndraDrive Mi Drive Systems with KCU02, KSM02, 271/407 KMS02/03, KMV03, KNK03, KLC03 Identification 8.2.6 KLC03 type plate Arrangement Fig. 8-11: Type plate arrangement A second type plate is enclosed with the product. R911335703_Edition 04 Bosch Rexroth AG...
Page 286: Design
Manufacturer code Hardware revision index Degree of protection in accordance with IEC 60529 Serial number Input current Input voltage Company address Allowed ambient temperature Cooling type Material number Production date Fig. 8-12: KLC03 type plate Bosch Rexroth AG R911335703_Edition 04...
Page 287: System Type Plate (Module Of Configured Variants)
Component A Component A material number Component B Component B material number Serial number, module of configured variants Material number, module of configured variants MAC address (Ethernet ID) Type designation Fig. 8-13: System type plate R911335703_Edition 04 Bosch Rexroth AG...
Page 288: Plates At Kcu02
Fig. 8-14: Arrangement of the plates Type plate design Device type Material number Serial number Bar code Country of manufacture Production week; example 13W47: year 2013, week 47 Hardware revision index Fig. 8-15: Type Plate Bosch Rexroth AG R911335703_Edition 04...
Page 289: Design Of Ul Performance Data Plate
IndraDrive Mi Drive Systems with KCU02, KSM02, 275/407 KMS02/03, KMV03, KNK03, KLC03 Identification Design of UL performance data plate Fig. 8-16: UL performance data plate R911335703_Edition 04 Bosch Rexroth AG...
Page 290 276/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Bosch Rexroth AG R911335703_Edition 04...
Page 291: Mounting And Installation
During transport and storage, the protective sleeves and covers must be attached to the device. ● Remove the protective sleeves just before mounting. ● Also use the protective sleeves if you return the goods. R911335703_Edition 04 Bosch Rexroth AG...
Page 292: System Overview
Optional: two connection points for connecting the communication (M12, 4-pin) Notes All connections have been designed as plug-in connectors. This ensures easy, quick and error-safe mounting and commissioning when using ready- made Rexroth connection cables. Bosch Rexroth AG R911335703_Edition 04...
Page 293: Cold Plate
IndraDrive Mi Drive Systems with KCU02, KSM02, 279/407 KMS02/03, KMV03, KNK03, KLC03 Mounting and installation 9.1.3 Cold plate Required cold plate properties: Description Unit Value Surface temperature °C ≤ 60 Flatness ≤ 0.1 Surface roughness Rz 6.3 Tab. 9-1: Cold plate R911335703_Edition 04 Bosch Rexroth AG...
Page 294: Ksm
Avoid jamming or getting stuck of the centering collar on the motor side. ● Avoid damage to the insertion fitting on the installation side. ● Check the stability and precision of the connection before you proceed. Bosch Rexroth AG R911335703_Edition 04...
Page 295: Mechanical Interfaces
X103.1 of the first KSM/KMS of a drive line. ● KSM/KMS have been equipped with two power connectors X103.1 and X103.2 which allow the hybrid cable to be looped through. Depending on the configuration, KSM/KMS is provided with a terminal connector at X103.2. R911335703_Edition 04 Bosch Rexroth AG...
Page 296: Kms
Devices of "A" or "W" cooling type: ● Thread: M6 ● Tightening torque: 6 Nm Cold plate Devices of cooling type "B" are mounted on a cold plate. Required cold plate properties: chapter 9.1.3 "Cold plate" on page 279. Bosch Rexroth AG R911335703_Edition 04...
Page 297: Kcu02
● At the first and last device in a line of interconnected devices, cutouts may not be removed from the outer side of the touch guard. Tab. 9-3: Cutouts at the touch guard R911335703_Edition 04 Bosch Rexroth AG...
Page 298 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Mounting and installation The touch guard is fixed to the device with a screw. Tightening torque: Max. 2.8 Nm Tab. 9-4: Touch guard at device Bosch Rexroth AG R911335703_Edition 04...
Page 299: Kcu02 Connection Diagram
IndraDrive Mi Drive Systems with KCU02, KSM02, 285/407 KMS02/03, KMV03, KNK03, KLC03 Mounting and installation 9.4.3 KCU02 connection diagram Optional Fig. 9-3: Connection Diagram KCU02 R911335703_Edition 04 Bosch Rexroth AG...
Page 300: Knk03, Kmv03, Klc03
● Before starting work, the appropriate measuring equipment must be used to check whether parts of the system are still under residual voltage (e.g. caused by capacitors, etc.). Wait to allow the system to discharge. Bosch Rexroth AG R911335703_Edition 04...
Page 301: Notes
5.9.1 "RKH hybrid cable incl. communication, technical data" on page 114. Ready-made hybrid cables have been coded in such a way that X103.1 and X103.2 cannot be interchanged when connecting the cables. R911335703_Edition 04 Bosch Rexroth AG...
Page 302: Electrical Interfaces
The additional components (DST, HNL, HNF …) contained in the figure are not absolutely necessary. As regards the detailed configuration of a drive system, see documentation "Rexroth IndraDrive Drive Systems with HMV01/02, HMS01/02, HMD01, HCS02/03". Bosch Rexroth AG R911335703_Edition 04...
Page 303: Hmv01 Used As Supply Unit
Terminal connector Communication cable Encoder cable (optional) Hybrid cable Motor cable (optional) Mains synchronization (only with regenerative HMVs) X103.1 Connection of RKH hybrid cable at first KSM Fig. 9-4: IndraDrive Mi drive system with HMV01 R911335703_Edition 04 Bosch Rexroth AG...
Page 304: Hcs02 Used As Supply Unit
Drive connection box Motor-integrated servo drive Servo motor 24V supply Terminal connector Communication cable Encoder cable Hybrid cable Motor cable X103.1 Connection of hybrid cable at first KSM Fig. 9-5: IndraDrive Mi drive system with HCS02 Bosch Rexroth AG R911335703_Edition 04...
Page 305: Hcs03 Used As Supply Unit
Drive connection box Motor-integrated servo drive Servo motor Terminal connector Communication cable Hybrid cable Encoder cable Motor cable 24V supply X103.1 Connection of hybrid cable at first KSM Fig. 9-6: IndraDrive Mi drive system with HCS03 R911335703_Edition 04 Bosch Rexroth AG...
Page 306: Hmv02 Used As Supply Unit
Terminal connector Communication cable Encoder cable (optional) Hybrid cable Motor cable (optional) Mains synchronization (only with regenerative HMVs) X103.1 Connection of RKH hybrid cable at first KSM Fig. 9-7: IndraDrive Mi drive system with HMV02 Bosch Rexroth AG R911335703_Edition 04...
Page 307: Hcs01.1E-W0054 Used As Supply Unit
Motor-integrated servo drive (alternative: KMS near mo‐ tor servo drive and motor) Servo motor Terminal connector Encoder cable Hybrid cable Motor cable X103.1 Connection of hybrid cable at first KSM Fig. 9-8: IndraDrive Mi system with HCS01.1E-W0054 R911335703_Edition 04 Bosch Rexroth AG...
Page 308: Kmv03 Used As Supply Unit
Mains filter with integrated mains choke and integrated mains contactor Terminal connector Encoder cable (optional) Hybrid cable Motor power cable X103.1 Connection of RKH hybrid cable at first KMS Fig. 9-9: IndraDrive Mi drive system with KNK03, KMV03, KMS03 Bosch Rexroth AG R911335703_Edition 04...
Page 309 Ready-made hybrid cable; connects KMV (XG3, XG14) to KNK (XG3, XG14) RKH0802 Ready-made hybrid cable; connects KMV (X103.1) to KLC (XG9) RKH0803 Ready-made hybrid cable; interconnects 2 KLC Fig. 9-10: Cables for IndraDrive Mi system with KMV03 as supply unit R911335703_Edition 04 Bosch Rexroth AG...
Page 310: Parallel Drive Lines
Hybrid cable connection Fig. 9-11: Parallel drive lines In the case of 2 drive lines (2 KCUs) and 2 unassigned communication interfaces at the higher-level control unit, both KCUs can be directly connected to the control unit. Bosch Rexroth AG R911335703_Edition 04...
Page 311: Fan Connection
Instead of 1 HMV + 2 KCU, it is possible to use 2 KMV for parallel drive lines. Fan connection Components of the "W" cooling type (forced cooling) need the RKB0054 cable (material number: R911378870) for the electrical connection of the fan. chapter 10.17 "RKB0054, fan cable" on page 330. R911335703_Edition 04 Bosch Rexroth AG...
Page 312 298/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Bosch Rexroth AG R911335703_Edition 04...
Page 313: Accessories
Ethernet network. Cable with open ends (M12‑A ↔ open) ● HAS05.1-021 Hybrid joint ● HAS05.1-023 HCS01 adapter ● HAS05.1-024 Passive 42 V supply unit ● Metallic flange for circular connectors Tab. 10-1: Accessories R911335703_Edition 04 Bosch Rexroth AG...
Page 314 KMV03, KNK03, KMS03, KLC03 ● HAS05.1-018 Dummy plate for KMS03 encoder connection ● HAS05.1-019 KNK03 mains voltage connection plate ● HAS05.1-020 KMV03 control voltage connection plate ● RKB0054 Fan cable Tab. 10-2: Accessories (KMV03, KNK03, KMS03, KLC03) Bosch Rexroth AG R911335703_Edition 04...
Page 315: Has01, Basic Accessory
Contact bars for connecting – the DC bus – the control voltage supply ● Joint bar for connecting equipment grounding conductors of KCU and neighboring device For a detailed description, see documentation "Rexroth IndraDrive Additional Components and Accessories". R911335703_Edition 04 Bosch Rexroth AG...
Page 316: Has02, Shield Connection
(12–18 mm or 19–30 mm). Fix the hybrid cable (3) to the corresponding support with a clip (2). Make sure that the shield (4) of the hybrid cable has good contact with the shielding plate (1). Bosch Rexroth AG R911335703_Edition 04...
Page 317: Has03, Control Cabinet Adapter
To connect the KCU drive connection box to an HMV01 or HCS03 device, you therefore have to use the HAS03.1-002 control cabinet adapter which compensates the different mounting depths. Fig. 10-2: HAS03 For a detailed description, see documentation "Rexroth IndraDrive Additional Components and Accessories". R911335703_Edition 04 Bosch Rexroth AG...
Page 318: Has05.1-018, Dummy Plate For Kms03 Encoder Connection
KMS02/03, KMV03, KNK03, KLC03 Accessories 10.5 HAS05.1-018, dummy plate for KMS03 encoder connection Material number: R911371165 Fig. 10-3: HAS05.1-018, dummy plate for KMS03 encoder connection The accessory contains the following parts: ● Plate incl. screws Bosch Rexroth AG R911335703_Edition 04...
Page 319: Has05.1-019, Knk03 Mains Voltage
Material number: R911372176 Fig. 10-4: HAS05.1-019, KNK03 mains voltage The accessory contains the following parts: ● Cable gland (plastic, M20, range: 6 … 12 mm) ● Plate incl. screws ● Connector (screw terminal) ● Coding pin R911335703_Edition 04 Bosch Rexroth AG...
Page 320: Has05.1-020, Kmv03 Control Voltage
HAS05.1-020, KMV03 control voltage Material number: R911372724 Fig. 10-5: HAS05.1-020, KMV03 control voltage The accessory contains the following parts: ● Cable gland (plastic, M20, range: 6 … 12 mm) ● Plate incl. screws ● Connector (screw terminal) Bosch Rexroth AG R911335703_Edition 04...
Page 321: Has05.1-021, Hybrid Joint
The accessory is a very short hybrid cable and connects two devices mounted side by side. ● Hybrid cable with communication ● Distance, connector center – connector center: 62 … 87 mm ● Degree of protection IP65 ● Material number: R911374654 R911335703_Edition 04 Bosch Rexroth AG...
Page 322: Has05.1-021-Ncn-Nn
(e.g., due to many motors with integrated holding brakes) ● Voltage drop on the control voltage lines in the hybrid cable has reached its allowed limit (e.g., due to long cables) Bosch Rexroth AG R911335703_Edition 04...
Page 323 42 V supply, max. 15 A M12 (4‑pin, T‑coded) female Unit min. max. Connection cable, stranded wire Cable cross section Connection cable e.g., PHOENIX CONTACT power cable - SAC-4P-M12MRT/ 10,0-PUR SH - 1424127 Tab. 10-3: Function, pin assignment, properties R911335703_Edition 04 Bosch Rexroth AG...
Page 324: Has05.1-023, Hcs01 Adapter
The minimum allowed top mounting clearance specified in the HCS01 dimensional drawings remains unchanged. For information on the HCS01 drive controller, please see the Project Planning Manual "Rexroth IndraDrive Cs Drive Systems with HCS01" (R911322210). Bosch Rexroth AG R911335703_Edition 04...
Page 325 Control voltage; 42 V power supply unit connection Suitable power supply units: ● PULS CPS20.361 (input voltage: AC 100 … 240 V) ● PULS QT20.361 (input voltage: AC 380 … 480 V) Tab. 10-4: Connection points R911335703_Edition 04 Bosch Rexroth AG...
Page 326 View Connec Function tion Control voltage negative pole Control voltage positive pole Tab. 10-5: Pin assignment Mechanical data Screw terminal (connector) Unit max. Connection cable Stranded wire Stripped length Tightening torque Tab. 10-6: Mechanical data Bosch Rexroth AG R911335703_Edition 04...
Page 327 Mechanical data X52.1; connection point View Connec Function tion ModBus+ ModBusGND SI_Ch2 SI_Ch1 nE-Stop Tab. 10-9: Pin assignment Mechanical data Spring terminal (connector) Unit max. Connection cable Stranded wire Stripped length Tab. 10-10: Mechanical data R911335703_Edition 04 Bosch Rexroth AG...
Page 328 314/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Accessories HAS05.1-023 product insert (page 1) Fig. 10-11: HAS05.1-023 product insert (page 1) Bosch Rexroth AG R911335703_Edition 04...
Page 329 IndraDrive Mi Drive Systems with KCU02, KSM02, 315/407 KMS02/03, KMV03, KNK03, KLC03 Accessories HAS05.1-023 product insert (page 2) Fig. 10-12: HAS05.1-023 product insert (page 2) R911335703_Edition 04 Bosch Rexroth AG...
Page 330: Has05.1-024, Passive 42 V Supply Unit
(e.g., due to long cables) The basic sizing criteria, like DC power or leakage capacitances, for the allowed length of the drive line and the number of axes also apply when the accessories are used. Bosch Rexroth AG R911335703_Edition 04...
Page 331: Properties
● Allowed current: 15 A ● Degree of protection: IP65 ● External power supply required (42 V , ±10%; e.g., PULS "CPS20.361" (100‑240 V, 480 W) or "QT20.361" (380‑480 V, 480 W) R911335703_Edition 04 Bosch Rexroth AG...
Page 332: Dimensions
Dimensions Mounting clearance (standard) More mounting clearance with HAS10 accessory (fixing clip for hybrid cable connectors). More mounting clearance is required to install the HAS10 accessory with a screwdriver. Drilling pattern Fig. 10-15: HAS05.1-024, dimensions Bosch Rexroth AG R911335703_Edition 04...
Page 333: Connection
Connection cable e.g., PHOENIX CONTACT power cable - SAC-4P-M12MRT/ 10,0-PUR SH - 1424127 Tab. 10-11: Function, pin assignment, properties X103.1, X103.2, hybrid cable connection point chapter 6.3.3 "X103.1, X103.2, hybrid cable connection point" on page 163 R911335703_Edition 04 Bosch Rexroth AG...
Page 334: Has10, Mechanical Mounting Parts
⑥ Other design: NN = None Device assignment "001" is only available with Other properties "001" and "002". Device assignment "002" is only available with Other properties "003" to "011". Tab. 10-12: HAS10, type code Bosch Rexroth AG R911335703_Edition 04...
Page 335: Use
Fixing clip with screw (tightening torque: 1.5 … 1.7 Nm) ● RKB0043 cable ● Cable tie The fixing clip increases the vibration resistance of the connected hybrid cable connectors. The RKB0043 cable is fixed to the fixing clip with 2 cable ties. R911335703_Edition 04 Bosch Rexroth AG...
Page 336: Scope Of Supply
322/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Accessories Fig. 10-17: HAS10.1-001-002-NN 10.11.3 Scope of supply Scope of supply Components of the accessory: see product insert Bosch Rexroth AG R911335703_Edition 04...
Page 337 IndraDrive Mi Drive Systems with KCU02, KSM02, 323/407 KMS02/03, KMV03, KNK03, KLC03 Accessories HAS10.1-001-001-NN product insert Fig. 10-18: HAS10.1-001-001-NN product insert R911335703_Edition 04 Bosch Rexroth AG...
Page 338 324/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Accessories HAS10.1-001-002-NN product insert Fig. 10-19: HAS10.1-001-002-NN product insert Bosch Rexroth AG R911335703_Edition 04...
Page 339: Rkb0021, Multi-Ethernet Cable
RKB0021/xxx,x (xxx,x = length in meters) R911389159 selected Example: 13.5 m ⇒ RKB0021/013,5 (max. 100 m) RKB0021/005,0 R911389205 Tab. 10-14: RKB0021 RKB0021 Plug-in connector bus Bulk cable Plug-in connector bus RJ‑45, 4-pin REB0400 RJ‑45, 4-pin Tab. 10-15: RKB0021 interconnection diagram R911335703_Edition 04 Bosch Rexroth AG...
Page 340: Rkb0013, Multi-Ethernet Cable
0.55 m RKB0013/00,55 R911317801 Tab. 10-16: RKB0013 RKB0013 Plug-in connector bus Bulk cable Plug-in connector bus RJ-45, 8-pin sercos III cable, 100-Base-T, CAT5E, shielded RJ-45, 8-pin Use instruction: only fixed lengths Tab. 10-17: RKB0013 interconnection diagram Bosch Rexroth AG R911335703_Edition 04...
Page 341: Rkb0033, Cable For Safety Technology
RKB0033 / 001,5 R911334865 10 m RKB0033 / 010,0 R911335718 Tab. 10-18: RKB0033 RKB0033 Plug-in connector Bulk cable Plug-in connector M12, 12-pin Bus cable Open ends Interconnection diagram Use instruction: only fixed lengths Tab. 10-19: RKB0033 parts R911335703_Edition 04 Bosch Rexroth AG...
Page 342: Rkb0043, Communication Cable
R911172134 selected Tab. 10-20: RKB0043 RKB0043 Plug-in connector Bulk cable Plug-in connector M12, 4-pin, male, Bus cable (REB400) M12, 4-pin, male, D‑coded D‑coded Interconnection diagram A: Coding groove; B: Coding nose Tab. 10-21: Parts RKB0043 Bosch Rexroth AG R911335703_Edition 04...
Page 343: Rkb0044, Communication Cable
RKB0044/xxx,x (xxx,x = length in meters) R911172135 selected Tab. 10-22: RKB0044 RKB0044 Plug-in connector Bulk cable Plug-in connector M12, 4-pin, male, Bus cable (REB400) RJ-45 D‑coded Interconnection diagram A: Coding groove; B: Coding nose Tab. 10-23: Parts RKB0044 R911335703_Edition 04 Bosch Rexroth AG...
Page 344: Rkb0054, Fan Cable
For devices of the "W" cooling type (forced cooling). Length that can be ordered, order code, material number Length Order code Material number To be freely RKB0054/xxx,x (xxx,x = length in meters) R911378870 selected Tab. 10-24: RKB0054 Bosch Rexroth AG R911335703_Edition 04...
Page 345: Rks0010, Interface Cable
Code, Material Number Length Order code Material number RKS0010 / 03,0 R911322843 Tab. 10-25: RKB0013 RKS0010 Plug-in connector Bulk cable Plug-in connector M12, A‑coded, shielded n.s. Open ends Interconnection diagram Tab. 10-26: Parts RKS0010 R911335703_Edition 04 Bosch Rexroth AG...
Page 346: Rbs0023, Connector For Safety Zone Node
KSM/KMS without optional safety technology can be operated within a safety zone without the connector RBS0023, because the signals are directly transmitted to the next safety zone node via X103.1 and X103.2. n. c. Tab. 10-28: Function, pin assignment, properties Bosch Rexroth AG R911335703_Edition 04...
Page 347: Rls0725, Kms03 Motor Power Cable Connector
M17, 1.0 mm : RL2-009CB-NN-xxx,x ● M23, 1.0 mm : RL2-029CB-NN-xxx,x ● M23, 1.5 mm : RL2-029DB-NN-xxx,x ● M40, 1.5 mm : RL2-049DB-NN-xxx,x ● M40, 2.5 mm : RL2-049EB-NN-xxx,x ● M58, 2.5 mm : RL2-069EB-NN-xxx,x R911335703_Edition 04 Bosch Rexroth AG...
Page 348: Rgs0725, Kms03 Encoder Cable Connector
334/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Accessories 10.21 RGS0725, KMS03 encoder cable connector Fig. 10-28: RGS0725/K02 Encoder cable: KMS03 ● RG2-003AAB-NN-xxx,x (digital encoder) ● RG2-003ABB-NN-xxx,x (analog encoder) Bosch Rexroth AG R911335703_Edition 04...
Page 349: Rhs0725, Kms03 Hybrid Motor Cable Connector
IndraDrive Mi Drive Systems with KCU02, KSM02, 335/407 KMS02/03, KMV03, KNK03, KLC03 Accessories 10.22 RHS0725, KMS03 hybrid motor cable connector Fig. 10-29: RHS0725/K02 Hybrid motor cable: MS2N ↔ KMS03 ● RH2-029DBB-NN-xxx,x R911335703_Edition 04 Bosch Rexroth AG...
Page 350: Rh2-030Db, Kms02 - Ms2N Hybrid Motor Cable
RH2-030DB, KMS02 - MS2N hybrid motor cable Line cross section ≥ 1.5 mm²; observe allowed cable length Line cross section ≥ 0.2 mm² Line cross section ≥ 0.75 mm² Fig. 10-30: RH2-030DB Hybrid motor cable: MS2N ↔ KMS02 ● RH2-030DBB-NN-xxx,x Bosch Rexroth AG R911335703_Edition 04...
Page 351: Metallic Flange For Circular Connectors
Clamping screw Housing, control cabinet wall Gasket Flange Mounted to front wall Mounted to back wall Tab. 10-29: Metallic flange for circular connectors Supply source Intercontec Produkt GmbH Metallic flange (hinged) with sealing ring: E0.222.02 R911335703_Edition 04 Bosch Rexroth AG...
Page 352: Netswitch Sercos Iii
III ring for drive system engineering. Drive system engineering is also possible via a connected control unit (MLC) or via a drive with an open sercos ring (can be connected at terminal connector RHS0014). Tab. 10-30: netSWITCH sercos III Bosch Rexroth AG R911335703_Edition 04...
Page 353: Commissioning, Operation, Diagnostics And Maintenance
WARNING! Lethal electric shock from live parts with more than 50 V! Never operate the KCU02 drive connection box without the touch guard mounted. See also chapter 9.4.2 "Touch guard" on page 283. Tab. 11-1: R911335703_Edition 04 Bosch Rexroth AG...
Page 354 340/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Commissioning, operation, diagnostics and maintenance Make sure that the ambient conditions described are complied with during operation. Bosch Rexroth AG R911335703_Edition 04...
Page 355: Diagnostic Functions
● ZKS (DC bus short circuit) ● Ab (drive ready for operation, power on) ● Bb (control section and power section ready for operation, mains voltage available) ● charg (DC bus charging active) R911335703_Edition 04 Bosch Rexroth AG...
Page 356 250 ms; the arrow marks the end of a cycle; abbreviations on the squares: GN = LED permanently lit green, RD = LED per‐ manently lit red, ‑‑ = LED is off Tab. 11-2: LED displays Bosch Rexroth AG R911335703_Edition 04...
Page 357: Kcu02 Diagnostic Display
DC bus voltage (L+; L-) too low Switch power on at supply unit DC Bus In Module bus not connected (if H54 Connect module bus (connection point X1) green) Green DC bus voltage (L+; L-) without None error (Ud), regular status R911335703_Edition 04 Bosch Rexroth AG...
Page 358 DC Bus Out Green DC bus (L+, L-) ready for power None output DC bus voltage (L+; L-) at output Check fuses F4, F5 and replace them, if X54 not okay necessary Tab. 11-3: KCU02 LED displays Bosch Rexroth AG R911335703_Edition 04...
Page 359: Ksm/Kms Diagnostic Display
If necessary, read exact status via "S‑0‑0095, yellow Diagnostic message" Switching command error (C01xx/C02xx) Firmware update running Do not interrupt the 24-V supply and do not unplug connectors while the firmware is being updated Loader active Drive command error (Cxxxx) R911335703_Edition 04 Bosch Rexroth AG...
Page 360: Diagnostic Display With Mpx-2X
A square in the illustrated flashing patterns corresponds to a time period of 250 ms. Tab. 11-4: LED Displays H14 Diagnostic display with MPx-2x tab. 11-2 "LED displays" on page 341. Bosch Rexroth AG R911335703_Edition 04...
Page 361: Led H25 H26
The significance of the network displays depends on the field bus system. LEDs provide general diagnostic information commissioning or troubleshooting in the scope of safety technology. These pieces of status information do not provide any safety- relevant information in terms of functional safety. R911335703_Edition 04 Bosch Rexroth AG...
Page 362: Led H25, Displays
GN = LED permanently lit green, RD = LED per‐ manently lit red, -- = LED is off TUNID = Target Unique Network Identifier The LED display is only active with safety bus communication via the master communication Tab. 11-5: LED display Bosch Rexroth AG R911335703_Edition 04...
Page 363: Led H26, Displays
The "Duplicate-IP-Adress-Check" showed that the IP address which was set already exists in the network. Permanently lit red The device is running up and carries out a self test. Flashing red-green Tab. 11-6: Diagnostic LED R911335703_Edition 04 Bosch Rexroth AG...
Page 364 200 ms; the arrow marks the end of a cycle; abbreviations on the squares: GN = LED permanently lit green, RD = LED per‐ manently lit red, -- = LED is off Tab. 11-7: Diagnostic LED Bosch Rexroth AG R911335703_Edition 04...
Page 365 Flashing orange-green Transition from Fast forward to Loopback Flashing green Application error (sub-device/device error [C1D]) Flashing red-orange MST warning (S‑0‑1045, Sercos: Device Status [S‑Dev], bit15) Flashing red-green Communication error (sub-device/device error [C1D]) Permanently lit red R911335703_Edition 04 Bosch Rexroth AG...
Page 366 RD = LED permanently lit red, ‑‑ = LED is off Display priority (1 = highest priority); the state of the highest priority is displayed NRT = None Real Time MST = Master synchronization telegram Tab. 11-8: Diagnostic LED Bosch Rexroth AG R911335703_Edition 04...
Page 367 The "Duplicate-IP-Adress-Check" showed that the IP address which was set already exists in the network. Permanently lit red The device is running up and carries out a self test. Flashing red-green Tab. 11-9: Diagnostic LED R911335703_Edition 04 Bosch Rexroth AG...
Page 368: Diagnostic Messages Via Parameters
"Rexroth IndraWorks D" commissioning software. For easy startup, the digital inputs have been preset as follows: ● E1 (X37.4): +24 V to activate positive direction of rotation ● E2 (X37.2): +24 V to activate negative direction of rotation Bosch Rexroth AG R911335703_Edition 04...
Page 369: Analog Outputs
The monitoring function provides extended diagnostic possibilities. See Functional Description of firmware → "Monitoring function". Logbook function With the logbook function you can reproduce the internal firmware sequence. See Functional Description of firmware → "Logbook function". R911335703_Edition 04 Bosch Rexroth AG...
Page 370: Service Functions/Troubleshooting
Check whether voltage has fallen below 50 V before touching live parts! The following section explains the tasks required to eliminate errors or malfunction. We distinguish the following actions: ● Replacing fuses F4 and F5 ● Deactivation ● Dismounting ● Replacing the component Bosch Rexroth AG R911335703_Edition 04...
Page 371: Replacing Fuses F4 And F5
Note: Always replace both fuses, even if only one of them is defective. The intact fuse probably was already damaged, 5. Insert new fuses (material number: R911319963) FWP-30A14Fa by BUSSMANN. 6. Close fuse carriers F4 and F5. R911335703_Edition 04 Bosch Rexroth AG...
Page 372: Deactivating And Dismounting The Drive
"deactivation". 3. Before dismounting them, secure the motor and the supply lines unit against falling or movements, before unfastening the mechanical connections. 4. Dismount the motor from the machine. 5. Store the motor appropriately. Bosch Rexroth AG R911335703_Edition 04...
Page 373: Replacing The Component
"release" the integrated holding brake: ● A voltage of 30 … 46 V has to be applied at X103.1 (pins 11 and 12). ● Short-circuit pin 3 with pin 9 at X141. R911335703_Edition 04 Bosch Rexroth AG...
Page 374: Saving Parameters
The programming module contains the firmware and parameters so that the drive can be easily programmed during commissioning. Use the "Rexroth IndraWorks D" software to configure the data transfer from the programming module after the control voltage has been switched on. Bosch Rexroth AG R911335703_Edition 04...
Page 375: Maintenance
Do not repair any connection cables provisionally. If the slightest damage is detected in the cable sheath, you must immediately put the installation out of operation and replace the connection cable. Check the equipment grounding conductor for proper connection and tight fit in regular intervals. R911335703_Edition 04 Bosch Rexroth AG...
Page 376: Holding Brake - Commissioning And Maintenance Instructions
Resurfacing routine by superior control. Here, special control programs adapted to the machine and system concepts are required. If necessary, please contact your Bosch Rexroth distribution partner and discuss the resurfacing routine parameters for your application. Bosch Rexroth AG R911335703_Edition 04...
Page 377: Maintenance Of The Electronic System Of The Drive
Do not work at hot surfaces. In regular intervals (at the latest, after one year is over), check the heat sink of the electronic system of the drive for accumulated dirt (e.g. dust deposits). Remove accumulated dirt. R911335703_Edition 04 Bosch Rexroth AG...
Page 378 364/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Bosch Rexroth AG R911335703_Edition 04...
Page 379: Environmental Protection And Disposal
Batteries and accumulators can contain hazardous substances which can harm the environment or people's health when improperly stored or disposed After use, the batteries or accumulators contained in Rexroth products must be properly disposed of according to the country-specific collection systems. R911335703_Edition 04 Bosch Rexroth AG...
Page 380 Plastic parts of the products may contain flame retardants. These plastic parts are labeled according to EN ISO 1043. They have to be recycled separately or disposed of according to the applicable legal provisions. Bosch Rexroth AG R911335703_Edition 04...
Page 381: Service And Support
Detailed description of malfunction and circumstances ● Type plate specifications of the affected products, in particular type codes and serial numbers ● Your contact data (phone and fax number as well as your e-mail address) R911335703_Edition 04 Bosch Rexroth AG...
Page 382 368/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Bosch Rexroth AG R911335703_Edition 04...
Page 383: Appendix
Unit Min. Max. Allowed input voltage High Current consumption For KCU02, the specified values must be multiplied with the number of zone nodes of the drive line. Tab. 14-2: Digital inputs (safety technology L options) R911335703_Edition 04 Bosch Rexroth AG...
Page 384: Digital Inputs (Safety Technology S Options)
Digital inputs (safety technology S options) Time behavior Description Unit min. max. Test pulse width (t µs 1000 Percentage of High time (T ×100%) Phase shift between two test pulses on both channels (φ) Tab. 14-4: Time behavior Bosch Rexroth AG R911335703_Edition 04...
Page 385: Digital Outputs
Output voltage OFF Output current ON Allowed energy content of connected inductive loads, e.g. relay coils; only allowed as single pulse Short circuit protection Available Overload protection Available Tab. 14-5: Digital outputs (safety technology L options) R911335703_Edition 04 Bosch Rexroth AG...
Page 386: Digital Outputs (Safety Technology S Options)
In the case of inductive loads with currents > 200 mA or in the case of inductive loads with a greater energy content, an exter‐ nal free-wheeling arm has to be installed. The effective termi‐ nal voltage has to be < 25 V. Tab. 14-6: Digital outputs Bosch Rexroth AG R911335703_Edition 04...
Page 387 373/407 KMS02/03, KMV03, KNK03, KLC03 Appendix Time behavior Description Unit min. max. Test pulse width (t μs Periodic time (T 1000 Phase shift between two test pulses on both channels (φ) Tab. 14-7: Time behavior R911335703_Edition 04 Bosch Rexroth AG...
Page 388: Two-Piece Connection Cover
More recent devices have a two-piece connection cover. Advantages ● Improved handling for plugging in and removing the connectors ● Easy access to the connection points (e.g., for measurements) Tightening torque of screws: 2.5 Nm Fig. 14-4: Two-piece connection cover Bosch Rexroth AG R911335703_Edition 04...
Page 389: Sizing Mains Filters (Drive System)
An Excel-based tool is available for sizing mains filters. If required, please sales representative ("FAQ_EMC_mains_filter_application_tool_EN"). Drive system In the drive system described below, the components IndraDrive M (HMS, HMD) or IndraDrive C/Cs (HCS) are operated together with IndraDrive Mi (KCU, KSM, KMS) components. R911335703_Edition 04 Bosch Rexroth AG...
Page 390 376/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Appendix Y-capacitance Leakage capacitance leak Hybrid cable damping factor Fig. 14-5: Drive system Bosch Rexroth AG R911335703_Edition 04...
Page 391 Mains filter: Limit values + k × [C Y_sum Y_sum Y_KCU Y_Hxx Y_KMS Y_KSM Y_sum Y_KCU HMS/HMD or HCS sum Y_Hxx KMS sum Y_KMS KSM sum Y_KSM k: Hybrid cable damping factor Tab. 14-10: Y_sum R911335703_Edition 04 Bosch Rexroth AG...
Page 392 : Sum of leakage capacitance, KSM leak_motor_KSM Tab. 14-12: leak_sum IndraDrive Mi capacitances Component [nF] [nF] leak_motor_KSM KSM02.1B-041C-42 KSM02.1B-061C-35 KSM02.1B-061C-61 KSM02.1B-071C-24 KSM02.1B-071C-35 KSM02.1B-076C-35 KMS02.1B-A018 KMS03.1B-A036 KMS03.1B-B036 KCU02.1N KCU02.2N KMV03 Tab. 14-13: IndraDrive Mi capacitances Bosch Rexroth AG R911335703_Edition 04...
Page 393 HCS01.1E-W0018-A-03 HCS01.1E-W0028-A-03 HCS01.1E-W0054-A-03 HCS02.1E-W0012 HCS02.1E-W0028 HCS02.1E-W0054 HCS02.1E-W0070 HCS02.1E-W0100 HCS03.1E-W0070 HCS03.1E-W0150 HCS03.1E-W0210 HCS03.1E-W0280 HCS03.1E-W0350 Tab. 14-14: IndraDrive C/Cs capacitances IndraDrive M capacitances Component [nF] HMS01.1N-W0020 HMS01.1N-W0036 HMS01.1N-W0054 HMS01.1N-W0070 HMS01.1N-W0110 HMS01.1N-W0150 HMS01.1N-W0210 HMS01.1N-W0300 HMS01.1N-W0350 HMS01.2N-W0028 HMS01.2N-W0054 HMD01.1N-W0012 R911335703_Edition 04 Bosch Rexroth AG...
Page 394 REL0108 (4.0 mm REL0109 (6.0 mm REL0110 (10.0 mm REL0111 (16.0 mm REL0112 (25.0 mm REL0113 (35.0 mm REH0804 (1.5 mm Tab. 14-16: Cables, capacitances Motor, capacitances Motor [nF] leak_motor MAD100B-0050 MAD100B-0100 MAD100B-0150 MAD100B-0200 MAD100B-0250 Bosch Rexroth AG R911335703_Edition 04...
Page 395 19.3 MAD130C-0250 20.1 MAD130D-0050 27.5 MAD130D-0100 27.3 MAD130D-0150 30.5 MAD130D-0200 27.5 MAD130D-0250 26.4 MAD160B-0050 25.5 MAD160B-0100 35.0 MAD160B-0150 35.0 MAD160B-0200 34.4 MAD160C-0050 28.0 MAD160C-0100 24.4 MAD160C-0150 27.2 MAD160C-0200 32.3 MAD180C-0050 29.2 MAD180C-0100 25.2 MAD180C-0150 28.3 R911335703_Edition 04 Bosch Rexroth AG...
Page 396 MAF100D-0050 11.0 MAF100D-0100 11.2 MAF100D-0150 11.0 MAF100D-0200 10.0 MAF100D-0250 MAF130B-0050 16.0 MAF130B-0100 16.0 MAF130B-0150 16.0 MAF130B-0200 11.6 MAF130B-0250 13.2 MAF130C-0050 20.0 MAF130C-0100 15.4 MAF130C-0150 20.0 MAF130C-0200 16.8 MAF130C-0250 20.0 MAF130D-0050 27.5 MAF130D-0100 26.7 MAF130D-0150 27.5 Bosch Rexroth AG R911335703_Edition 04...
Page 397 MAF180C-0100 35.9 MAF180C-0150 30.0 MAF180C-0200 38.9 MAF180D-0050 37.4 MAF180D-0100 38.0 MAF180D-0150 30.3 MAF180D-0200 50.0 MAF225C-0050 40.0 MAF225C-0100 39.7 MAF225C-0150 43.9 MCP015A-L040 MCP015B-L040 MCP020B-V180 MCP020B-V720 MCP020C-V180 MCP020D-V720 MCP030B-V180 MCP030B-V390 MCP030C-V180 MCP030C-V390 MCP030D-V180 MCP030D-V390 MCP040A-V300 MCP040B-V070 MCP040B-V300 R911335703_Edition 04 Bosch Rexroth AG...
Page 398 MCP040C-V300 MCP040E-V070 MCP040E-V300 MCP040G-V070 MCP040G-V300 MCP070C-V050 MCP070C-V300 MCP070D-V050 MCP070D-V300 MCP070F-V050 MCP070F-V300 MCP070M-V050 MCP070M-V230 MLP040A-0300 MLP040B-0150 MLP040B-0250 MLP040B-0300 MLP052A-0300 MLP052B-0300 MLP070A-0150 MLP070A-0220 MLP070A-0300 MLP070B-0100 MLP070B-0120 MLP070B-0150 MLP070B-0250 MLP070B-0300 MLP070C-0120 MLP070C-0150 MLP070C-0240 MLP070C-0300 MLP100A-0090 MLP100A-0120 MLP100A-0150 MLP100A-0190 Bosch Rexroth AG R911335703_Edition 04...
Page 399 18.0 MLP152B-0060 20.0 MLP152C-0060 22.0 MLP152D-0060 23.7 MLP200A-0090 MLP200A-0120 MLP200B-0040 12.0 MLP200B-0120 12.0 MLP200C-0090 15.8 MLP200C-0120 15.9 MLP200C-0170 15.8 MLP200D-0060 19.2 MLP200D-0100 19.6 MLP200D-0120 19.6 MLP300A-0090 12.3 MLP300A-0120 12.3 MLP300B-0070 18.0 MLP300B-0120 18.0 MLP300C-0060 23.7 R911335703_Edition 04 Bosch Rexroth AG...
Page 400 MLP300Z-0090 ML3P03-A_BW ML3P03-B_BW ML3P03-D_BW ML3P03-F_BN ML3P03-F_BU ML3P06-B_BK ML3P06-B_BR ML3P06-C_BC ML3P06-C_BR ML3P06-D_BK ML3P06-D_BR ML3P06-E_BK ML3P06-E_BR ML3P06-F_BK ML3P06-F_BR ML3P06-H_BK ML3P06-H_BR ML3P11-D_BF ML3P11-D_BQ ML3P11-E_BC ML3P11-E_BQ ML3P11-L_BC ML3P11-L_BQ MSK030B-0900 MSK030C-0900 MSK040B-0450 MSK040B-0600 MSK040C-0450 MSK040C-0600 MSK050B-0300 MSK050B-0450 MSK050B-0600 MSK050C-0300 MSK050C-0450 Bosch Rexroth AG R911335703_Edition 04...
Page 401 MSK060B-0300 MSK060B-0600 MSK060C-0300 MSK060C-0600 MSK061B-0300 MSK061C-0200 MSK061C-0300 MSK061C-0600 MSK070C-0150 MSK070C-0300 MSK070C-0450 MSK070D-0150 MSK070D-0300 MSK070D-0450 MSK070E-0150 MSK070E-0300 MSK070E-0450 MSK071C-0200 MSK071C-0300 MSK071C-0450 MSK071D-0200 MSK071D-0300 MSK071D-0450 MSK071E-0200 MSK071E-0300 MSK071E-0450 MSK075C-0300 MSK075C-0450 MSK075D-0200 MSK075D-0300 MSK075D-0450 MSK075E-0200 MSK075E-0300 MSK076C-0300 MSK076C-0450 R911335703_Edition 04 Bosch Rexroth AG...
Page 402 MSK101D-0200 13.2 MSK101D-0300 MSK101D-0450 13.2 MSK101E-0200 15.2 MSK101E-0300 16.7 MSK101E-0450 16.7 MSK103A-0300 MSK103B-0300 MSK103D-0300 MSK131B-0200 14.3 MSK131D-0200 27.7 MSK133B-0202 14.4 MSK133B-0203 10.7 MSK133C-0202 15.2 MSK133C-0203 15.2 MSK133D-0202 16.4 MSK133D-0203 18.4 MSK133E-0202 24.3 MSK133E-0203 22.6 MSM019A-0300 Bosch Rexroth AG R911335703_Edition 04...
Page 403 MSS142F-0700 MSS162B-0400 MSS162D-0400 MSS162F-0310 MSS162J-0200 MSS182A-0100 MSS182A-0250 MSS182B-0280 MSS182D-0260 MSS182F-0200 MSS202A-0200 MSS202B-0150 MSS202B-0210 MSS202D-0170 MSS202F-0120 10.2 MSS242B-0100 MSS242D-0070 MSS242F-0060 14.4 MSS272B-0065 12.8 MSS272B-0080 MSS272D-0050 10.3 MSS272F-0040 20.5 MSS312B-0035 19.9 MSS312D-0028 24.9 MSS312D-0060 24.9 MSS312F-0028 29.8 R911335703_Edition 04 Bosch Rexroth AG...
Page 404 11.7 MST160E-0050 17.5 MST210A-0027 MST210C-0027 MST210C-0050 MST210D-0070 13.3 MST210E-0027 19.0 MST210R-0010 MST210E-0035 MST290B-0018 MST290D-0002 15.6 MST290D-0004 12.6 MST290D-0018 14.7 MST290E-0004 21.0 MST290E-0018 20.0 MST360B-0018 MST360D-0012 13.5 MST360D-0018 13.5 MST360D-0045 14.0 MST360E-0018 20.0 MST450B-0012 MST450D-0006 14.5 Bosch Rexroth AG R911335703_Edition 04...
Page 405 MST530G-0006 50.7 MST530G-0007 50.7 MST530G-0010 50.7 MST530L-0006 76.1 MST530L-0007 76.1 MS2C03-K0BYN MS2E03-B0BYN MS2E03-D0BYN MS2E04-B0BNN MS2E04-B0BTN MS2E04-C0BTN MS2E05-B0BTN MS2E05-C0BTN MS2E05-D0BRN MS2E06-C0BNN MS2E06-D0BNN MS2E06-D0BRN MS2E06-E0BRN MS2E07-C0BQN MS2E07-D0BNN MS2E07-D0BRN MS2E07-E0BNN MS2E07-B0BQN MS2N03-B0BYN MS2N03-D0BYN MS2N04-B0BNN MS2N04-B0BTN MS2N04-C0BNN MS2N04-C0BTN MS2N04-D0BHN R911335703_Edition 04 Bosch Rexroth AG...
Page 406 MS2N05-B0BNN MS2N05-BOBTN MS2N05-C0BNN MS2N05-C0BTN MS2N05-D0BHN MS2N05-D0BRN MS2N06-B1BNN MS2N06-C0BNN MS2N06-C0BTN MS2N06-D0BNN MS2N06-D1BNN MS2N06-D0BRN MS2N06-E0BHN MS2N06-E0BRN MS2N07-C0BQN MS2N07-C1BNN MS2N07-D0BHN MS2N07-D1BHN MS2N07-D0BRN MS2N07-D1BNN MS2N07-E0BHN MS2N07-E0BNN MS2N07-E0BQN MS2N07-E1BNN MS2N07-E1BHA MS2N07-D0BNN MS2N07-D1BHA MS2N07-D1BHB MS2N07-D1BNA MS2N07-D1BNB MS2N07-E0BNA MS2N07-E0BNB MS2N07-E0BQA MS2N07-E0BQB MS2N10-C0BHN Bosch Rexroth AG R911335703_Edition 04...
Page 407 KMS02/03, KMV03, KNK03, KLC03 Appendix Motor [nF] leak_motor MS2N10-C0BNN MS2N10-D0BHN MS2N10-D0BNN MS2N10-E0BNN MS2N10-E1BNN MS2N10-F0BHN MS2N10-C0BNA MS2N10-C0BNB MS2N10-D0BHA MS2N10-D0BHB MS2N10-D0BNA MS2N10-D0BNB MS2N10-D1BNA MS2N10-D1BNB MS2N10-E0BHA MS2N10-E0BHB MS2N10-E0BNA MS2N10-E0BNB MS2N10-E1BNA MS2N10-E1BNB MS2N10-F0BHA MS2N10-F0BHB MS2N10-F1BHA MS2N10-F1BHB Tab. 14-17: Motor, capacitances R911335703_Edition 04 Bosch Rexroth AG...
Page 408 394/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Bosch Rexroth AG R911335703_Edition 04...
Page 409: Index
IndraDrive Mi Drive Systems with KCU02, KSM02, 395/407 KMS02/03, KMV03, KNK03, KLC03 Index Index Symbols Ambient conditions..........50 Analog outputs..........355 +24V, 0V Approvals............45 Control voltage supply connection....156 ATEX KSM02, dimensions........74 0 … 9 Average speed..........251 24V supply Axial load............
Page 410 396/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Index Flange............337 KMS02............180 Hybrid cables..........127 KMS03............186 Cleaning............361 KMV03............198 Cold plate KNK03............207 Specification..........279 KSM02............158 Commissioning..........339 Contained substances Communication see "Significant components"...... 365 Address selector switch.......
Page 411 IndraDrive Mi Drive Systems with KCU02, KSM02, 397/407 KMS02/03, KMV03, KNK03, KLC03 Index KCU02............89 HAS05.1-018-NNN-NN........ 304 KLC03.1N-A04M7 (natural convection)..103 Duty cycle............63 KLC03.1N-B04M7 (thermal interface)..102 KLC03.1N-W04M7 (forced cooling)..... 104 KMS02............84 E-Stop KMS03............112 Function............240 KMV03 (forced cooling)......... 93 Input, X50.............
Page 412 398/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Index Safety requirements........253 Sizing............254 G1, G2, G3, G4, G5 Hotline............... 367 Mounting positions......... 58 Housing overtemperature........63 Gearbox attachment......... 256 Hybrid cables............7 Ground connection..........143 Between KCU and first KSM/KM....
Page 413 IndraDrive Mi Drive Systems with KCU02, KSM02, 399/407 KMS02/03, KMV03, KNK03, KLC03 Index RKH0800............. 138 Dimensional drawing........89 RKH0801............. 139 Dimensions............ 89 RKH0802............. 140 Hybrid cable length vs. performance... 231 RKH0803............. 140 KCU02.2 vs. KCU02.1........20 RKH0900..........127, 128 LEDs............343 RKH0901.............
Page 414 400/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Index Type code............17 KNK03.1A-NR-Axxxx dimensions (natu‐ Type plate............ 263 ral convection)..........107 KMS03 KNK03.1A-NR-B/Ixxxx dimensional draw‐ Connection points........186 ing (thermal interface)........106 Data sheet............ 109 KNK03.1A-NR-B/Ixxxx dimensions (ther‐ Dimensional drawing........
Page 415 IndraDrive Mi Drive Systems with KCU02, KSM02, 401/407 KMS02/03, KMV03, KNK03, KLC03 Index Mounting............277 Cold plate............. 279 L+, L-..............153 KCU02............283 KLC03............286 Safe Torque Off........... 148 KMS02............282 KMV03............286 H14 (KMV)........... 341 KNK03............286 H14 (KSM/KMS).......... 345 KSM02............
Page 416 402/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Index When decelerating........225 KMS03 hybrid motor cable connector..335 PELV..............40 RKB0013............146 Performance profile Cables............326 UEL_P_e............244 RKB0021............146 Pinions.............. 256 Cables............325 Power supply RKB0033 By HCS01............
Page 417 IndraDrive Mi Drive Systems with KCU02, KSM02, 403/407 KMS02/03, KMV03, KNK03, KLC03 Index RKH0421 Hybrid cables..........134 S3, SD RKH0441 Safe Motion..........176 Hybrid cables..........132 Safe Motion RKH0511 S3, SD............176 Hybrid cables..........123 X141............. 176 RKH0521 Safe Torque Off Hybrid cables..........
Page 418 404/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Index Status messages KMS03............19 X52............... 150 KMV03............21 Storing KNK03............22 Components........... 47 KSM02............14 Supply unit Type plate HCS02............217 KCU02............274 HCS03............217 KLC03............271 HMV01............
Page 419 IndraDrive Mi Drive Systems with KCU02, KSM02, 405/407 KMS02/03, KMV03, KNK03, KLC03 Index X107 Programming module........165 X108, X109 Communication output coupling....167 X118, X119 Communication, external......170 X141 KMV03, safety technology......200 Safe Motion safety technology ....176 Safety technology........173 Safety technology Safe Torque Off....
Page 420 406/407 IndraDrive Mi Drive Systems with KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03 Notes...
Page 421 IndraDrive Mi Drive Systems with KCU02, KSM02, 407/407 KMS02/03, KMV03, KNK03, KLC03 Notes...
Page 422 Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Phone +49 9352 18 0 Fax +49 9352 18 8400 www.boschrexroth.com/electrics *R911335703* R911335703 DOK-INDRV*-KCU02+KSM02-PR04-EN-P...

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Rexroth indradrive mi ksm02 Rexroth indradrive mi kms02 Rexroth indradrive mi kms03 Rexroth indradrive mi kmv03 Rexroth indradrive mi knk03 Rexroth indradrive mi klc03 ... Show all

Bosch rexroth IndraDrive Mi KCU02 Project Planning Manual

1 System Presentation

2 Important Directions for Use

3 Safety Instructions for Electric Drives and Controls

4 General Data and Specifications

5 Technical Data of the Components

6 Connection Points

7 Notes on Project Planning

8 Identification

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Summary of Contents for Bosch rexroth IndraDrive Mi KCU02