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Bosch Rexroth Diax 04 Instruction Manual
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Bosch Rexroth Diax 04 Instruction Manual

Hdd and hds drive controllers 2nd generation
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Electric Drives
and Controls
Hydraulics
Rexroth Diax 04
HDD and HDS
Drive Controllers 2nd Generation
Instruction Manual
Linear Motion and
Assembly Technologies
Pneumatics
Service
R911320338
Edition 01

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Summary of Contents for Bosch Rexroth Diax 04

  • Page 1 Electric Drives Linear Motion and and Controls Hydraulics Assembly Technologies Pneumatics Service Rexroth Diax 04 R911320338 Edition 01 HDD and HDS Drive Controllers 2nd Generation Instruction Manual...
  • Page 2 About this Documentation Rexroth Diax 04 HDD and HDS Rexroth Diax 04 Title HDD and HDS Drive Controllers 2nd Generation Instruction Manual Type of Documentation DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P Document Typecode 120-0800-B343-01/EN Internal File Reference This documentation provides information on the installation and operation...

  • Page 3: Table Of Contents

    Rexroth Diax 04 HDD and HDS Contents Contents Important Notes Safety Instructions ........................1-1 General Information......................... 1-1 Contact with Electrical Parts....................1-2 Handling and Assembly......................1-2 Dangerous Movements ......................1-2 Magnetic and Electromagnetic Fields ..................1-4 Hot Parts..........................1-4 Appropriate Use..........................1-4 Identification Type Codes ..........................
  • Page 4 Contents Rexroth Diax 04 HDD and HDS General Information on How to Install the Drive Controller ........... 5-15 Touch Guard at Devices......................5-16 Sizing of Enclosure and Control Cabinet................5-16 Appendix Discharging of DC Bus Capacitors ....................6-1 Discharging Device........................6-2...

  • Page 5: Important Notes

    • If these documentations contain some information you do not understand, it is absolutely necessary that you ask Bosch Rexroth for explanation before you start working on or with the devices.

  • Page 6: Contact With Electrical Parts

    Important Notes Rexroth Diax 04 HDD and HDS Contact with Electrical Parts High electrical voltage! Danger to life, electric shock and severe bodily injury! • Follow general construction and safety regulations when working on power installations. • Before switching on the device, the equipment grounding conductor must have been...
  • Page 7 Rexroth Diax 04 HDD and HDS Important Notes Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily harm and material damage, this alone cannot be relied upon to ensure complete safety.

  • Page 8: Magnetic And Electromagnetic Fields

    Important Notes Rexroth Diax 04 HDD and HDS Magnetic and Electromagnetic Fields Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! • Persons with heart pacemakers and metal implants are not permitted to enter following...

  • Page 9: Identification

    Rexroth Diax 04 HDD and HDS Identification Identification Type Codes Note: The following figures illustrate the basic structure of the type codes. Your sales representative will help you with the current status of available versions. Basic unit Configuration no. Example 2 .

  • Page 10: Hdd02.2-W0Xx-Hd32

    Identification Rexroth Diax 04 HDD and HDS HDD02.2-W0xx-HD32 Basic unit Configuration no. Example: H D D 2 . 2 - W 0 x - H D 3 2 - 0 1 - F W Product group 1.1 HDD ..= HDD Line 2.1 2 .

  • Page 11: Scope Of Supply

    Rexroth Diax 04 HDD and HDS Identification Unit type Fig. 2-4: Type plate – example Scope of Supply • Drive controller HDx0x.2 (According to the ordering with firmware module and plug-in modules) • Contact guard • 2 cables for DC bus connection •...
  • Page 12 Identification Rexroth Diax 04 HDD and HDS DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P...

  • Page 13: Ratings And Dimensions

    Rexroth Diax 04 HDD and HDS Ratings and Dimensions Ratings and Dimensions HDD02.2 and HDS02.2-W040N HDD02.2- HDD02.2- HDS02.2- W016N W040N W040N Description Symbol Unit -HD32 -HD32 listing according UL-standard (UL) UL 508 C listing according CSA-standard (UL) Canadian National Standard(s) C22.2 No. 14-05...
  • Page 14 Ratings and Dimensions Rexroth Diax 04 HDD and HDS Distances air intake air outlet mounting surface in control cabinet distance top distance bottom Fig. 3-2: Air intake and air outlet at drive controller DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P...

  • Page 15: Hds03.2

    Rexroth Diax 04 HDD and HDS Ratings and Dimensions HDS03.2 … HDS05.2 HDS03.2- HDS03.2- HDS04.2- HDS05.2- Description Symbol Unit W075N W100N W200N W300N listing according UL-standard (UL) UL 508 C listing according CSA-standard (UL) Canadian National Standard(s) C22.2 No. 14-05...
  • Page 16 Ratings and Dimensions Rexroth Diax 04 HDD and HDS Distances air intake air outlet mounting surface in control cabinet distance top distance bottom Fig. 3-4: Air intake and air outlet at drive controller DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P...

  • Page 17: Reference Documentations

    Rexroth Diax 04 HDD and HDS Reference Documentations Reference Documentations Overview Title Type of documentation Document typecode DIAX04 HVE and HVR 2 Generation Power Application Manual DOK-POWER*-HVE+HVR**G2-AWxx-EN-P Supply Units "List of Connecting Cables for DIAX04 and Selection lists DOK-CONNEC-CABLE*STAND-AUxx-EN-P ECODRIVE03"...
  • Page 18 Reference Documentations Rexroth Diax 04 HDD and HDS DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P...

  • Page 19: Instructions For Use

    Rexroth Diax 04 HDD and HDS Instructions for Use Instructions for Use Overcurrent Protection Branch circuit protection has to be provided externally according to the maximum values (voltage and current or voltage and percent of FLA of the fuses [FLA: Full Load Ampacity]).

  • Page 20: Wiring Diagram (Supply Unit Hvr)

    Instructions for Use Rexroth Diax 04 HDD and HDS Wiring Diagram (Supply Unit HVR) mains ground connection control cabinet connecting clamps main switch control voltage connection distributor clamps fuse shielded cable power connection to the motors earth rail shielded control cabinet compartment or intermediate panel B02EMV.fh7...

  • Page 21: Connection Diagram

    Rexroth Diax 04 HDD and HDS Instructions for Use Connection Diagram Rexroth Diax 04 (HDS) Command Software module communications module Additional plugin module Additional plugin module MKD/MKE MHD/MKE resolver VT 0,25 Additional plugin BU 0,25 module RD 0,25 (not with HDS02)
  • Page 22 Instructions for Use Rexroth Diax 04 HDD and HDS Rexroth Diax 04 (HDD) BN 1,0 +5V_G2 external WH 1,0 inputs 11,13,14,15 BN 0,25 Referenzschalter A-_G2 GN 0,25 pos. Fahrbereichsgrenzschalter A+_G2 neg. Fahrbereichsgrenzschalter BK0,25 B+_G2 Meßtaster 1 RD 0,25 B-_G2 Meßtaster 2...
  • Page 23 Rexroth Diax 04 HDD and HDS Instructions for Use external inputs reference switch pos. travel limit switch neg. travel limit switch measuring probe 1 BN 1,0 +5V_G2 measuring probe 2 WH 1,0 E-Stop E-Stop 11,13,14,15 DC +24V external U ext...

  • Page 24: Connection Of Control Interfaces And Terminals

    Instructions for Use Rexroth Diax 04 HDD and HDS Connection of Control Interfaces and Terminals See project planning manual for more details. X1, Connector for integrated bus connections from the neighboring unit Technical data of connector The control electronics of the drive controller receive their power via Connector X1, bus connector X1.
  • Page 25 Rexroth Diax 04 HDD and HDS Instructions for Use Ap5338f1.FH7 Fig. 5-10: Connector X5 HDS05 Design: Type No. of pins Design Screw-type terminal socket at the unit Fig. 5-11: Design Connection cross section: Cross section Cross section Cross section single wire...
  • Page 26 Instructions for Use Rexroth Diax 04 HDD and HDS HDD and HDS drive controllers are equipped with two ground Ground connections to the supply module connections (grounding system) to the supply module: • back wall of the unit and the mounting rails as well as •...
  • Page 27 Rexroth Diax 04 HDD and HDS Instructions for Use The entire shield of the motor cable is mounted to shield attachment XS1 Connector XS1, shield using the enclosed clamp fitting. It is matched to the diameter of the cable attachment of motor cable by simply selecting the relevant clamp base on the mounting panel.

  • Page 28: X6, Holding Brake, Motor Temperature Monitoring

    5-10 Instructions for Use Rexroth Diax 04 HDD and HDS Fig. 5-17: Horizontally arranged mounting plate X6, Holding brake, motor temperature monitoring Technical data of connector Illustration Ap5332f1.FH7 Fig. 5-18: Connector X6 Design Type No. of pins Design screw-type terminal pins at the unit Fig.
  • Page 29 5-11 Rexroth Diax 04 HDD and HDS Instructions for Use Dangerous movements! Persons at risk by falling or dropping axles! The standard motor holding brake as delivered, or ⇒ any external motor holding brake activated by the DANGER drive controller by itself does not provide adequate...
  • Page 30 5-12 Instructions for Use Rexroth Diax 04 HDD and HDS Connection device-external device-internal monitoring TM+, TM-: motor temperature monitoring AP5297F1.FH7 Fig. 5-22: Motor temperature monitoring Motor temperature evaluation: Drive Controller MOTOR AP5326F1.FH7 Schematics approximately 5 V approximately 2 k Fig. 5-23: Motor temperature evaluation...

  • Page 31: Arranging The Units Vertically

    5-13 Rexroth Diax 04 HDD and HDS Instructions for Use If the units are not arranged directly horizontally, you will need a longer cable for the connection of the X1 terminals: Cable Length Item / Material number INB648/0250 250 mm...
  • Page 32 5-14 Instructions for Use Rexroth Diax 04 HDD and HDS GLD (only with HVE) twisted max. 1 m 100 mm 300 mm Line cross HVR02.2- HVR02.2- HVR03.2- HVE02.2- HVE03.2- HVE04.2- Gewicht section W010N W025N W045N W018N W030N W075N 10 mm...

  • Page 33: Installation

    5-15 Rexroth Diax 04 HDD and HDS Instructions for Use Installation General Information on How to Install the Drive Controller Damage can be caused to the drive controller or circuit boards if electrostatic charging present in people and/or tools is discharged across them.

  • Page 34: Touch Guard At Devices

    5-16 Instructions for Use Rexroth Diax 04 HDD and HDS Touch Guard at Devices Lethal electric shock caused by live parts with more than 50 V! • The appropriate touch guard must be mounted for each device following connection work.
  • Page 35 5-17 Rexroth Diax 04 HDD and HDS Instructions for Use conveying direction of heated air in flow-off area outlet air to cooling unit intake area of cooling air for upper device line air guide addit- ional blower conveying direction of heated air...
  • Page 36 5-18 Instructions for Use Rexroth Diax 04 HDD and HDS correct incorrect Cooling system Cooling system warm cold warm cold Air duct electronic electronic equipment equipment Cabinet Cabinet Eb0001f1.fh7 Fig. 5-29: Arranging the cooling unit on the control cabinet incorrect...

  • Page 37: Appendix

    Rexroth Diax 04 HDD and HDS Appendix Appendix Discharging of DC Bus Capacitors In the drive system capacitors are used in the DC bus as energy stores. In the drive controllers and particularly in the supply units such capacitors have already been integrated.

  • Page 38: Discharging Device

    Appendix Rexroth Diax 04 HDD and HDS Discharging Device Lethal electric shock caused by live parts with more than 50 V! Before touching live parts check in any case whether ⇒ the voltage between the DC bus terminals L+ and L-...
  • Page 39 Rexroth Diax 04 HDD and HDS Index Index Appendix 6-1 Bus connection 5-6 Complete shield 5-8 Connection cross section X5 5-7 X6 5-10 Connector for integrated bus connections from the neighboring unit 5-6 Connector X1 5-6 Connector X5 5-6 control cabinet...
  • Page 40 Index Rexroth Diax 04 HDD and HDS Ratings 3-1 Reference documentations 4-1 Technical data of connector 5-6, 5-10 Technical data of connector X5 5-8 Temperature monitor 5-10 Tightening torques X5 5-7 TM+, TM- 5-12 Total connection diagram (HDS) 5-3 Type codes HDD HDD02.2-W0xx-HD32 2-2...
  • Page 42 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 (0)93 52-40-50 60 +49 (0)93 52-40-49 41 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany...

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