Rexroth IndraDrive Supply Units

Transcription

1 Industrial Hydraulics Electric Drives and Controls Linear Motion and Assembly Technologies Pneumatics Service Automation Mobile Hydraulics Rexroth IndraDrive Supply Units R Edition 01 Project Planning Manual

2 About this Documentation Rexroth IndraDrive Title Type of Documentation Rexroth IndraDrive Supply Units Project Planning Manual Document Typecode Internal File Reference Document number B312-01/EN Record of Revisions Description Release Date Notes Project Planning Manual; first edition Copyright 2004 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Published by Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 D Lohr a. Main Telephone +49 (0)93 52/40-0 Tx Fax +49 (0)93 52/ Dept. EDC1/EDY1 (EH/US) Note This document has been printed on chlorine-free bleached paper.

3 Rexroth IndraDrive Contents I Contents 1 Introduction About this Documentation Purpose of Documentation Introducing the Devices Features and Fields of Application Main Features Basic Structure Drive System Tests and Certifications Important Directions for Use Appropriate Use Introduction Areas of Use and Application Inappropriate Use Safety Instructions for Electric Drives and Controls Introduction Explanations Hazards by Improper Use General Information Protection Against Contact with Electrical Parts Protection Against Electric Shock by Protective Low Voltage (PELV) Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Protection Against Contact with Hot Parts Protection During Handling and Mounting Battery Safety Protection Against Pressurized Systems Identifying and Checking the Delivered Components Delivery of Components Packaging Accompanying Documents Scope of Delivery Overview Checking the Delivered Components Component Designation

4 II Contents Rexroth IndraDrive Type Plates on the Unit Device Types Type Code Transport and Storage Transporting the Devices Conditions Storing the Devices Conditions In Case of Long Storage Periods Mechanical Mounting Mounting Conditions Ambient and Operating Conditions Duty Capacity Mechanical Technical Data Dimensions Installation Orientation Arrangement of Components in the Control Cabinet Cooling and Cooling Units Power Dissipation Mounting Cooling Units Electrical Installation General Information Interference Elimination and EMC Interference Elimination Rules for EMC-Correct Installation of Drives Optimal EMC Installation Electrical Data HMV01.1E-W0030, -W0075, -W HMV01.1R-W0018, -W0045, -W Control Voltage Complete Connection Diagram Connecting Cables and Rails Connections (Power Section) Control Voltage (+24 V, 0 V) DC Bus (L+, L-) PE Connection of Power Supply PE Connection, Power Supply Unit and Neighboring Device X1, Bus Module X2, RS X3, Mains Connection X31, Connection for Messages X32, Mains Contactor Control, DC Bus Short Circuit, Braking Resistor Threshold X33, Acknowledge Messages of Internal Mains Contactor

5 Rexroth IndraDrive Contents III X14, Mains Voltage Synchronization Touch Guard Cutouts Mounting Determination of Appropriate Power Supply Units Introduction DC Bus Continuous Power DC Bus Peak Power Regenerated Energy Continuous Regenerated Power Peak Regenerated Power Connected Load of the Supply Unit Control Mains Contactor Control Possibilities Shutdowns with Faulty Drive Electronics Braking with Emergency Stop or Power Failure Controlling the Supply Unit with Emergency Stop Relays With DC Bus Dynamic Brake Without DC Bus Dynamic Brake Control via NC Controller Troubleshooting General Fault Diagnostics and Resetting Faults Checking and Repairing the Unit Replacing the Unit Diagnostic Display Disposal and Environmental Protection Disposal Products Packaging Materials Environmental Protection No Release of Hazardous Substances Materials Contained in the Products Recycling Service & Support Helpdesk Service-Hotline Internet Vor der Kontaktaufnahme... - Before contacting us Kundenbetreuungsstellen - Sales & Service Facilities

6 IV Contents Rexroth IndraDrive 13 Appendix Connection of Supply Unit by Wires Supply Unit to the Left of the Drive Controller Supply Unit to the Right of the Drive Controller Stacked Devices Counterclockwise Cable Routing Clockwise Cable Routing Mains Connection General Mains Supply Requirements HMV01.1E HMV01.1R Fusing with Direct Mains Supply Grounding the Power Supply System Fault Current Protective Device Earth Leakage Monitor Chronological Sequence when Switching ON and OFF When Switching On When Switching Off Auxiliary Components Mains Choke Mains Filter HFD Index 14-1

7 Rexroth IndraDrive Introduction Introduction 1.1 About this Documentation Purpose of Documentation 1.2 Introducing the Devices Features and Fields of Application Main Features This documentation describes planning the mechanical control cabinet construction planning the electrical control cabinet construction logistical handling of the equipment The supply unit supplies IndraDrive M drive controllers with the required DC bus voltage loops the 24 V control voltage of an external 24 V power supply through to the drive controllers communicates with the drive controllers via a module bus The supply units can be used for realizing a multitude of drive tasks in most diverse applications. For these purposes there are 2 different device types (regenerative, non-regenerative) with graduated supply power available. design with regeneration back to the mains (HMV01.1R-Wxxxx) and without regeneration back to the mains (HMV01.1E-Wxxxx) external 24 V supply required (signal processing not supplied from DC bus) 3-phase mains connection (380V V, +-10% 50Hz-60Hz) integrated mains contactor for E-Stop integrated braking resistor (bleeder) for feeding supply units (HMV01.1E-Wxxxx) integrated emergency braking resistor for regenerative supply units (HMV01.1R-Wxxxx)

8 1-2 Introduction Rexroth IndraDrive Basic Structure Supply Unit hmv_aufbau.fh7 1: Signal processing 2: Control panel (Display) 3: Power connections and control voltage connection Fig. 1-1: Basic structure Control Panel The control panel is a separate part which is plugged on the supply unit. The supply unit is supplied ex works complete with control panel. 01.F4002 Esc Enter Fig. 1-2: Standard control panel with sample display and control elements Operating status, command and error diagnoses, and warnings for problems requiring attention are shown in the display. Using the four buttons, the commissioning operator or service engineer can opt, in addition to master communication using the commissioning tool or NC control, to display further error diagnoses.

9 Rexroth IndraDrive Introduction 1-3 Drive System The following figure shows the components of the drive system. firmware drive controller DC bus resistor unit supply unit DC bus capacitor unit 24 V supply unit battery RKS - ready-made encoder cable RKG - ready-made power cable 3 motor mains supply components shown in gray are absolutely necessary Fa5147f1.fh7 Fig. 1-3: Drive system

10 1-4 Introduction Rexroth IndraDrive Tests and Certifications CE Mark CEf1.fh7 Fig. 1-4: CE mark C-UL-US Listing In preparation Tests Insulation-high-voltage test in accordance with EN50178 Separation between control and power voltage circuits Air gaps and leakage distances Fig. 1-5: Tests Routine testing with DC 2230 V, 1 min resp. Routine testing with AC 1575 V, 1 min; Power supply with 0,1 A short-circuit current Safe separation in accordance with EN50178 In accordance with EN50178

11 Rexroth IndraDrive Important Directions for Use Important Directions for Use 2.1 Appropriate Use Introduction Rexroth products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability. The products may only be used in the manner that is defined as appropriate. If they are used in an inappropriate manner, then situations can develop that may lead to property damage or injury to personnel. Note: Rexroth, as manufacturer, is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks. Before using Rexroth products, make sure that all the pre-requisites for an appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use. If the product takes the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the manner described in the relevant documentation.

12 2-2 Important Directions for Use Rexroth IndraDrive Areas of Use and Application Supply units of Rexroth are designed to supply the Rexroth IndraDrive M drive controllers. Control and monitoring of the motors may require additional sensors and actors. Note: The supply units may only be used with the accessories and parts specified in this document. If a component has not been specifically named, then it may not be either mounted or connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant function descriptions. 2.2 Inappropriate Use The supply units may only be operated under the assembly, installation and ambient conditions as described here (temperature, system of protection, humidity, EMC requirements, etc.) and in the position specified. Using the supply units outside of the above-referenced areas of application or under operating conditions other than described in the document and the technical data specified is defined as inappropriate use". Supply units may not be used if they are subject to operating conditions that do not meet the above specified ambient conditions. This includes, for example, operation under water, in the case of extreme temperature fluctuations or extremely high maximum temperatures or if Rexroth has not specifically released them for that intended purpose. Please note the specifications outlined in the general safety instructions!

13 Rexroth IndraDrive Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls 3.1 Introduction Read these instructions before the initial startup of the equipment in order to eliminate the risk of bodily harm or material damage. Follow these safety instructions at all times. Do not attempt to install or start up this equipment without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation of the equipment prior to working with the equipment at any time. If you do not have the user documentation for your equipment, contact your local Rexroth representative to send this documentation immediately to the person or persons responsible for the safe operation of this equipment. If the equipment is resold, rented or transferred or passed on to others, then these safety instructions must be delivered with the equipment. WARNING Improper use of this equipment, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death! 3.2 Explanations The safety instructions describe the following degrees of hazard seriousness in compliance with ANSI Z535. The degree of hazard seriousness informs about the consequences resulting from noncompliance with the safety instructions. Warning symbol with signal word Degree of hazard seriousness according to ANSI Death or severe bodily harm will occur. DANGER Death or severe bodily harm may occur. WARNING Bodily harm or material damage may occur. CAUTION Fig. 3-1: Hazard classification (according to ANSI Z535)

14 3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive 3.3 Hazards by Improper Use DANGER High voltage and high discharge current! Danger to life or severe bodily harm by electric shock! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! WARNING High electrical voltage due to wrong connections! Danger to life or bodily harm by electric shock! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Surface of machine housing could be extremely hot! Danger of injury! Danger of burns! CAUTION CAUTION Risk of injury due to improper handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock or incorrect handling of pressurized systems! Risk of injury due to incorrect handling of batteries! CAUTION

15 Rexroth IndraDrive Safety Instructions for Electric Drives and Controls General Information Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before starting up the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe operation of this equipment. Only persons who are trained and qualified for the use and operation of the equipment may work on this equipment or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the equipment as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and equipment on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer. Follow all safety regulations and requirements for the specific application as practiced in the country of use. The equipment is designed for installation in industrial machinery. The ambient conditions given in the product documentation must be observed. Use only safety features and applications that are clearly and explicitly approved in the Project Planning Manual. For example, the following areas of use are not permitted: construction cranes, elevators used for people or freight, devices and vehicles to transport people, medical applications, refinery plants, transport of hazardous goods, nuclear applications, applications sensitive to high frequency, mining, food processing, control of protection equipment (also in a machine). The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applications and suggestions. The machine and installation manufacturer must make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements. Startup of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application.

16 3-4 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the documentation "EMC in Drive and Control Systems". The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations. Technical data, connections and operational conditions are specified in the product documentation and must be followed at all times.

17 Rexroth IndraDrive Safety Instructions for Electric Drives and Controls Protection Against Contact with Electrical Parts Note: This section refers to equipment and drive components with voltages above 50 Volts. Touching live parts with voltages of 50 Volts and more with bare hands or conductive tools or touching ungrounded housings can be dangerous and cause electric shock. In order to operate electrical equipment, certain parts must unavoidably have dangerous voltages applied to them. DANGER High electrical voltage! Danger to life, severe bodily harm by electric shock! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain or repair this equipment. Follow general construction and safety regulations when working on high voltage installations. Before switching on power the ground wire must be permanently connected to all electrical units according to the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the ground wire is not permanently connected to the points of the components provided for this purpose. Before working with electrical parts with voltage higher than 50 V, the equipment must be disconnected from the mains voltage or power supply. Make sure the equipment cannot be switched on again unintended. The following should be observed with electrical drive and filter components: Wait five (5) minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Install the covers and guards provided with the equipment properly before switching the equipment on. Prevent contact with live parts at any time. A residual-current-operated protective device (RCD) must not be used on electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device. Electrical components with exposed live parts and uncovered high voltage terminals must be installed in a protective housing, for example, in a control cabinet.

18 3-6 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive To be observed with electrical drive and filter components: DANGER High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! Connect the electrical equipment, the housings of all electrical units and motors permanently with the safety conductor at the ground points before power is switched on. Look at the connection diagram. This is even necessary for brief tests. Connect the safety conductor of the electrical equipment always permanently and firmly to the supply mains. Leakage current exceeds 3.5 ma in normal operation. Use a copper conductor with at least 10 mm² cross section over its entire course for this safety conductor connection! The cross section must not be smaller than the cross section of a phase of the mains suppy wire. Prior to startups, even for brief tests, always connect the protective conductor or connect with ground wire. Otherwise, high voltages can occur on the housing that lead to electric shock. 3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) All connections and terminals with voltages between 0 and 50 Volts on Rexroth products are protective low voltages designed in accordance with international standards on electrical safety. WARNING High electrical voltage due to wrong connections! Danger to life, bodily harm by electric shock! Only connect equipment, electrical components and cables of the protective low voltage type (PELV = Protective Extra Low Voltage) to all terminals and clamps with voltages of 0 to 50 Volts. Only electrical circuits may be connected which are safely isolated against high voltage circuits. Safe isolation is achieved, for example, with an isolating transformer, an opto-electronic coupler or when battery-operated.

19 Rexroth IndraDrive Safety Instructions for Electric Drives and Controls Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of the connected motors. Some common examples are: improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors 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 injury and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.

20 3-8 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive DANGER Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. Unintended machine motion is possible if monitoring devices are disabled, bypassed or not activated. Pay attention to unintended machine motion or other malfunction in any mode of operation. Keep free and clear of the machine s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine s range of motion: - use safety fences - use safety guards - use protective coverings - install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum, especially if there is a possibility of loose parts flying off. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the machine if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Safe standstill can be achieved by switching off the power supply contactor or by safe mechanical locking of moving parts. Secure vertical axes against falling or dropping after switching off the motor power by, for example: - mechanically securing the vertical axes - adding an external braking/ arrester/ clamping mechanism - ensuring sufficient equilibration of the vertical axes The standard equipment motor brake or an external brake controlled directly by the drive controller are not sufficient to guarantee personal safety!

21 Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-9 Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: - maintenance and repair work - cleaning of equipment - long periods of discontinued equipment use Prevent the operation of high-frequency, remote control and radio equipment near electronics circuits and supply leads. If the use of such equipment cannot be avoided, verify the system and the installation for possible malfunctions in all possible positions of normal use before initial startup. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation. 3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Magnetic and electromagnetic fields generated near current-carrying conductors and permanent magnets in motors represent a serious health hazard to persons with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with heart pacemakers, hearing aids and metal implants are not permitted to enter the following areas: - Areas in which electrical equipment and parts are mounted, being operated or started up. - Areas in which parts of motors with permanent magnets are being stored, operated, repaired or mounted. If it is necessary for a person with a heart pacemaker to enter such an area, then a doctor must be consulted prior to doing so. Heart pacemakers that are already implanted or will be implanted in the future, have a considerable variation in their electrical noise immunity. Therefore there are no rules with general validity. Persons with hearing aids, metal implants or metal pieces must consult a doctor before they enter the areas described above. Otherwise, health hazards will occur.

22 3-10 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive 3.9 Protection Against Contact with Hot Parts CAUTION Housing surfaces could be extremely hot! Danger of injury! Danger of burns! Do not touch housing surfaces near sources of heat! Danger of burns! After switching the equipment off, wait at least ten (10) minutes to allow it to cool down before touching it. Do not touch hot parts of the equipment, such as housings with integrated heat sinks and resistors. Danger of burns! 3.10 Protection During Handling and Mounting Under certain conditions, incorrect handling and mounting of parts and components may cause injuries. CAUTION Risk of injury by incorrect handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock! Observe general installation and safety instructions with regard to handling and mounting. Use appropriate mounting and transport equipment. Take precautions to avoid pinching and crushing. Use only appropriate tools. If specified by the product documentation, special tools must be used. Use lifting devices and tools correctly and safely. For safe protection wear appropriate protective clothing, e.g. safety glasses, safety shoes and safety gloves. Never stand under suspended loads. Clean up liquids from the floor immediately to prevent slipping.

23 Rexroth IndraDrive Safety Instructions for Electric Drives and Controls Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or material damage. CAUTION Risk of injury by incorrect handling! Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and cauterization). Never charge non-chargeable batteries (danger of leakage and explosion). Never throw batteries into a fire. Do not dismantle batteries. Do not damage electrical components installed in the equipment. Note: Be aware of environmental protection and disposal! The batteries contained in the product should be considered as hazardous material for land, air and sea transport in the sense of the legal requirements (danger of explosion). Dispose batteries separately from other waste. Observe the legal requirements in the country of installation Protection Against Pressurized Systems Certain motors and drive controllers, corresponding to the information in the respective Project Planning Manual, must be provided with pressurized media, such as compressed air, hydraulic oil, cooling fluid and cooling lubricant supplied by external systems. Incorrect handling of the supply and connections of pressurized systems can lead to injuries or accidents. In these cases, improper handling of external supply systems, supply lines or connections can cause injuries or material damage. CAUTION Danger of injury by incorrect handling of pressurized systems! Do not attempt to disassemble, to open or to cut a pressurized system (danger of explosion). Observe the operation instructions of the respective manufacturer. Before disassembling pressurized systems, release pressure and drain off the fluid or gas. Use suitable protective clothing (for example safety glasses, safety shoes and safety gloves) Remove any fluid that has leaked out onto the floor immediately. Note: Environmental protection and disposal! The media used in the operation of the pressurized system equipment may not be environmentally compatible. Media that are damaging the environment must be disposed separately from normal waste. Observe the legal requirements in the country of installation.

24 3-12 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Notes

25 Rexroth IndraDrive Identifying and Checking the Delivered Components Identifying and Checking the Delivered Components 4.1 Delivery of Components Packaging Packaging Units Packaging Labels Disposal of Packaging Material The components are supplied in separate packaging units. The content of the packed components and the order number may be identified using the adhesive barcode label on the packaging. See chapter 11 "Disposal and Environmental Protection". Accompanying Documents A delivery note in duplicate can be found in an envelope on one of the packages supplied. No other accompanying documents are provided. The total number of containers supplied is recorded on the delivery note or consignment note. 4.2 Scope of Delivery Overview as standard touch guard grounding bracket connector X31, X32, X33 safety instructions (brochure; DOK- GENERAL-DRIVE******-SVSx-MS-P) Fig. 4-1: Scope of delivery optional rails for connecting the DC bus rails for connecting the control voltage Checking the Delivered Components Please immediately check whether the delivered components are: complete correct intact

26 4-2 Identifying and Checking the Delivered Components Rexroth IndraDrive 4.3 Component Designation Type Plates on the Unit Each drive component is identified by a type designation. A type plate is attached to all units, including the motor. A label (cable marker) is wrapped round the ready-made cable. The type designation and length are indicated on this label. (The designation for the cable itself, without connector, is printed on the cable sheath.) The identification of accessories packed in bags is either printed on the bag or indicated in an accompanying note. Fig. 4-2: Type plate arrangement hmv_typenschild.fh7

27 Rexroth IndraDrive Identifying and Checking the Delivered Components Device Types Type Code Note: The following figure illustrates the basic structure of the type code. Your sales representative will help with the current status of available versions. Abbrev. Column Example: H M V E - W A NNNN Product 1.1 HMV = HMV 2. Line = Design = 1 4. Power supply 4.1 feeded = E 4.2 regenerative = R 5. Cooling mode 5.1 Air, internal (through integrated blower) = W 6. Rated output Rated output Power supply Code [ KW ] E R with choke 30 X X Protection mode 7.1 IP = A 8. DC-bus nominal voltage 8.1 DC 700V = Other design 9.1 none = NNNN 10. Standard reference Standard Titel Edition DIN EN Degrees of protection provided by enclosures (IP-Code) Fig. 4-3: Type code

28 4-4 Identifying and Checking the Delivered Components Rexroth IndraDrive Notes

29 Rexroth IndraDrive Transport and Storage Transport and Storage 5.1 Transporting the Devices Conditions temperature C relative humidity %; climatic category 2K3 absolute humidity g/m 3 climatic category 2K3 moisture condensation icing Shock check not in operation according to EN Fig. 5-1: Conditions for transport not allowed not allowed Halve sine in 3 axis: 10g / 11ms 5.2 Storing the Devices Conditions temperature C relative humidity %; climatic category 1K3 absolute humidity g/m 3 climatic category 1K3 moisture condensation icing Fig. 5-2: In Case of Long Storage Periods Conditions for storage not allowed not allowed The power supply units contain sensitive electrolytic capacitors. Therefore, in the case of long storage periods, operate the power supply units once a year for at least 1 hour with power on (DC bus voltage must be applied).

30 5-2 Transport and Storage Rexroth IndraDrive Notes

31 Rexroth IndraDrive Mechanical Mounting Mechanical Mounting 6.1 Mounting Conditions Ambient and Operating Conditions Note: The supply units and their additional components are designed to be built into control cabinets. Note: The user must check that the ambient conditions, and in particular the temperature of the control cabinet, are complied with by calculating the heat levels in the control cabinet. Designation Information Ambient temperature 0 to +40 C Ambient temperature with derating 2% per C to +55 C Temperature in storage Temperature during transportation Mounting altitude at rating Mounting altitude with derating* Maximum mounting altitude* Relative humidity (operation) see chapter 5 "Transport and Storage" see chapter 5 "Transport and Storage" 1000 m above sea level Absolute humidity 1 to 29 g/m 3 Climatic class Contamination level Vibration sinus in operation according to EN Vibration distortion (Random) in operation according to IEC Up to 2000 m 2.0% per 100 m from 1000 m From 2000 m: see characteristic in Fig m (upper temperature limit falls to 40 C instead of 55 C) 5% to 95% Cl.3K5 with reservation, as not 5 C Cl.3K5 Contamination level 2 in accordance with EN50178 Amplitude and frequency: 0,15 mm (peak-peak) at Hz Acceleration and frequency: 1 g at Hz Tolerance: ±15 % Frequency: Hz Spectral acceleration density amplitude: 0,005 g 2 /Hz Tolerance: ± 3 db Virtual value (r.m.s.) of the total acceleration: 1,0 g * For mounting altitudes of more than 2000 m, an overvoltage limiter for transient overvoltage 1.2/50 µs must be installed in the installation or building in order to limit the voltage to 1.0 kv between the outer conductors and to 2.5 kv between conductor-ground. Fig. 6-1: Ambient and operating conditions

32 6-2 Mechanical Mounting Rexroth IndraDrive Compatibility with foreign matters All Rexroth controls and drives are developed and tested according to the state-of-the-art of technology. As it is impossible to follow the continuing development of all materials (e.g. lubricants in machine tools) which may interact with our controls and drives, it cannot be completely ruled out that any reactions with the materials used by Bosch Rexroth might occur. For this reason, before using the respective material a compatibility test has to be carried out for new lubricants, cleaning agents etc. and our housings/our housing materials.

33 Rexroth IndraDrive Mechanical Mounting 6-3 Duty Capacity Where conditions differ, the following performance data diminish in accordance with the diagrams (see Fig. 6-2: Duty capacity at higher ambient temperature and Fig. 6-3: Duty capacity at higher mounting altitude ): Permitted DC bus continuous output Continuous output of the braking resistor Continuous current If differing ambient temperatures and higher mounting altitudes occur simultaneously, both duty factors must be multiplied. The mounting altitude must be taken into account just once, differing ambient temperatures must be considered separately for the motor and drive controller. 1 Degree of utilization at higher ambient temperatures 0,7 Load factor Ambient temperature in C Fig. 6-2: Duty capacity at higher ambient temperature DG0006F1.FH7 1 Degree of utilization at higher installation altitudes 0,8 Load factor 0,6 0,4 0, Installation altitude above sea level in meters Fig. 6-3: Duty capacity at higher mounting altitude DG0007F1.FH7

34 6-4 Mechanical Mounting Rexroth IndraDrive 6.2 Mechanical Technical Data Dimensions A) Dimensional Drawing for HMV01.1E-W0*** and HMV01.1R-W00** L 466 (7) 7L1 262 A) maszblatt_hmv.fh7 A) minimum mounting clearance Fig. 6-4: Dimensional drawing for HMV01.1E-W0*** and HMV01.1R-W00** Device L [mm] L1 [mm] HMV01.1E-W HMV01.1E-W HMV01.1E-W HMV01.1R-W HMV01.1R-W HMV01.1R-W Fig. 6-5: L and L1 dimensions

35 Rexroth IndraDrive Mechanical Mounting 6-5 Installation Orientation Install supply units in such a way that their longitudinal axis corresponds to the natural direction of convection (connections for motor and power downwards). In this way the natural convection supports the forced cooling air current. This avoids the generation of pockets of heat. Arrangement of Components in the Control Cabinet Power-dependent Arrangement drive controllers drive controllers low power high power high power low power supply unit Fig. 6-7: Example of an arrangement versorg_antrieb_sym.fh7 Arrange the drive controllers with higher power needs and high currents as close to the supply unit as possible. Ideally the drive controllers should be distributed equally to the left and right side of the power supply. Position DC bus capacitor unit next to drive with the greatest DC bus continuous output. Position DC bus resistor unit next to drive with the greatest negative feed power.

36 6-6 Mechanical Mounting Rexroth IndraDrive Control Cabinet with Multiple Line Structure Note: Particular attention should be paid to the maximum permissible air intake temperature of components when they are arranged in multiple lines in the control cabinet. Where necessary, cooling air guides are to be allowed for with ventilators specially inserted for this purpose. Discharge direction of the warmed air in the flow-off area Exhaust air from the air conditioner Additional fan Entry area of the cooling air for the upper device line Discharge direction of the warmed air in the flow-off area For example: air baffle Entry area of the cooling air for the lower device line Supply air from the air conditioner Fig. 6-8: Example of arrangement for multiple line structure with components

37 Rexroth IndraDrive Mechanical Mounting Cooling and Cooling Units Power Dissipation The power dissipation of a drive system radiated to the control cabinet is calculated from the sum of the power dissipation of the supply unit, the power dissipation of the mains connecting unit, the power dissipation of each drive controller, and the power dissipation of additional units (e.g. DC bus resistor unit or DC bus capacitor unit). The power dissipation of a supply unit is composed of power dissipation of the control voltage supply unit current-related power dissipation of rectifier (HMV01.1E) resp. inverter (HMV01.1R), wiring and mains contactor power dissipation of braking resistor unit (HMV01.1E) resp. emergency braking resistor (HMV01.1R)

38 6-8 Mechanical Mounting Rexroth IndraDrive Mounting Cooling Units Unless the ratings are reduced the drive controller may only be operated up to an specified ambient temperature (see chapter 6.1). It is therefore possible that a cooling unit will be required. CAUTION Possible damage to the drive controller Operational safety of the machine endangered Note the following instructions Avoiding Dripping or Sprayed Water As a matter of principle condensation water is formed when cooling units are used. For this reason, please observe the following information: Always position cooling units in such a way that condensation water cannot drip onto electrical equipment in the control cabinet. Position the cooling unit so that the ventilator for the cooling unit does not spray accumulated condensation water onto electrical equipment. correct Cooling system incorrect Cooling system warm cold warm cold Air duct electronic equipment electronic equipment Cabinet Cabinet Fig. 6-9: Arrangement of the cooling unit on the control cabinet Eb0001f1.fh7

39 Rexroth IndraDrive Mechanical Mounting 6-9 correct incorrect control cabinet air inflow control cabinet air inflow cooling unit air duct cooling unit air outflow electronic equip. electronic equip. Fig. 6-10: Eb0002f1.fh7 Arrangement of the cooling unit on the front of the control cabinet Avoiding Condensation Condensation occurs when the temperature of the unit is lower than the ambient temperature. Set cooling units with temperature adjustment to the maximum surrounding temperature and no lower. Set cooling units with traced temperature so that the interior temperature of the control cabinet is no lower than the temperature of the surrounding air. Set the temperature delimitation to the maximum surrounding temperature. Only use well-sealed control cabinets so that condensation cannot arise as a result of warm and moist external air entering the cabinet. In the event that control cabinets are operated with the doors open (start-up, servicing etc.) it is essential to ensure that after the doors are closed the drive controllers cannot at any time be cooler than the air in the control cabinet, as otherwise condensation can occur. For this reason ample circulation must be provided inside the control cabinet to avoid pockets of heat.

40 6-10 Mechanical Mounting Rexroth IndraDrive Notes

41 Rexroth IndraDrive Electrical Installation Electrical Installation 7.1 General Information Damage can be caused to the supply unit or circuit boards if electrostatic charging present in people and/or tools is discharged across them. Therefore, please note the following information: CAUTION Electrostatic charges can cause damage to electronic components and interfere with their operational safety! Objects coming into contact with components and circuit boards must be discharged by means of grounding. Otherwise errors may occur when triggering motors and moving elements. Such objects include: the copper bit when soldering the human body (ground connection caused by touching a conductive, grounded item) parts and tools (placing on a conductive support) Endangered components may only be stored or dispatched in conductive packaging. Note: Rexroth connection diagrams are only to be used for producing installation connection diagrams. The machine manufacturer s installation connection diagrams must be used for wiring the installation! Lay signal lines separately from the load resistance lines because of the occurrence of interference. Feed analog signals (e.g., command values, actual values) via sheathed lines. Do not connect mains, DC bus or power leads to low voltages or allow them to come into contact. When carrying out a high voltage or insulation test withstand test on the machine s electrical equipment, disconnect all connections to the units. This protects the electronic components (permitted in accordance with EN ). During their routine check test, Rexroth drive components are tested for high voltage and insulation in accordance with EN CAUTION Plugging and unclamping live connections can damage the controller. Do not plug in or unclamp live connections.

42 7-2 Electrical Installation Rexroth IndraDrive 7.2 Interference Elimination and EMC Interference Elimination Note: The subject interference elimination and electromagnetic compatibility (EMC) is described in detail in a separate documentation. It is absolutely necessary to read this documentation for the proper operation of AC-drives! The document is titled "Electromagnetic compatibility (EMC) in drive and control systems". Doc-Type: DOK-GENERAL- EMV********-PRxx-EN-P. The item number is Note: As the HMV01.1R power supply unit must be operated together with a combining filter, the indications concerning the mains filter arrangement apply above all to the HMV01.1E. (The line filter is already included in the combining filter). Interference emission To maintain class B limit values (interference suppression N) as per EN / 3.91 at the machine (required in residential and light industrial areas), suitable interference suppression filters must be installed in the mains supply line in the machine. The motor power cable should be routed in a shielded manner or a shielded motor power cable should be used. CAUTION Risk of damage! Only use Rexroth filters. These filters have been adjusted to the Rexroth supply units, inverters and motors in the best possible way. If you use different filters, the limit values possibly cannot be complied with. Moreover the filters and other components of the drive system might be destroyed.

43 Rexroth IndraDrive Electrical Installation Rules for EMC-Correct Installation of Drives Rule 1 Rule 2 Rule 3 Rule 4 Rule 5 Rule 6 Rule 7 Rule 8 The following 10 rules are the basics for designing drive systems in compliance with EMC. Rules 1 to 7 are generally valid. Rules 8 to 10 are especially important to limit noise emission. All metal parts of the cabinet should be connected with one another through the largest possible surface area so that the best electrical connection is established (not paint on paint!). If required, use serrated washers which cut through the paint surface. The cabinet door should be connected to the cabinet using the shortest possible grounding straps. Signal, line supply, motor and power cables should be routed away from another (this eliminates mutual interference!). The minimum clearance is: 10 cm. Barriers should be provided between power- and signal cables. These barriers should be grounded at several locations. Contactors, relays, solenoid valves, electromechanical operating hour counters etc. in the cabinet must be provided with noise suppression devices. These devices must be connected directly at the coil. Non-shielded cables belonging to the same circuit (feeder and return cables) should be twisted with the smallest possible distance between them. Cores which are not used must be grounded at both ends. Generally, interference injection can be reduced by routing cables as close as possible to grounded sheet steel panels. For this reason, cables and wires should not be routed freely in the cabinet, but as close as possible to the cabinet itself and the mounting panels. This is also true for reserve cables. Incremental encoders must be connected using shielded cables. The shield must be connected at the incremental encoder and at the drive controller through the largest possible surface area. The shield may not be interrupted, e.g. using intermediate terminals. The shields of signal cables must be connected to ground at both ends through the largest possible surface area to establish a good electrical connection (transmitter and receiver). If the potential bonding between the screen connections is poor, to reduce the shield current, an additional potential bonding conductor with a cross-section of at least 10 mm² should be connected in parallel with the shield. The shield can be connected to ground (=cabinet housing) at several locations. This is also true outside the cabinet. Foil shields are not recommended. Braided screens provide a better shielding effect (factor of 5). If the potential bonding is poor, analog signal cables may only be grounded at one end to the drive controller in order to prevent lowfrequency noise being injected into the screen (50 Hz). Always locate a radio interference suppression filter close to the noise source. The filter should be connected through the largest possible surface area with the cabinet housing, mounting panel etc. The best solution is a bare metal mounting panel (e.g. manufactured from stainless steel, galvanized steel), as the complete mounting surface can be used to establish good electrical contact. The incoming and outgoing cables of the radio interference suppression filter should be separated.

44 7-4 Electrical Installation Rexroth IndraDrive Rule 9 Rule 10 All variable-speed motors should be connected using shielded cables, whereby the shield is connected at both ends to the housings through the largest possible surface area to minimize the inductance. The motor feeder cables should also be shielded outside the cabinet, or at least screened using barriers. Cables with steel shield are not suitable. To connect the shield at the motor, a suitable PG gland with shield connection can be used (e.g. "SKINDICHT SHV/SRE/E" from the Lapp Company, Stuttgart). It should be ensured that the connection between the motor terminal box and the motor housing has a low impedance. Otherwise, use an additional grounding strap between them. Never use plastic motor terminal boxes! The shield between the motor and drive controller may not be interrupted by installing components such as output reactors, sinusoidal filters, motor filters, fuses, contactors. The components must be mounted on mounting panels which also simultaneously serve as shield connection for the incoming and outgoing motor cables. If required, metal barriers may be required to shield the components. Note: Detailed information is available in the instructions in the Project Planning Manual "Electromagnetic compatibility (EMC) in drive and control systems". Doc-Type: DOK-GENERAL- EMV********-PRxx-EN-P. The item number is

45 Rexroth IndraDrive Electrical Installation 7-5 Optimal EMC Installation With regard to an optimal EMC installation, a spatial separation of the interference-free area (mains connection) and the interference susceptible area (drive components) is advisable. See the next figure in this respect. HMV01.1E-Wxxxx mains PE shielded control cabinet compartment or intermediate panel control cabinet connecting clamps main switch supply unit drive controller drive controller distributor clamps fuse mains filter load earth rail to the motors mains choke power connection HMVE_emv.fh7 Fig. 7-1: HMV01.1E - Separation of interference-free and interference susceptible areas

46 7-6 Electrical Installation Rexroth IndraDrive HMV01.1R-Wxxxx mains PE ground connection control cabinet connecting clamps main switch filter supply unit drive controller drive controller distributor clamps fuse mains choke shielded cable power connection earth rail to the motors shielded control cabinet compartment or intermediate panel HMVR_emv.fh7 Fig. 7-2: HMV01.1R - Separation of interference-free and interference susceptible areas

47 Rexroth IndraDrive Electrical Installation Electrical Data HMV01.1E-W0030, -W0075, -W0120 Designation Symbol Unit HMV01.1E-W0030 HMV01.1E-W0075 HMV01.1E-W0120 kind of connection (mode of operation at the mains) phase mains input voltage (rated voltage) U LN V % to % transient overvoltage limit values U L trans max V 1200 mains frequency f LN Hz 48 to 62 Maximum mains frequency change per time unit mains input continuous current (r.m.s. value) df LN/t Hz/s 2% * f LN I LN cont A connected mains power without DC bus S LN kw choke (at max. DC bus power) 1) connected mains power with DC bus choke (at max. DC bus power) S LN (L_DC) kw power factor (cosϕ) cosϕ - 1 DC bus voltage (range) U DC V 435 to 710 upper DC bus voltage limit (shutdown U DC limit (max) V 900 threshold) 2) lower DC bus voltage limit (shutdown U DC limit (min) V 0,75 * 2 * U LN threshold) 3) continuous DC bus power (at U LN =400V) P DC cont kw with choke 4) continuous DC bus power (at U LN =400V) without choke P DC cont kw continuous DC bus power depending on mains input voltage peak DC bus power (for max. 0,3 s with a preload of 0,6 x I LN cont and 40 C ambient temperature) at U LN < 400 V: 1% power reduction per 4 V at U LN > 400 V: 1% power increasing per 4 V P DC peak kw braking resistor switch-on threshold U DC (R_DC On) V constant 820V or variable 80V + 2 * U LN continuous brake power kw 1,5 2 2,5 maximum brake power kw brake energy absorption kws DC bus capacity C DC µf overload capacity factor / duration I out_max1/ A factor 2,5 I out_cont1 (related to rated power without DC bus choke) power dissipation P Diss W ) These data refer to a supply impedance of 40 µh. 2) When the upper DC bus voltage limit has been reached, the supply unit does not switch off. The display shows a warning message. The output stages of the drive controllers are locked. 3) When the lower DC bus voltage limit has been reached, the supply unit does not switch off. The display shows a warning message. At an undervoltage of 0,75 * U LN the supply unit switches off. 4) Inductance of the choke: HMV01.1E-W0030: 400 µh HMV01.1E-W0075: 200 µh HMV01.1E-W0120: 100 µh Fig. 7-3: Technical data

48 7-8 Electrical Installation Rexroth IndraDrive HMV01.1R-W0018, -W0045, -W0065 Designation Symbol Unit HMV01.1R- W0018 kind of connection (mode of operation at the mains) HMV01.1R- W phase mains input voltage (rated voltage) U LN V % to % transient overvoltage limit values U L trans max V 1200 mains frequency f LN Hz 48 to 62 Maximum mains frequency change per time unit mains input continuous current (r.m.s. value) connected mains power with DC bus choke (at max. DC bus power) df LN/t Hz/s 2% * f LN HMV01.1R- W0065 I L cont A S LN (L_DC) kw power factor (cosϕ) cosϕ - 1 DC bus voltage (range) U DC V 750 (controlled) upper DC bus voltage limit (shutdown threshold) lower DC bus voltage limit (shutdown threshold) U DC limit (max) V 900 U DC limit (min) V 0,75 * 2 * U LN continuous DC bus power (at U LN =400V) P DC cont kw continuous DC bus power depending on mains input voltage DC bus peak power (for max. 0,3 s with a preload of 0,6 x I LN cont and 40 C ambient temperature) at U LN < 400 V: 1% power reduction per 4 V at U LN > 400 V: no power increasing P DC peak kw braking resistor switch-on threshold U DC (R_DC On) V 820 continuous brake power (braking resistor) kw 0,4 0,4 0,4 maximum brake power (braking resistor) kw brake energy absorption (braking resistor) kws DC bus capacity C DC µf output voltage U out eff V 750 (controlled) overload capacity factor / duration I out_max1/ A factor 2,5 I out_cont1 (related to rated power) power dissipation P Diss W Fig. 7-4: Technical data

49 Rexroth IndraDrive Electrical Installation 7-9 Control Voltage (Information at ambient temperature of 25 C) Designation Symbol Unit Value Control voltage U N3 V 24 ±5% Max. ripple content w - controlled Max. allowed overvoltage U N3max V % Max. charging current I EIN3 A HMV01.1E-W0030: 7 A HMV01.1E-W0075: 16 A HMV01.1E-W0120: 15 A HMV01.1R-W0018: 6 A HMV01.1R-W0045: 8 A HMV01.1R-W0065: 14 A Max. pulse duration of I EIN3 t EIN3Lade ms HMV01.1E-W0120: 50 all other devices: 15 Max. input capacity C N3 mf 10 Power consumption: HMV01.1-1E-W0030 P N3 W 24 (preliminary) HMV01.1-1E-W0075 P N3 W 38 (preliminary) HMV01.1-1E-W0120 P N3 W 41 (preliminary) HMV01.1-1R-W0018 P N3 W 27 (preliminary) HMV01.1-1R-W0045 P N3 W 40 (preliminary) HMV01.1-1R-W0065 P N3 W 60 (preliminary) Fig. 7-5: Control voltage

50 7-10 Electrical Installation Rexroth IndraDrive 7.4 Complete Connection Diagram 4 X33 acknowledgment power ON 3 mains contactor ON 2 acknowledgment power OFF 1 mains contactor OFF 24V for interface DC bus short circuit 24V mains OFF X32 5 mains ON 4 braking resistor threshold fixed/variable ** 0V for interface ready for operation DC bus ok X31 HMV 01.1x - Wxxxx X module bus 3 2 prewarning temp./bleeder 1 RS232 mains connection for synchronization X2 X14* 24V 0V L+ L- 24V control voltage DC bus X3 L1 L2 L3 PE mains connection PE * only for HMV01.1R-Wxxxx ** only for HMV01.1E-Wxxxx Fig. 7-6: Complete connection diagram anschlussplan_hmv.fh7

51 Rexroth IndraDrive Electrical Installation Connecting Cables and Rails Connections (Power Section) Overview C D A B installation_hmv_system.fh7 No. A B C D Designation UPS (uninterruptible power system) 24 V control voltage supply Supply unit Drive controller 1 PE connection of mains supply 2 Mains connection 3 PE connection to drive controller; If cables are used for ground connection they must have a cross section of at least 10 mm 2. 4 Module bus X1 5 Control voltage connection (+24V, 0V); If connection with contact isn t possible you can also use wires. 6 DC bus connection (L+, L-); If connection with contact isn t possible you can also use wires. Fig. 7-7: Connections - overview

52 7-12 Electrical Installation Rexroth IndraDrive HMV01.1E-W0030 and HMV01.1E-W0075 X33 X32 X31 X2 control panel X1 +24 V 0 V control voltage L+ L- DC bus PE mains PE hmv_e30_front.fh7 Fig. 7-8: HMV01.1E-W0030 and HMV01.1E-W0075 Description of connections: Connection See page control voltage 7-15 DC bus 7-17 mains voltage (X5) 7-22 PE connection power supply unit resp. neighboring device 7-20 X X X X X7 7-25

53 Rexroth IndraDrive Electrical Installation 7-13 HMV01.1E-W0120 X33 X32 X31 X2 control panel X1 +24 V 0 V control voltage L+ L- DC bus PE connection to drive controller PE connection to drive controller PE mains PE Fig. 7-9: HMV01.1E-W0120 hmv_e120_front.fh7 Description of connections: Connection See page control voltage 7-15 DC bus 7-17 mains voltage (X5) 7-22 PE connection power supply unit resp. neighboring device 7-20 X X X X X7 7-25

54 7-14 Electrical Installation Rexroth IndraDrive HMV01.1R-W0018, -W0045, -W0065 X33 X32 X31 X2 X14 control panel +24 V 0 V control voltage L+ L- DC bus PE mains PE hmv_r18_front.fh7 Fig. 7-10: HMV01.1R-W0018, -W0045, -W0065 Description of connections: Connection See page control voltage 7-15 DC bus 7-17 mains voltage (X5) 7-22 PE connection power supply unit resp. neighboring device 7-20 X X X X X X

55 Rexroth IndraDrive Electrical Installation 7-15 Control Voltage (+24 V, 0 V) The control voltage is supplied by an external 24-V power supply unit. Note: Technical data: see page 7-9 Falling short of the permissible control voltage leads to a corresponding error message (=> refer also to firmware function description). Interruption to the control voltage when the motor is running leads to torque-free (brakeless) runout in the motor. If a power supply unit is used with a DC bus dynamic braking function, an interruption to the control voltage supply causes braking to the axes through the DC bus dynamic braking. DANGER Dangerous movement caused by brakeless motor coasting to stop in the event of an interruption to the control voltage supply! Do not stay within the motional range of the machine. Possible measures to prevent personnel accidentally accessing the machine: protective fencing protective grid protective cover light barrier. Fencing and covers must be adequately secured against the maximum possible force of movement. Design The external 24-V power supply unit is connected to the supply unit by cables with a cross section of 1.5 mm 2 at least. The cables must not be to long in order to keep the claimed tolerance (±5%) of the control voltage. The control voltage supply is connected by contact rails and screws (M6) to the front of the drive controller (cross section of a contact rail: 4 x 12 mm). There are various lengths of contact rail depending on the width of the drive controllers.

56 7-16 Electrical Installation Rexroth IndraDrive A B A: cables (to the source of control voltage) B: contact rails Fig. 7-11: Contact rails schienen_steuerspg Tightening Torque 6 Nm

57 Rexroth IndraDrive Electrical Installation 7-17 DC Bus (L+, L-) The DC bus connection connects the supply unit to the drive controller the supply unit to additional components in order to increase the stored power by means of DC bus capacitor unit increase the permissible braking resistor continuous output by means of DC bus resistor unit Design The DC bus is connected by contact rails and screws (M6) to the front of the drive controller. There are various lengths of contact rail depending on the width of the drive controllers. schienen_zwkreis Fig. 7-12: Contact rails Tightening Torque 6 Nm DC Bus Wiring If in special cases it is not possible to use the DC bus rails provided to make the connection, the connection must be made using the shortest possible twisted wires. Length of the twisted wire Wire cross-section Wire protection Voltage stability of a single strand against grounding max. 2 m min. 10 mm², however, no less than the cross-section of the power input line by means of fuses in the mains supply > 750 V (e.g., strand type - H07) CAUTION Risk of voltage arcing! If wires instead of contact rails are used to connect the supply unit, the connections have to be correctly made (see page 13-1 onward).

58 7-18 Electrical Installation Rexroth IndraDrive CAUTION Risk of voltage arcing! If devices are stacked in the control cabinet, the connections for the DC buses between the drive controllers have to be correctly made. There is otherwise a risk of voltage arcing (see page 13-3 onward).

59 Rexroth IndraDrive Electrical Installation 7-19 PE Connection of Power Supply HMV01.1E-W0030, -W0075 HMV01.1R-W0018, -W0045, -W0065 HMV01.1E-W0120 hmv_erdanschluss_netz_30.fh7 Abb. 7-13: PE connection of power supply hmv_erdanschluss_netz_120.fh7 Design The ground wire is fixed to the supply unit with screws: HMV01.1E-W0030, -W0075 HMV01.1R-W0018, -W0045, -W0065 M6 x 25 HMV01.1E-W0120 M10 Tightening Torque HMV01.1E-W0030, -W0075 HMV01.1R-W0018, -W0045, -W0065 HMV01.1E-W Nm 18 Nm

60 7-20 Electrical Installation Rexroth IndraDrive PE Connection, Power Supply Unit and Neighboring Device The PE connection (grounding) to the drive controller can be provided in duplicate in the case of the drive controllers through: a grounding bracket on the front (see figure below) the rear panel of the device if the devices are positioned against a shared, bare metal surface Note: You must use the grounding bracket on the front for ground connection in any case. The rear panel of the device can be used in addition. 1 1: Grounding bracket for ground connection Fig. 7-14: PE connection to supply unit resp. neighboring device erdungslasche_hmv Note: If cables are used for PE connection they must have a cross section of at least 10 mm 2. The cross section must not be smaller than the cross section of the mains supply cable. Design The grounding bracket is fixed to the supply unit with screws (M6 x 25) Tightening Torque 6 Nm

61 Rexroth IndraDrive Electrical Installation 7-21 X1, Bus Module The bus module permits data exchange between the supply unit and the drive controllers. Graphic Representation Fig. 7-15: X1 X1_hmv Design Type Number of poles Type of design Flat line connector 8 Connector on device Fig. 7-16: Design Note: If extension leads are used the leads must be shielded. Their total length must not exceed a maximum of 40 m.

62 7-22 Electrical Installation Rexroth IndraDrive X2, RS232 RS232 Interface The RS232 interface is required for diagnosis during commissioning and servicing. Graphic Representation Fig. 7-17: X2 PS2_stecker_hmv.fh7 Design Type Number of poles Type of design MiniDIN 8 socket on device Fig. 7-18: Design Connection cross section Fig. 7-19: Cross section single-wire [mm²] Cross section multiwire [mm²] Cross section in AWG Gauge No Connection cross section Connection n.c. 1 n.c. 2 RS232_TxD 3 GND 4 RS232_RxD 5 n.c. 6 n.c. 7 n.c. 8 GND is connected to the housing.

63 Rexroth IndraDrive Electrical Installation 7-23 X3, Mains Connection Graphic Representation L1 L2 L3 Fig. 7-20: X3 hmv_x3 Design HMV01.1E- Type Number of poles Type of design W0030 Terminal block 3 Threaded terminal end W0075 Terminal block 3 Threaded terminal end W0120 Terminal block 3 Threaded terminal end HMV01.1R- Type Number of poles Type of design W0018 Terminal block 3 Threaded terminal end W0045 Terminal block 3 Threaded terminal end W0065 Terminal block 3 Threaded terminal end Fig. 7-21: Design Connection Cross Section HMV01.1E- Cross section single-wire [mm²] Cross section multiwire [mm²] Cross section in AWG W W W HMV01.1R- Cross section single-wire [mm²] Cross section multiwire [mm²] Cross section in AWG W W W Fig. 7-22: Connection cross sections

64 7-24 Electrical Installation Rexroth IndraDrive Tightening Torque HMV01.1E- Torque W W W HMV01.1R- Torque W W W Fig. 7-23: Tightening torques Note: See chapter 13.3 onward for further information on mains connection.

65 Rexroth IndraDrive Electrical Installation 7-25 X31, Connection for Messages Description The X31 interface is used as a connection for messages: supply unit ready for operation (Bb1) power supply ok (UD) warning signal for bleeder overload and overtemperature (WARN) Graphic Representation hmv_x31 Fig. 7-24: X31 Design Type Number of poles Type of design LK06-1M WIN R3,5 series 0734 Fig. 7-25: Design 6 Bushing on device Connection cross section Cross section single-wire [mm²] Cross section multiwire [mm²] Cross section in AWG Gauge No. 0,14-1,5 0,14-1, Fig. 7-26: Connection cross section

66 7-26 Electrical Installation Rexroth IndraDrive Connection X31 ready for operation 6 5 Bb1 DC bus ok 4 3 UD warning overtemperature/ bleeder overload 2 1 WARN hmv_x31_schalt Name Pin no. Description Level Notes Bb1_1 6 supply unit ready for contact Bb1_2 5 operation UD_1 4 UD_2 3 WARN_1 2 WARN_2 1 load DC 30V / 1A inrush current max. 5A contact closes: if no error is present contact opens: if error is present power supply ok contact load DC 30V / 1A inrush current max. 5A contact closes: if DC bus voltage is within the specified range contact opens: if DC bus voltage is too low resp. in case of mains failure warning signal for bleeder overload and overtemperature contact Fig. 7-27: Connection X31 load DC 30V / 1A inrush current max. 5A contact closes: in case of bleeder overload resp. overtemperature contact opens: setting by default

67 Rexroth IndraDrive Electrical Installation 7-27 X32, Mains Contactor Control, DC Bus Short Circuit, Braking Resistor Threshold Description The X32 interface is used to connect the mains contactor control the DC bus short circuit the switching signal for braking resistor threshold Note: See chapter 9 onward for further information on mains contactor control. Graphic Representation hmv_x32 Fig. 7-28: X32 Design Type Number of poles Type of design LK09-1M WIN R3,5 series 0734 Fig. 7-29: Design 9 Bushing on device Connection cross section Cross section single-wire [mm²] Cross section multiwire [mm²] Cross section in AWG Gauge No. 0,14-1,5 0,14-1, Fig. 7-30: Connection cross section

68 7-28 Electrical Installation Rexroth IndraDrive Connection X32 24V for interface DC bus short circuit 24V mains OFF mains ON braking resistor threshold fixed/variable * 24V 0V for interface * only for HMV01.1E-Wxxxx hmv_x32_schalt Name Pin no. Description Level Notes 24V_IF 9 24V supply for interface (input) 24V ±5% 24V supply for interface, because interface inputs are isolated DC bus s.c. 8 activating DC bus short circuit function 24V no DC bus short circuit function => 24V via external contact OFF1 7 OFF2 6 ON1 5 ON2 4 switching off mains contactor 24V for switching mains contactor on => pins jumpered via N/O switching on mains contactor 24V switching mains contactor on by closing pins for longer than 200 ms (pushbutton) braking resistor threshold 3 switching signal for braking resistor threshold 24V for HMV01.1E => switching between braking resistor threshold fixed <-> variable; input open: threshold variable (concerning braking resistor threshold see electrical data HMV01.1E on page 7-7) 24V 2 output 24V 24V for jumper on pin 3 for switching the braking resistor threshold 0V 1 0V reference signal 0V 0V reference potential for interface Fig. 7-31: Connection X32

69 Rexroth IndraDrive Electrical Installation 7-29 X33, Acknowledge Messages of Internal Mains Contactor Description The X33 interface is used as a connection for acknowledge messages of the internal mains contactor. Graphic Representation hmv_x33 Fig. 7-32: X33 Design Type Number of poles Type of design LK04-1M WIN R3,5 series 0734 Fig. 7-33: Design 4 Bushing on device Connection cross section Cross section single-wire [mm²] Cross section multiwire [mm²] Cross section in AWG Gauge No. 0,14-1,5 0,14-1, Fig. 7-34: Connection cross section Connection 4 X33 feedback contact mains contactor ON 3 2 feedback contact mains contactor OFF 1 hmv_x33_schalt Name Pin no. Description Level Notes MAINS_ON1 4 MAINS_ON2 3 MAINS_OFF1 2 MAINS_OFF2 1 feedback contact mains contactor ON (N/O) contact load DC 30V / 1A inrush current max. 5A feedback contact mains contactor OFF (N/C) contact load DC 30V / 1A inrush current max. 5A Fig. 7-35: Connection X33

70 7-30 Electrical Installation Rexroth IndraDrive X14, Mains Voltage Synchronization Description The X14 interface is only available for regenerative supply units (HMV01.1R). It is used to connect the mains voltage synchronization. Graphic Representation hmv_x14 Fig. 7-36: X14 Design Type Number of poles Type of design LE 7,62 M PC 4,0 / 3G 3 Connector on device Fig. 7-37: Design Connection cross section Cross section single-wire [mm²] Cross section multiwire [mm²] Cross section in AWG Gauge No. 1,5-4 1, Fig. 7-38: Connection cross section Connection Pin no. Description Level Notes 3 mains connection phase L3 before choke max. 900V current load max. 5A 2 mains connection phase L2 before choke max. 900V current load max. 5A 1 mains connection phase L1 before choke max. 900V current load max. 5A Fig. 7-39: Connection X14

71 Rexroth IndraDrive Electrical Installation Touch Guard WARNING Lethal electric shock caused by live parts with more than 50 V! The appropriate touch guard must be mounted for each supply unit following connection work. Never mount a damaged touch guard. Immediately replace a damaged touch guard by an undamaged touch guard. Cutouts A B C hms_beruehrschutz_seite.fh7 Fig. 7-40: Cutouts at the touch guard WARNING Lethal electric shock caused by live parts with more than 50 V! You have to provide the best possible protection against contact. Therefore keep the cutouts at the touch guard as small as possible. Only break off the cutouts if necessary. If the DC bus and the control voltage are connected by means of contact rails, only the cutout C (see picture) may be broken off the touch guard. If the DC bus and the control voltage are connected by means of cables (e.g. in the case of multiple-line arrangement of the drive controllers), the cutouts A, B and C (see picture) may be broken off the touch guard.

72 7-32 Electrical Installation Rexroth IndraDrive At the first and last drive controller in a line of devices connected to each other there mustn t any cutout be broken off at the outer side of the touch guard. Mounting The touch guard must always be mounted following connection work. hmv_beruehrschutz Fig. 7-41: Touch guard Note: Risk of damage to the touch guard! The maximum tightening torque for the fixing screw for the touch guard is 2.8 Nm. Tightening Torque 2.8 Nm

73 Rexroth IndraDrive Determination of Appropriate Power Supply Units Determination of Appropriate Power Supply Units 8.1 Introduction 8.2 DC Bus Continuous Power The mains supply for an AC drive system of the IndraDrive M product family mainly consists of the power supply unit. Depending on the tasks and design of the supply unit and the conditions of its use, it may be necessary to add link reactors, auxiliary capacitors, bleeder modules and transformers as needed. The mains supply must make available to the drives the DC bus continuous power and the DC bus peak power for acceleration. During regenerative operation it must be able to store continuous and peak regenerated power. The supply unit also makes the control voltage for the drive controllers available. Prior to selecting supply unit and auxiliary components it is necessary to determine the motors and drive controllers which will be used. It is advisable to carry out calculations in accordance with the following chapters in order to make sure that the layout of the mains supply is correct. Mechanical power Continuous mechanical power for servo drives Average motor speed The DC bus continuous power is calculated from the mechanical power and based on the efficiency of motor and controller as well as coincidence factors. P P m m M * 2πn [W] = M ω = 60 [kw] = P m: mechanical power M: torque [Nm] ω: angular speed [min -1 ] n: motor speed [min -1 ] Fig. 8-1: Mechanical power M * n 9550 The effective motor torque and average motor speed are needed to calculate the mechanical continuous power of a servo drive. The effective motor torque of the servo drive calculations can be assumed. The average motor speed is determined as follows: The average motor speed equals approximately 25% of the rapid motion speed - in the case of servo drive tasks in conventional NC machine tools. In some cases, however, this approximate estimation is not sufficient. A precise calculation of the average motor speed is necessary. or

74 8-2 Determination of Appropriate Power Supply Units Rexroth IndraDrive Average speed without accel and decel time If the duration over which the drive is operated at constant speed is considerably greater than the accel and decel time, then it applies: n av n = 1 * t 1 + n t 1 2 * t + t n... + t n av: average motor speed [min -1 ] n 1... n n: motor speed [min -1 ] t 1... t n: ON time [s] Fig. 8-2: Average speed; influence of accel and decel time is not taken into consideration n n * t n n 1 n 2 t n 3 t1 t2 t3 t4 DGoE.fh7 Abb. 8-3: Speed cycle; influence of accel and decel time is not taken into consideration Average speed with accel and decel times Accel and decel times with short cycle times must be taken into consideration in such dynamic applications as is the case with rollers and nibble machines: n av = n * t 2 t H H + n * t + t t B n + * t 2 + t n av: average motor speed [min -1 ] n: motor speed [min -1 ] t: time [s] t H: accel time [s] t B: decel time [s] Fig. 8-4: Average speed; influence of accel and decel time is taken into consideration 2 B n t H t t 1 t B t 2 DGmE.fh7 Abb. 8-5: Average speed; influence of accel and decel time is taken into consideration

75 Rexroth IndraDrive Determination of Appropriate Power Supply Units 8-3 Mechanical power for servo drives Mechanical power for main drives P mse: M eff: P mse = M eff * n 9550 continuous mech. power for servo drives [kw] effective motor torque [Nm] n av: average motor speed [min -1 ] Fig. 8-6: Mechanical power for servo drives Main drives are primarily used with constant power over a specific speed range. This means that when planning power supply, nominal power is important. The mechanical nominal power of the main drives is illustrated in the operating characteristics or it can be calculated using nominal speed and torque. av P mha = Mn * n 9550 P mha: mechanical nominal power for main drives (shaft output) [kw] M n: motor nominal torque [Nm] n n: motor nominal speed [min -1 ] Fig. 8-7: Mechanical power for main drives n DC bus continuous power for servo drives The power supply unit must make the DC bus continuous power available to all servo drives. All drives are operated simultaneously in only a few applications which means that only the simultaneously occurring output needs to be considered. For the calculation of the required DC bus continuous power for typical NC feed axes on tool machines, it has proven in practice that a so-called coincidence factor is included: Number of Axes Coincidence factor (F G) 1 1,15 1,32 1,75 2,0 2,25 Fig. 8-8: Coincidence factors P (P = mse1 + P mse P F G msen ) * 1,25 P ZWSe: DC bus continuous power for servo drives [kw] P mse1... P msen: cont. mech. power for servo drives [kw] F G: coincidence factor 1,25: constant for motor and controller efficiency Fig. 8-9: DC bus continuous power for servo drives DC bus continuous power for main drives If several main drives are operated on one DC bus, then add the simultaneously required power: PZWHa = (PmHa1 + PmHa P mhan P ZWHa: DC bus continuous power for main drives [kw] P mha1... P mhan: mech. cont. power for main drives [kw] 1,25: constant for motor and controller efficiency Fig. 8-10: DC bus continuous power for main drives ) * 1,25 Chokes and auxiliary capacitors are selected in terms of the actually required DC bus continuous power. It is fixed by the nominal power of the spindle drives. Note: When selecting the power supply unit make sure that the DC bus continuous power does not limit the short-term power of the main drives.

76 8-4 Determination of Appropriate Power Supply Units Rexroth IndraDrive DC bus continuous power for main and servo drives If main and servo drives are operated on a power supply unit, the required DC bus continuous power needs to be added. It is the spindle drive in a NC machine tool that primarily determines the DC bus power needed. Therefore, the following equation should be applied in such applications: PZW = [PmHa + 0,3 * (PmSe1 + PmSe P msen )] * 1,25 0,3: experimental value for standard machine tools 1,25: constant for motor and controller efficiency P ZW: DC bus continuous power [kw] P mse1... P msen: continuous mech. servo drive output [kw] P ZWHa: nominal power for spindle drives (shaft output) [kw] Fig. 8-11: DC bus continuous power for spindle and servo drives in machine tools 8.3 DC Bus Peak Power The DC bus peak power is demanded of the power supply unit when, e.g., several axes of a machine tool simultaneously accelerate to rapid traverse and then go to a workpiece after a tool change. CAUTION Damages due to overloaded power supply unit! Damages to the power supply unit can be avoided, if the sum of the peak power of all drives does not exceed the DC bus peak power of the power supply unit. P ZWS (M = NC ± MG ) * n 9550 eil *1,25 1,25: constant for motor and controller efficiency M NC: acceleration torque in NC mode [Nm] M G: weight torque in vertical axes [Nm] n eil: speed in rapid traverse [min -1 ] P ZWS: DC bus peak power [kw] Fig. 8-12: DC bus peak power per drive P ZWS P ZWS 03 P ZWS: DC bus peak power [kw] P ZWS03: DC bus peak power of the power supply unit [kw] Fig. 8-13: Sum of DC bus peak powers

77 Rexroth IndraDrive Determination of Appropriate Power Supply Units Regenerated Energy The energy content of all main and servo drives that brake simultaneously under unfavorable conditions may not be greater than the maximum regenerated energy of the power supply unit as specified in the data sheet. If this is not taken into consideration during the layout stage, then there could be thermal damage to the bleeder resistor in the power supply unit! CAUTION Property damages due to overloaded bleeder resistor! Use a power supply unit that is appropriate for the consumption of the regenerated power which arises when all the main and servo drives connected to the power supply unit brake simultaneously. W rot JG = * n 2 eil 2π * 60 W rot: rotary energy [Ws] n eil: rapid traverse speed [min -1 ] J G: inertia of motor and load inertia reduced to shaft [kgm²] Fig. 8-14: Regenerated energy per drive 2 W rot: W MAX: Fig. 8-15: W rot WMAX rotary energy [Ws] max. permissible regenerated energy of the power supply module [kws] Sum of regenerated energies Auxiliary capacitance as energy storage in the HMV01.1E In servo drive applications with numerous accel and decel procedures, as is the case, for example, with nibble machines and rollers, it is advisable to connect additional capacitors to the DC bus. The following advantages result from this: This prevents the bleeder resistor in the HMV01.1E power supply unit from being actuated while braking: The heat dissipated within the control cabinet is considerably reduced. The stored energy can be used to accelerate thus reducing energy requirements of the installation. W ZW: C ZW: U B: U ZW: Fig. 8-16: W ZW C = 2 ZW * 2 2 ( U U ) B ZW energy stored in the DC bus DC bus capacitor [F] bleeder actuation threshold DC bus nominal voltage Energy that can be stored in the DC bus

78 8-6 Determination of Appropriate Power Supply Units Rexroth IndraDrive The auxiliary capacitor must be designed so that it is capable of storing rotary drive energy: C Zu U 2W rot U 2 ZW 2 B * 1000 C HMV01.1Eintern U B: bleeder actuation threshold (approx. 820 V) U ZW: DC bus nominal voltage W rot: rotatory energy [Ws] C Zu: auxiliary capacitor [mf] C HMV01.1Ein intern: internal capacitance of supply unit [mf] Fig. 8-17: Required auxiliary capacitance In power supply units with regulated DC bus voltage (HMV01.1R) approximately 75 Ws per mf auxiliary capacitance can be stored. In power supply units with unregulated DC bus voltage (HMV01.1E) the auxiliary capacitance should be designed for 10% overvoltage. The storable energy per mf auxiliary capacitance is listed in the table below. Mains voltage 3 x AC 380 V 3 x AC 400 V 3 x AC 440 V 3 x AC 480 V storable energy per mf auxiliary capacitance 163 Ws 144 Ws 103 Ws 89 Ws Fig. 8-18: Storable energy with auxiliary capacitance on an HMV01.1E 8.5 Continuous Regenerated Power The average sum of the continuous regenerated power of all drives may not exceed the continuous regenerated power in the HMV01.1R or the continuous bleeder power in the HMV01.1E. Note: For operation with continuous power, an additional load caused by DC bus short circuit is no longer allowed. The processing time in servo drive applications given a typical NC machine tool, is relatively long in terms of the entire cycle time. There is little regenerated continuous power. An exact calculation is generally not required. It suffices if the peak regenerated power is not exceeded. An exact calculation is needed in specific cases such as, for example: servo drive applications with numerous accel / decel procedures such as is the case in nibble machines and rollers machine tools with modular main drives applications in which excessive masses must be lowered as is the case with those overhead gantries used with storage and transport technologies To calculate continuous regenerated power, the rotary energy of the drives and the potential energy of non-compensated masses must be known. W rot Jg = * n 2 eil 2π * 60 W rot: rotary energy [Ws] n eil: speed in rapid traverse [min -1 ] J g: moment of inertia (motor + load) [kgm²] z: number of decels per cycle Fig. 8-19: Rotary energy 2 * z

79 Rexroth IndraDrive Determination of Appropriate Power Supply Units 8-7 W pot = m * g * h * z W pot: potential energy [Ws] m: load mass [kg] g: gravity constant = 9,81 m/s² h: drop height [m] z: number of drops per cycle Fig. 8-20: Potential energy of non-compensated masses P RD: P BD: t z: W potg: W rotg: Fig. 8-21: P W + W potg rotg RD = PRD PBD t z continuous regenerated power [kw] continuous bleeder power [kw] cycle time [s] sum of potential energy [kws] sum of rotary energies [kws] Continuous regenerated energy 8.6 Peak Regenerated Power The peak regenerated power usually arises, when an Emergency Stop signal has been released and all the axes brake simultaneously. CAUTION Property damages due to longer braking periods/paths! Choose the power supply unit such that the sum of the peak regenerated power of the all drives does not exceed the bleeder peak power of the power supply unit. The peak regenerated power of the servo drives is listed in the motor selection documentation. Roughly estimated, the peak regenerated power can be calculated as follows: Mmax * nmax PRS = 9550 * 1,25 P Rs PBS P RS: peak regenerated power [kw] P BS: peak bleeder power [kw] M max: max. drive torque [Nm] n max: max. NC usable speed [min -1 ] 1,25: constant for motor and controller efficiency Fig. 8-22: Peak regenerated power

80 8-8 Determination of Appropriate Power Supply Units Rexroth IndraDrive 8.7 Connected Load of the Supply Unit The connected load is calculated to be able to determine mains fuses, line cross sections and, if needed, commutation chokes and transformers. The connected load is dependent on the continuous power of the drives and the functional principle of the power supply unit. without mains choke (KD) : with mains choke (KD) : S N1: P ZW: Fig. 8-23: S S S N1 = P N1 N1 = P ZW = P ZW ZW * 1,7 (for * 1,5 (for HMV01.1E W0075, W0120) * 1,15 HMV01.1E W0030) connected load [kva] DC bus continuous power [kw] Connected load for power supply units of the HMV01.1E line S N1: P ZW: Fig. 8-24: S N 1 = P ZW * 1,05 connected load [kva] DC bus continuous power [kw] Connected load for power supply units of the HMV01.1R line I N1: S N1: U N1: Fig. 8-25: mains current [I] connected load [kva] mains voltage [U] Mains current SN1 *1000 I N1 = 3 * U N1

81 Rexroth IndraDrive Control Mains Contactor Control Mains Contactor 9.1 Control Possibilities The controls of the mains contactor and of the DC bus dynamic brake in the supply unit, that are suggested in this documentation, explain the function principles. In this chapter, several control options are discussed and explained. Note: Which control and functions are selected ultimately depend on the extent of functions required and the range of actions of the entire installation and is primarily the responsibility of the manufacturer. Shutdowns with Faulty Drive Electronics An additional safety for braked shutdowns of the drives in case of faulty drive electronics is to short-circuit the DC bus voltage. If the DC bus voltage is short-circuited, the motors with permanent energized magnet will always be shut down to a braked condition. This is the case whether the drive electronics is operative or not. Note: Asynchronous drives do not brake when DC bus voltage is short circuited! If the drive electronics is interfered and the DC bus voltage is not shortcircuited, then the motors with energized permanent magnet will slow down uncontrolled. Braking with Emergency Stop or Power Failure In an emergency stop or power failure situation, drives are generally shutdown by the drive control. Given an emergency stop or with actuation of the drive-internal monitor, the drive control command value is set to go to zero and the drives brake controlled at maximum torque. In some applications, however, e.g., electronically-coupled gear cutting machines, it is necessary to bring the drives, given an emergency stop or power failure, to a standstill controlled by the CNC. In an emergency stop situation or given the actuation of the drive-internal monitor, the drives are shutdown position-controlled by the NC control. 9.2 Controlling the Supply Unit with Emergency Stop Relays With DC Bus Dynamic Brake If the mains contactor in the supply unit is controlled via the emergency stop relay and the DC bus is short-circuited, you will reach maximum safety possible thus with very little expenditure. The drive system monitors are most effectively used.

82 9-2 Control Mains Contactor Rexroth IndraDrive Applications You should use this mode, if only motors with permanent magnetic excitation have been mounted, or if motors with permanent magnetic excitation and asynchronous motors (induction machines) have been mounted, or if the E-Stop circuit must be duplicated or if e.g. a protection door monitor is required, or if your drive system includes an extended and substantial E-Stop circuit. Note: As the energizing current of the auxiliary relay for triggering the mains contactor flows via the E-Stop circuit, the voltage drop must not become too great. To ensure a reliable energizing, the total resistance of the E-Stop circuit which comes into effect between the connections X3/1 and X3/9 must be under 45 Ω! Features The DC bus dynamic brake can shutdown motors with permanent magnetic excitation even with a fault in the drive electronics. In order to trigger the DC bus dynamic brake in such a case, the Bb contacts of the drive controllers in the E-Stop circuit have to be connected in series with the CNC contact. The DC bus dynamic brake is only active in the event of drive errors. If the emergency stop is actuated, asynchronous drives will also brake. When the Bb contacts of the supply unit are connected in series with the CNC contact in the E-Stop circuit, the DC bus dynamic brake is only triggered in the case of a supply unit error. In an emergency stop situation or with actuation of the monitor in the supply unit (e.g., power failure), the drives are shutdown by the drive electronics in the manner set for the specific error reaction. WARNING Property damages due to uncontrolled axis movements! The DC bus dynamic brake protects machines against drive errors. It alone cannot assume the function of protecting personnel. Given faults in the drive and supply unit, uncontrolled drive movements are still possible even if the DC bus dynamic brake is activated. Asynchronous machines do not brake if the DC bus is short-circuited. Depending on the type of machine, injury to personnel is possible. Additional monitoring and protective devices should be installed in the installation. Function When actuating the emergency stop key, the mains contactor in the supply unit immediately falls off. Drive enables are shut off by the emergency stop relay or an auxiliary contact of the mains contactor. The drives are shutdown as per the error reaction set in the drive controller. A drive error message from the supply module (Bb1-contact), an error message by the NC control (servo error) or the overtravelling of the end limit switch causes the mains contactor to be switched off and the DC bus dynamic brake to be actuated.

83 Rexroth IndraDrive Control Mains Contactor V +/-5% X3 0 V X32/1 X32/9 X31/5 Bb1 S2 CNC A10 1) X31/6 X32/8 X32/7 signal processing bleeder control >1 K1 2) L+ 1) X32/6 X32/5 X32/4 K1 DC bus dynamic brake & enable converter L- K1 ready-tooperate ON delay approx. 1.5 seconds... 4 minutes 3) Power supply unit +24V +/- 5% RF 1 2 Control voltage K1 UD X33/4 HMV01.1E/ HMV01.1R X33/3 X31/4 X31/3 K4 A10 X33/1 K1 X33/2 S5 S11 S12 safety door closed S4 S1 K4 Bb U AF AF AF Drive controllers A10 Emergency-stop relay 0V Example. Depending on safety requirements at A10 = Emergency-stop relay the machine, additional monitoring devices and AF = drive enable of the drive controllers locks may be necessary! Bb1 = power supply unit ready (drive system) Bb = drive controllers ready CNC = lag error message of control (use only contacts that do not open with E-stop switch is open) K1 = mains contactor in power supply unit K4 = drive enable signal control RF = drive enable signal of the control S1 = Emergency-stop S2 = axis end position S4 = power OFF S5 = power ON S11/S12 = safety door monitor 1) K1 control if no emergency-stop switch is used 2) unregulated rectifier in HMV01.1E; regulated one in HMV01.1R 3) depending on power supply unit and possibly connected external capacitors SS2HMV.fh7 Fig. 9-1: Control of the supply unit with DC bus dynamic brake in the event of faulty drive electronics

84 9-4 Control Mains Contactor Rexroth IndraDrive Without DC Bus Dynamic Brake Application Features Function If an uncontrolled running out of the drives cannot damage the installation. If only asynchronous drives are connected to the supply unit. If the end positions of the feed axes are sufficiently attenuated. The DC bus voltage is not short-circuited. In an emergency stop situation, or if the monitors of the supply unit are actuated (e.g., power failure), then the drives are shutdown by the drive electronics as per the set error reaction. The mains contactor in the supply unit immediately falls off when the emergency stop sequence is initiated. The drive enable is removed by the emergency stop relay or by an auxiliary contact of the mains contactor. The drives are shutdown depending on the set error reaction. CAUTION Machine damages due to brakeless slowing down of the drives in the event of faulty drive electronics! Use motors with mechanical brakes (a holding brake must not be used as operating brake). End positions of feed axes must be sufficiently attenuated.

85 Rexroth IndraDrive Control Mains Contactor V +/-5% X3 0 V X32/1 X31/5 Bb1 for diagnostics X32/9 X31/6 bleeder control K1 A10 1) X32/8 X32/7 signal processing >1 2) L+ X32/6 L- 1) X32/5 X32/4 K1 DC bus dynamic brake & enable converter K1 ready-tooperate ON delay approx. 1.5 seconds... 4 minutes 3) Power supply unit +24V +/- 5% RF K1 UD 1 2 X33/4 HMV01.1E/ HMV01.1R X33/3 X31/4 X31/3 K4 A10 X33/1 K1 X33/2 S5 Control voltage S11 S12 safety door closed S4 S1 K4 Bb U AF AF AF Drive controllers A10 Emergency-stop 0V Example. Depending on safety requirements at A10 = Emergency-stop relay the machine, additional monitoring devices and AF = drive enable of the drive controllers locks may be necessary! Bb1 = power supply unit ready (drive system) Bb = drive controllers ready CNC = lag error message of control (use only contacts that do not open with E-stop switch is open) K1 = mains contactor in power supply unit K4 = drive enable signal control RF = drive enable signal of the control S1 = Emergency-stop S2 = axis end position S4 = power OFF S5 = power ON S11/S12 = safety door monitor 1) K1 control if no emergency-stop switch is used 2) unregulated rectifier in HMV01.1E; regulated one in HMV01.1R 3) depending on power supply unit and possibly connected external capacitors SS3HMV.fh7 Fig. 9-2: Control of the supply unit without DC bus dynamic brake

86 9-6 Control Mains Contactor Rexroth IndraDrive 9.3 Control via NC Controller Application Features If the mains contactor is controlled via NC controller, it is possible to provide a position controlled shutdown of the drive via the NC controller in the event of an emergency stop or as reaction of the internal monitoring of the drive. This kind of mains contactor control is mostly used with drives which are electronically coupled and shutdown synchronously when a power failure occurs. The DC bus voltage is not short-circuited so that power for a positioncontrolled shutdown of the drives is available. Note: The energy stored in the DC bus or the regenerated energy must be greater than the energy needed to excite asynchronous machines or for the return motion. Function The parameter "Activating NC reactions with a fault" must be programmed in the drive controller (P , bit 0 = 1). Given an emergency stop or the actuation of the supply unit monitor (e.g., power failure), the drives are shutdown position-controlled by the position controller. Upon initiating the emergency stop sequence, or with the actuation of the monitor in the supply unit (e.g., power failure), the mains contactor in the supply unit falls off. Drives with SERCOS interface signal the error to the NC control, meaning that the drives can be shutdown position controlled. Drives without SERCOS interface require the control to evaluate the UD contact. If the UD contact is actuated, then the NC control must shut down the drives. CAUTION Machine damages due to brakeless slowing down of the drives in case of too little DC bus voltage! The controller should evaluate the UD contact and shut down the drives, when the contact reacts.

87 Rexroth IndraDrive Control Mains Contactor V +/-5% U V W X3 0 V X32/1 X31/5 Bb1 for diagnostics X32/9 braking resistor control K1 X31/6 A10 1) X32/8 X32/7 signal processing >1 2) L+ 1) X32/6 X32/5 X32/4 K1 DC bus dynamic brake & enable converter L- K1 ready-tooperate ON delay approx. 1.5 seconds... 4 minutes 3) Power supply unit +24V +/- 5% Control voltage RF Bb UD X31/4 X31/3 X33/1 K1 X33/2 S11 S4 AF AF AF Drive controller Machine control S5 S12 safety door closed S1 A10 Emergency-stop ralay 0V Example. Depending on safety requirements at the machine, additional monitoring devices and A10 = Emergency-stop relay locks may be necessary! AF = drive enable of the drive controllers Bb1 = power supply units ready (drive system) Bb = drive controllers ready CNC = lag error message of control (use only contacts that do not open with E-stop switch is open) K1 = mains contactor in power supply unit K4 = drive enable signal control RF = drive enable signal of the control S1 = Emergency-stop S2 = axis end position S4 = power OFF S5 = power ON S11/S12 = safety door monitor 1) K1 control if no emergency-stop switch is used 2) unregulated rectifier in HMV01.1E; regulated one in HMV01.1R 3) depending on power supply unit and possibly connected external capacitors SS4HMV.fh7 Fig. 9-3: Control for position controlled shutdown of the drives via NC-controller (without DC bus voltage brake)

88 9-8 Control Mains Contactor Rexroth IndraDrive Notes

89 Rexroth IndraDrive Troubleshooting Troubleshooting 10.1 General Extensive searches for faults and repair of drive components on the machine are not acceptable due to the production downtime involved. The modular concept of Rexroth drives makes it possible to completely exchange drive components. Service thus means localizing problems either on the motor, drive controller or power supply unit and replacing the part. Hinweis: No further adjustments are needed Fault Diagnostics and Resetting Faults Fault diagnostics Resetting faults The supply unit signals operating states, warnings or faults via a display. A prerequisite for fault diagnoses is control voltages and processors in the supply units and drive controllers that are working properly. Stored fault messages must be reset before the unit will again operate. An error can be reset by pressing key "Esc" on the control panel (display), switching the control voltage off or generating the reset command of the drive controller via the bus module. CAUTION Destruction of the power supply module, if the power is switched on to a faulty drive controller! Upon RESET of an over current fault and after replacement of a defective supply module, the fault memories of the drive controllers must be read out prior to switching it on. If either checks or repairs are needed, then it applies: Checks and repairs may only be conducted by Rexroth customer service personnel or such personnel that has been trained to do so. Observe the applicable safety regulations when checking the unit. Repairing drive components on the machine is very time consuming. Replace defective drive components completely. WARNING When faults are cleared, damages to the machine and injury to the personnel may occur! Fault clearance should only be conducted by trained personnel. Protective devices must not be switched off. Note the warnings in chapter 3.

90 10-2 Troubleshooting Rexroth IndraDrive 10.3 Checking and Repairing the Unit When contacting our service personnel we would like to ask you to provide the following information so that a quick and precise assistance can be assured: type designations and serial numbers of units and motors, the status of the fault, any diagnostic displays and software status, if necessary. You ll find the telephone number of our service hotline in the chapter "Service & Support".

91 Rexroth IndraDrive Troubleshooting Replacing the Unit Note: Replacing the unit requires, depending upon unit weight, a lifting device and an identical replacement unit. DANGER Electrical shock due to voltage-containing parts of more than 50 V! The unit may only be replaced by qualified personnel, which have been trained to perform the work on or with electrical devices. Note: Prior to the replacement of the unit please check according to the type plates, whether these units are of the same types. Replace only units of the same types. Proceed as follows: 1. Switch voltage to installation off and secure it against being switched back on. 2. Using an appropriate measuring device, check whether the installation is power free. Wait the discharge time. 3. Motors must be standing still. 4. Secure vertical axes against motion. 5. Release all connections from the defective unit. 6. Release the fixing bolts and remove the unit from the control cabinet. Use the lifting device, if necessary. 7. Hang replacement unit into mounting rails. Use the lifting device, if necessary. 8. Reconnect the unit as per the terminal diagram of the machine manufacturer. 9. If vertical axes have been mechanically secured prior to replacement, then remove these devices at this point. 10. While reading out the fault memories of the connected drive controllers make sure that the device fault has not been triggered by the drive controllers (see warnings in chapter 10.2 "Fault Diagnostics and Resetting Faults"). The unit replacement is completed. The system can be put back into operation.

92 10-4 Troubleshooting Rexroth IndraDrive 10.5 Diagnostic Display Concerning error diagnoses displayed on the control panel see Troubleshooting Guide of firmware documentation.

93 Rexroth IndraDrive Disposal and Environmental Protection Disposal and Environmental Protection 11.1 Disposal Products Our products can be returned to us free of charge for disposal. It is a precondition, however, that the products are free of oil, grease or other dirt. In addition, when returned the products mustn t contain any undue foreign matter or foreign component. Please send the products free domicile to the following address: Bosch Rexroth AG Electric Drives and Controls Bürgermeister-Dr.-Nebel-Straße 2 D Lohr am Main Packaging Materials The packaging materials consist of cardboard, wood and polystyrene. They can be easily recycled. For ecological reasons you should not return the empty packages to us Environmental Protection No Release of Hazardous Substances Materials Contained in the Products Our products do not contain any hazardous substances that they can release in the case of appropriate use. Normally there aren't any negative effects on the environment to be expected. Electronic Devices Electronic devices mainly contain: steel aluminum copper synthetic materials electronic components and modules Motors Motors mainly contain: steel aluminum copper brass magnetic materials electronic components and modules

94 11-2 Disposal and Environmental Protection Rexroth IndraDrive Recycling Due to their high content of metal most of the product components can be recycled. In order to recycle the metal in the best possible way it is necessary to disassemble the products into individual modules. The metals contained in the electric and electronic modules can also be recycled by means of specific separation processes. The synthetic materials remaining after these processes can be thermally recycled.

95 Rexroth IndraDrive Service & Support Service & Support 12.1 Helpdesk Unser Kundendienst-Helpdesk im Hauptwerk Lohr am Main steht Ihnen mit Rat und Tat zur Seite. Sie erreichen uns Our service helpdesk at our headquarters in Lohr am Main, Germany can assist you in all kinds of inquiries. Contact us - telefonisch - by phone: 49 (0) über Service Call Entry Center Mo-Fr 07:00-18:00 - via Service Call Entry Center Mo-Fr 7:00 am - 6:00 pm - per Fax - by fax: +49 (0) per - by service.svc@boschrexroth.de 12.2 Service-Hotline Außerhalb der Helpdesk-Zeiten ist der Service direkt ansprechbar unter After helpdesk hours, contact our service department directly at +49 (0) oder - or +49 (0) Internet Unter finden Sie ergänzende Hinweise zu Service, Reparatur und Training sowie die aktuellen Adressen *) unserer auf den folgenden Seiten aufgeführten Vertriebsund Servicebüros. Verkaufsniederlassungen Niederlassungen mit Kundendienst Außerhalb Deutschlands nehmen Sie bitte zuerst Kontakt mit unserem für Sie nächstgelegenen Ansprechpartner auf. *) Die Angaben in der vorliegenden Dokumentation können seit Drucklegung überholt sein. At you may find additional notes about service, repairs and training in the Internet, as well as the actual addresses *) of our sales- and service facilities figuring on the following pages. sales agencies offices providing service Please contact our sales / service office in your area first. *) Data in the present documentation may have become obsolete since printing Vor der Kontaktaufnahme... - Before contacting us... Wir können Ihnen schnell und effizient helfen wenn Sie folgende Informationen bereithalten: 1. detaillierte Beschreibung der Störung und der Umstände. 2. Angaben auf dem Typenschild der betreffenden Produkte, insbesondere Typenschlüssel und Seriennummern. 3. Tel.-/Faxnummern und -adresse, unter denen Sie für Rückfragen zu erreichen sind. For quick and efficient help, please have the following information ready: 1. Detailed description of the failure and circumstances. 2. Information on the type plate of the affected products, especially type codes and serial numbers. 3. Your phone/fax numbers and address, so we can contact you in case of questions.

96 12-2 Service & Support Rexroth IndraDrive 12.5 Kundenbetreuungsstellen - Sales & Service Facilities Deutschland Germany vom Ausland: (0) nach Landeskennziffer weglassen! from abroad: don t dial (0) after country code! Vertriebsgebiet Mitte Germany Centre SERVICE SERVICE SERVICE Rexroth Indramat GmbH Bgm.-Dr.-Nebel-Str. 2 / Postf Lohr am Main / Lohr Kompetenz-Zentrum Europa Tel.: +49 (0) Fax: +49 (0) CALL ENTRY CENTER MO FR von 07:00-18:00 Uhr from 7 am 6 pm Tel. +49 (0) service.svc@boschrexroth.de HOTLINE MO FR von 17:00-07:00 Uhr from 5 pm - 7 am + SA / SO Tel.: +49 (0) oder / or Tel.: +49 (0) ERSATZTEILE / SPARES verlängerte Ansprechzeit - extended office time - nur an Werktagen - only on working days - von 07:00-18:00 Uhr - from 7 am - 6 pm - Tel. +49 (0) Vertriebsgebiet Süd Germany South Vertriebsgebiet West Germany West Gebiet Südwest Germany South-West Bosch Rexroth AG Landshuter Allee München Tel.: +49 (0) Fax: +49 (0) Bosch Rexroth AG Regionalzentrum West Borsigstrasse Ratingen Tel.: +49 (0) Fax: +49 (0) (0) Bosch Rexroth AG Service-Regionalzentrum Süd-West Siemensstr Fellbach Tel.: +49 (0) Fax: +49 (0) Vertriebsgebiet Nord Germany North Vertriebsgebiet Mitte Germany Centre Vertriebsgebiet Ost Germany East Vertriebsgebiet Ost Germany East Bosch Rexroth AG Walsroder Str Langenhagen Tel.: +49 (0) Service: +49 (0) Fax: +49 (0) Service: +49 (0) Bosch Rexroth AG Regionalzentrum Mitte Waldecker Straße Mörfelden-Walldorf Tel.: +49 (0) Fax: +49 (0) Bosch Rexroth AG Beckerstraße Chemnitz Tel.: +49 (0) Fax: +49 (0) Bosch Rexroth AG Regionalzentrum Ost Walter-Köhn-Str. 4d Leipzig Tel.: +49 (0) Fax: +49 (0)

97 Rexroth IndraDrive Service & Support 12-3 Europa (West) - Europe (West) vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen from abroad: don t dial (0) after country code, Italy: dial 0 after country code Austria - Österreich Austria Österreich Belgium - Belgien Denmark - Dänemark Bosch Rexroth GmbH Electric Drives & Controls Stachegasse Wien Tel.: +43 (0) Fax: +43 (0) Bosch Rexroth GmbH Electric Drives & Controls Industriepark Pasching Tel.: +43 (0) Fax: +43 (0) Bosch Rexroth AG Electric Drives & Controls Industrielaan Ternat Tel.: +32 (0) service: +32 (0) Fax: +32 (0) service@boschrexroth.be BEC A/S Zinkvej Randers Tel.: +45 (0) Fax: +45 (0) Great Britain Großbritannien Finland - Finnland France - Frankreich France - Frankreich Bosch Rexroth Ltd. Electric Drives & Controls Broadway Lane, South Cerney Cirencester, Glos GL7 5UH Tel.: +44 (0) Fax: +44 (0) sales@boschrexroth.co.uk service@boschrexroth.co.uk Bosch Rexroth Oy Electric Drives & Controls Ansatie Vantaa Tel.: +358 (0) Fax: +358 (0) Bosch Rexroth SAS Electric Drives & Controls Avenue de la Trentaine (BP. 74) Chelles Cedex Tel.: +33 (0) Fax: +33 (0) Hotline: +33 (0) Bosch Rexroth SAS Electric Drives & Controls ZI de Thibaud, 20 bd. Thibaud (BP. 1751) Toulouse Tel.: +33 (0) Fax: +33 (0) France Frankreich Italy - Italien Italy - Italien Italy - Italien Bosch Rexroth SAS Electric Drives & Controls 91, Bd. Irène Joliot-Curie Vénissieux Cedex Tel.: +33 (0) Fax: +33 (0) Bosch Rexroth S.p.A. Via G. Di Vittorio, Cernusco S/N.MI Hotline: Tel.: Service: Fax: Service: Bosch Rexroth S.p.A. Via Paolo Veronesi, Torino Tel.: Fax: Bosch Rexroth S.p.A. Via Mascia, Castellamare di Stabia NA Tel.: Fax: Italy - Italien Italy - Italien Netherlands - Niederlande/Holland Netherlands Niederlande/Holland Bosch Rexroth S.p.A. Via del Progresso, 16 (Zona Ind.) Padova Tel.: Fax: Bosch Rexroth S.p.A. Via Isonzo, Casalecchio di Reno (Bo) Tel.: Fax: Bosch Rexroth Services B.V. Technical Services Kruisbroeksestraat 1 (P.O. Box 32) 5281 RV Boxtel Tel.: +31 (0) (0) Fax: +31 (0) (0) services@boschrexroth.nl Bosch Rexroth B.V. Kruisbroeksestraat 1 (P.O. Box 32) 5281 RV Boxtel Tel.: +31 (0) Fax: +31 (0) Norway - Norwegen Spain - Spanien Spain Spanien Sweden - Schweden Bosch Rexroth AS Electric Drives & Controls Berghagan 1 or: Box Ski-Langhus 1402 Ski Tel.: +47 (0) Fax: +47 (0) Hotline: +47 (0) jul.ruud@rexroth.no Bosch Rexroth S.A. Electric Drives & Controls Centro Industrial Santiga Obradors s/n Santa Perpetua de Mogoda Barcelona Tel.: Fax: Goimendi S.A. Electric Drives & Controls Parque Empresarial Zuatzu C/ Francisco Grandmontagne no San Sebastian Tel.: service: Fax: service: sat.indramat@goimendi.es Bosch Rexroth AB Electric Drives & Controls - Varuvägen 7 (Service: Konsumentvägen 4, Älfsjö) Stockholm Tel.: +46 (0) Fax: +46 (0) Sweden - Schweden Switzerland West - Schweiz West Switzerland East - Schweiz Ost Bosch Rexroth AB Electric Drives & Controls Ekvändan Helsingborg Tel.: +46 (0) Fax: +46 (0) Bosch Rexroth Suisse SA Av. Général Guisan Vevey 1 Tel.: +41 (0) Fax: +41 (0) Bosch Rexroth Schweiz AG Electric Drives & Controls Hemrietstrasse Buttikon Tel. +41 (0) Fax +41 (0)

98 12-4 Service & Support Rexroth IndraDrive Europa (Ost) - Europe (East) vom Ausland: (0) nach Landeskennziffer weglassen from abroad: don t dial (0) after country code Czech Republic - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland Polen Bosch -Rexroth, spol.s.r.o. Hviezdoslavova Brno Tel.: +420 (0) Fax: +420 (0) DEL a.s. Strojírenská Zdar nad Sázavou Tel.: Fax: Bosch Rexroth Kft. Angol utca Budapest Tel.: +36 (1) Fax: +36 (1) Bosch Rexroth Sp.zo.o. ul. Staszica Pruszków Tel.: service: Fax: service: Poland Polen Romania - Rumänien Romania - Rumänien Russia - Russland Bosch Rexroth Sp.zo.o. Biuro Poznan ul. Dabrowskiego 81/ Poznan Tel.: /-63 Fax: East Electric S.R.L. Bdul Basarabia no.250, sector Bucuresti Tel./Fax:: +40 (0) (0) Fax: +40 (0) eastel@rdsnet.ro Bosch Rexroth Sp.zo.o. Str. Drobety nr. 4-10, app Bucuresti, Sector 2 Tel.: +40 (0) (0) Fax: +40 (0) Bosch Rexroth OOO Wjatskaja ul. 27/ Moskau Tel.: Fax: laura.kanina@boschrexroth.ru Russia - Russland Turkey - Türkei Slowenia - Slowenien ELMIS 10, Internationalnaya Gomel, Belarus Tel.: +375/ / Fax: +375/ elmis_ltd@yahoo.com Servo Kontrol Ltd. Sti. Perpa Ticaret Merkezi B Blok Kat: 11 No: Okmeydani-Istanbul Tel: Fax: remzi.sali@servokontrol.com DOMEL Otoki Zelezniki Tel.: Fax: brane.ozebek@domel.si

99 Rexroth IndraDrive Service & Support 12-5 Africa, Asia, Australia incl. Pacific Rim Australia - Australien Australia - Australien China China AIMS - Australian Industrial Machinery Services Pty. Ltd. 28 Westside Drive Laverton North Vic 3026 Melbourne Tel.: Fax: Hotlines: enquires@aimservices.com.au Bosch Rexroth Pty. Ltd. No. 7, Endeavour Way Braeside Victoria, Melbourne Tel.: Fax: mel@rexroth.com.au Shanghai Bosch Rexroth Hydraulics & Automation Ltd. Waigaoqiao, Free Trade Zone No.122, Fu Te Dong Yi Road Shanghai P.R.China Tel.: Fax: richard.yang_sh@boschrexroth.com.cn gf.zhu_sh@boschrexroth.com.cn Shanghai Bosch Rexroth Hydraulics & Automation Ltd. 4/f, Marine Tower No.1, Pudong Avenue Shanghai P.R.China Tel: Fax: China China China China Bosch Rexroth China Ltd. 15/F China World Trade Center 1, Jianguomenwai Avenue Beijing , P.R.China Tel.: Fax: Bosch Rexroth China Ltd. Guangzhou Repres. Office Room , Metro Plaza, Tian He District, 183 Tian He Bei Rd Guangzhou , P.R.China Tel.: Fax: Bosch Rexroth (China) Ltd. A-5F., 123 Lian Shan Street Sha He Kou District Dalian , P.R.China Tel.: Fax: Melchers GmbH BRC-SE, Tightening & Press-fit 13 Floor Est Ocean Centre No.588 Yanan Rd. East 65 Yanan Rd. West Shanghai Tel.: Fax: Hongkong India - Indien India - Indien India - Indien Bosch Rexroth (China) Ltd. 6 th Floor, Yeung Yiu Chung No.6 Ind Bldg. 19 Cheung Shun Street Cheung Sha Wan, Kowloon, Hongkong Tel.: Fax: alexis.siu@boschrexroth.com.hk Bosch Rexroth (India) Ltd. Electric Drives & Controls Plot. No.96, Phase III Peenya Industrial Area Bangalore Tel.: Fax: mohanvelu.t@boschrexroth.co.in Bosch Rexroth (India) Ltd. Electric Drives & Controls Advance House, II Floor Ark Industrial Compound Narol Naka, Makwana Road Andheri (East), Mumbai Tel.: Fax: singh.op@boschrexroth.co.in Bosch Rexroth (India) Ltd. S-10, Green Park Extension New Delhi Tel.: Fax: koul.rp@boschrexroth.co.in Indonesia - Indonesien Japan Japan Korea PT. Bosch Rexroth Building # 202, Cilandak Commercial Estate Jl. Cilandak KKO, Jakarta Tel.: (5 lines) Fax: rudy.karimun@boschrexroth.co.id Bosch Rexroth Automation Corp. Service Center Japan Yutakagaoka 1810, Meito-ku, NAGOYA , Japan Tel.: Fax: Bosch Rexroth Automation Corp. Electric Drives & Controls 2F, I.R. Building Nakamachidai , Tsuzuki-ku YOKOHAMA , Japan Tel.: Fax: Bosch Rexroth-Korea Ltd. Electric Drives and Controls Bongwoo Bldg. 7FL, 31-7, 1Ga Jangchoong-dong, Jung-gu Seoul, Tel.: Fax: Korea Bosch Rexroth-Korea Ltd Dadae-Dong, Saha-gu Electric Drives & Controls Pusan Metropolitan City, Tel.: Fax: eunkyong.kim@boschrexroth.co.kr Malaysia Bosch Rexroth Sdn.Bhd. 11, Jalan U8/82, Seksyen U Shah Alam Selangor, Malaysia Tel.: Fax: hockhwa@hotmail.com rexroth1@tm.net.my Singapore - Singapur Bosch Rexroth Pte Ltd 15D Tuas Road Singapore Tel.: Fax: South Africa - Südafrika TECTRA Automation (Pty) Ltd. 71 Watt Street, Meadowdale Edenvale 1609 Tel.: Fax: Hotline: georgv@tectra.co.za Taiwan Bosch Rexroth Co., Ltd. Taichung Branch 1F., No. 29, Fu-Ann 5th Street, Xi-Tun Area, Taichung City Taiwan, R.O.C. Tel : Fax: charlie.chen@boschrexroth.com. tw jim.lin@boschrexroth.com.tw david.lai@boschrexroth.com.tw Thailand NC Advance Technology Co. Ltd. 59/76 Moo 9 Ramintra road 34 Tharang, Bangkhen, Bangkok Tel.: Fax: Hotline sonkawin@hotmail.com

100 12-6 Service & Support Rexroth IndraDrive Nordamerika North America USA Headquarters - Hauptniederlassung Bosch Rexroth Corporation Electric Drives & Controls 5150 Prairie Stone Parkway Hoffman Estates, IL Tel.: Fax: servicebrc@boschrexroth-us.com repairbrc@boschrexroth-us.com USA Central Region - Mitte Bosch Rexroth Corporation Electric Drives & Controls Central Region Technical Center 1701 Harmon Road Auburn Hills, MI Tel.: Fax: USA Southeast Region - Südwest Bosch Rexroth Corporation Electric Drives & Controls Southeastern Technical Center 3625 Swiftwater Park Drive Suwanee, Georgia Tel.: Fax: USA SERVICE-HOTLINE - 7 days x 24hrs REX-ROTH USA East Region Ost USA Northeast Region Nordost USA West Region West Bosch Rexroth Corporation Electric Drives & Controls Charlotte Regional Sales Office South Lakes Drive Charlotte, North Carolina Tel.: Bosch Rexroth Corporation Electric Drives & Controls Northeastern Technical Center 99 Rainbow Road East Granby, Connecticut Tel.: Fax: Bosch Rexroth Corporation 7901 Stoneridge Drive, Suite 220 Pleasant Hill, California Tel.: Fax: Canada East - Kanada Ost Canada West - Kanada West Mexico Mexico Bosch Rexroth Canada Corporation Burlington Division 3426 Mainway Drive Burlington, Ontario Canada L7M 1A8 Bosch Rexroth Canada Corporation 5345 Goring St. Burnaby, British Columbia Canada V7J 1R1 Bosch Rexroth Mexico S.A. de C.V. Calle Neptuno 72 Unidad Ind. Vallejo Mexico, D.F. Bosch Rexroth S.A. de C.V. Calle Argentina No 3913 Fracc. las Torres Monterrey, N.L. Tel.: Fax: Hotline: michael.moro@boschrexroth.ca Tel Fax Hotline: david.gunby@boschrexroth.ca Tel.: Fax: mariofelipe.hernandez@boschrexroth.com.m x Tel.: Fax: mario.quiroga@boschrexroth.com.mx Südamerika South America Argentina - Argentinien Argentina - Argentinien Brazil - Brasilien Brazil - Brasilien Bosch Rexroth S.A.I.C. "The Drive & Control Company" Rosario 2302 B1606DLD Carapachay Provincia de Buenos Aires Tel.: Fax: victor.jabif@boschrexroth.com.ar NAKASE Servicio Tecnico CNC Calle 49, No. 5764/66 B1653AOX Villa Balester Provincia de Buenos Aires Tel.: Fax: Hotline: nakase@usa.net nakase@nakase.com gerencia@nakase.com (Service) Bosch Rexroth Ltda. Av. Tégula, 888 Ponte Alta, Atibaia SP CEP Tel.: Fax sales: Fax serv.: alexandre.wittwer@rexroth.com.br Bosch Rexroth Ltda. R. Dr.Humberto Pinheiro Vieira, 100 Distrito Industrial [Caixa Postal 1273] Joinville - SC Tel./Fax: Mobil: prochnow@zaz.com.br Columbia - Kolumbien Reflutec de Colombia Ltda. Calle 37 No Santafé de Bogotá, D.C. Colombia Tel.: Fax: reflutec@neutel.com.co reflutec@007mundo.com

101 Rexroth IndraDrive Appendix Appendix 13.1 Connection of Supply Unit by Wires CAUTION Risk of voltage arcing! If wires are used to connect the supply unit, the connections have to be correctly made. Supply Unit to the Left of the Drive Controller If the contact rails supplied for connecting the supply unit cannot be used you can use wires, too. The wires used must comply with the specification (see page 7-17). The connection depends on the cable routing (to the left or to the right of the supply unit). The following figure shows the correct DC bus connection of the drive controller to the supply unit. The illustrated way of connection keeps bare wire sections from being situated directly vis-à-vis. This avoids voltage arcing. supply unit drive controller (DC bus connection) correct incorrect DC bus nach links zum versorgerf3.fh7 Fig. 13-1: Connection of supply unit by wires to the DC bus connection of the drive controller

102 13-2 Appendix Rexroth IndraDrive Supply Unit to the Right of the Drive Controller drive controller (DC bus connection) supply unit correct incorrect DC bus nach rechts zum versorger Fig. 13-2: Connection of supply unit by wires to the DC bus connection of the drive controller

103 Rexroth IndraDrive Appendix Stacked Devices CAUTION Risk of voltage arcing! If devices are stacked in the control cabinet, the connections for the DC buses between the devices have to be correctly made. Counterclockwise Cable Routing The connection depends on the cable routing (clockwise or counterclockwise). The following figures show the correct DC bus connection for stacked devices. The illustrated way of connection keeps bare wire sections from being situated directly vis-à-vis. This avoids voltage arcing. device 1 (DC bus connection) device 2 (DC bus connection) device 1 (DC bus connection) device 2 (DC bus connection) correct incorrect DC bus nach links_hmv Fig. 13-3: DC bus connection for counterclockwise cable routing

104 13-4 Appendix Rexroth IndraDrive Clockwise Cable Routing device 1 (DC bus connection) device 2 (DC bus connection) device 1 (DC bus connection) device 2 (DC bus connection) correct incorrect DC bus nach rechts_hmv Fig. 13-4: DC bus connection for clockwise cable routing

105 Rexroth IndraDrive Appendix Mains Connection General DANGER High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! Connect the electrical equipment, the housings of all electrical units and motors permanently with the safety conductor at the ground points before power is switched on. Look at the connection diagram. This is even necessary for brief tests. Connect the safety conductor of the electrical equipment always permanently and firmly to the supply mains. Leakage current exceeds 3.5 ma in normal operation. Use a copper conductor with at least 10 mm² cross section over its entire course for this safety conductor connection! The cross section must not be smaller than the cross section of a phase of the mains supply wire. Prior to startups, even for brief tests, always connect the protective conductor or connect with ground wire. Otherwise, high voltages can occur on the housing that lead to electric shock. Direct mains connection Mains fuse protection with direct mains connection Supply units of the HMV01.1E and HMV01.1R line can be connected to grounded three-phase without the need of a transformer. (Concerning electrical data of the mains: see chapter 7.3) For more information about the subject "Mains fuse protection with direct mains connection" read the recommendations in chapter "Fusing with Direct Mains Supply" on page Connecting the mains via a transformer A transformer is needed if the mains voltage is smaller than 380 V or greater than 480 V. The required transformers power must be equal to or greater than the incoming power. The isolating transformer must have a short-circuit voltage of U K < 2.5%. Note: The mains inductance (leakage inductance) of transformers varies dependent upon power and type. (Mains) voltage cutoff (Mains) voltage drop-outs If no additional capacitance is used, the supply voltage can be cut off for 3 ms in case of nominal load and 3 x AC 380 V mains voltage. More than 1 second should have passed between successive voltage cutoffs. With 3 x AC 380 V mains voltage, the supply voltage may drop-out by 20% of the peak voltage for a maximum of 10 ms (in case of higher supply voltages proportionally more). More than 1 second should have passed between successive voltage drop-outs.

106 13-6 Appendix Rexroth IndraDrive Mains Supply Requirements Connected load Depending on the connected load there must be certain necessary shortcircuit power of the mains supply present to use HMV01.1x devices. Connected load [kva] Required short-circuit power S K [MVA] , Examples of application several devices in line Fig. 13-5: Connected load Mains supply failure These values are from a directive of german energy supply companies and are applicable only to european mains supplies. If you need the values for different mains supplies you have to contact your energy supply company. Supply units HMV01.1E and HMV01.1R tolerance mains supply failures up to a duration of 10 ms. When the supply voltage falls below its minimal value (see technical data) for longer than 10 ms or when a single phase breaks down for longer than 10 ms the supply unit switches off with a specific dignostic message.

107 Rexroth IndraDrive Appendix 13-7 HMV01.1E Power Supply Direct mains connection [with 3 x AC V (±10 %)] In case of mains voltages with 3 x AC V (±10 %) the power supply unit can be connected directly to the mains; no other components are necessary. Note: For interference suppression we recommend a line filter HFD. supply unit HMV01.1E mains filter mains choke 3) L1 L2 L3 2) PE 1) HMVE_NFD_anschluss.fh7 1) Like mains wires, but not smaller than 10 mm 2 2) Twist main wires - cable selections according to EN ) Whether a mains choke is necessary or not depnds on the continuous DC bus power (see electrical data). Fig. 13-6: Direct mains connection via mains filter

108 13-8 Appendix Rexroth IndraDrive Connecting the mains via autotransformer (with mains voltages < 3 AC x 380 V e.g. > 3 AC x 480 V) If mains voltages are smaller than 3 AC x 380 V respectively greater than 3 AC x 480 V, it is necessary to use a transformer. supply unit HMV01.1E L1 L2 L3 PE autotransformer 1) mains filter mains choke 2) 1) Like main wires, but not smaller than 10 mm 2 2) Twist main wires - cable selections according to EN HMVE_spartrafo_NFD_anschluss.fh7 Fig. 13-7: Mains connection via autotransformer

109 Rexroth IndraDrive Appendix 13-9 HMV01.1R Mains connection with 3 x AC V (±10 %) Power Supply As the power part of the HMV01.1R power supply units consists of a clocked 3-phase IGBT bridge, a mains choke KDxx will always be needed for the mains connection. In addition, a so-called combining filter HFD will be required. L1 3 x AC V Hz L2 L3 mains input L1 L2 L3 L1.1 L2.1 L3.1 HFD combining filter PE twisted Q1 KDxx mains choke U1 V1 W1 to the central ground connection U2 V2 W2 twisted F2 X3 L1 L2 L3 X K1 ~ = power supply L+ +24V 0V drive controller L- Supply unit HMV01.1R to the central ground connection Fig. 13-8: Mains connection via mains choke and combining filter HMVR_Netzanschluss.fh7 Basically, the HFD combining filters to be provided for the mains connection of the power supply units have two tasks: to suppress the current leakages from parasitic capacities of the construction (motor cable, winding capacities) and

110 13-10 Appendix Rexroth IndraDrive to ensure a sufficient interference suppression. The combining filters are exclusively provided for the operation with HMV01.1R/E supply modules. On the filter outlet side no other devices may be connected. If other components in the control cabinet are to be suppressed, it is necessary to employ an appropriate interference suppression which should preferably be installed at the control cabinet entry Note: It is not advisable to switch an additional interference suppression with the HFD in series, as non-linear procedures in the interference suppression filter (saturation of the chokes) could affect the combining filters effect. Make sure there aren t any circuits with resonance produced, for example, by compensating capacitors, transformers, lines or capacitive contents of the filters that are not matching. Exceeding the allowed limit values for the high-frequency voltage contents at the filter can damage or destroy the filters and the capacitors at the mains choke. Rexroth does not supply HFD filters for asymmetric mains. If required, the appropriate HFD filters must be selected for the specific installation. It is only allowed to operate combining filters within the allowed mains voltage range. Harmonics (f n) on the mains voltage will lead to a temperature rise of the dielectric material of the capacitors built in the filters. You can calculate the temperature rise using the following formula: T n = ( UMn ) 2 ( U ) 10 x U Mn: measured voltage value at frequency f n U Gn: voltage limit value for frequency f n T n: calculated temperature rise of the dielectric material for frequency f n Fig. 13-9: Calculating the temperature rise of the dielectric material The temperature rises have to be added up for all frequencies f n f k (f k: frequency at which the voltage derating starts; see Fig ): U Mv: U Gv: T ges: m m Tges = Tv = v= 1 v= 1 Gn 2 [ K] ( UMv ) 2 ( U ) 10 x Gv 2 [ K] 10 [ K] voltage value at frequency f v voltage limit value for frequency f v calculated temperature rise of the dielectric material for all frequencies Fig : Calculating the temperature rise of the dielectric material for all frequencies By means of the above formulas and the measured voltages it is possible to determine the real load of a filter with voltages of higher frequencies. To do this, it is necessary to measure by means of Fourier analysis, for all combinations of line/line and line/pe, the r.m.s. value of the voltage on the mains side of the filter with all occurring frequencies (higher than f k). You always have to measure the voltages under conditions of operation at the nominal working point, the filter having been installed. By means of the measured values it is then possible to calculate the temperature rise. To

111 Rexroth IndraDrive Appendix do this, the limit values of the following diagram are read at the respective frequency and used in the formula together with the measured value. f k f k Dg5027f1.fh7 Fig : Derating If the total of the temperature values is greater than 10 K, the harmonics have to be reduced by means of appropriate measures. Mains connection via transformer (with mains voltages < 3 x AC 380 V or > 3 x AC 480 V) The supply line to the HFD must be shielded in order to avoid guided interference emissions. The connection cables of the mains choke have a connected voltage of high amplitude and frequency. This can result in a possible interference of sensitive units in the control cabinet. Therefore, the connection cables need to be kept as short as possible and absolutely twisted (here it would also be better to use shielded cables). If a transformer is used, it is possible to connect HMV01.1R supply modules to networks with mains voltages smaller than 3 x AC 380 V or greater than 3 x AC 480 V. Here, it is also required to use a mains choke KDxx and a combining filter HFD just as for the direct mains connection of the HMV01.1R supply modules.