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Project Planning Manual Electric Drives and Controls Pneumatics Service Linear Motion and Hydraulics Assembly Technologies Rexroth IndraDrive Drive Controllers.
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- Rexroth IndraDrive C Drive Controllers HCS02.1, HCS03.1 R911314905 Edition 01 Operating Instructions Electric Drives and Controls Pneumatics Service.
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Project Planning Manual Electric Drives and Controls Pneumatics Service Linear Motion and Hydraulics Assembly Technologies Rexroth IndraDrive Cs.
Dimensions – Power Sections Dimensions – Mains Filter HNF Dimensions – Mains Choke HNL01.1E (infeeding) Dimensions – Standard Braking Resistors HLR01.1 Dimensions – Reinforced Braking Resistors HLR01.1 Dimensions – Motor Filter HMF Combination of Drive Controllers of the Rexroth IndraDrive C Product Range Multiple-Line Arrangement of Drive Controllers Electrical Installation Rules for Design of Installations with Drive Controllers in Compliance with EMC EMC-Optimal Installation in Facility and Control Cabinet Ground Connections Installing Signal Lines and Cables General Measures of Radio Interference Suppression for Relays, Contactors, Switches, Chokes, Inductive Loads Installing the 24V Supply Connection Diagram Connections and Connectors Accessories HAS Index Electric Drives and Controls Hydraulics Linear Motion and Assembly Technologies Pneumatics Service Rexroth IndraDrive C Drive Controllers HCS02.1, HCS03.1 Operating Instructions R911314905 Edition 01 About this Documentation Rexroth IndraDrive Title Rexroth IndraDrive C Drive Controllers HCS02.1, HCS03.1 Type of Documentation Document Typecode Internal File Reference Purpose of Documentation Operating Instructions DOK-INDRV*-FU*********-IB01-EN-P Document Number, 120-2400-B327-01/EN; Mat. No.: R911314905 This documentation describes the mounting, installation, commissioning, parameterization and troubleshooting of Rexroth IndraDrive controllers on the basis of the power sections HCS02 or HCS03 and the control sections BASIC OPENLOOP or BASIC PROFIBUS with comfort control panel. Record of Revisions Description DOK-INDRV*-FU*********-IB01-EN-P Release Date 06-2006 Notes First Release Copyright Bosch Rexroth AG 2006 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 data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging. Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85 http://www.boschrexroth.de/ Dept. EDY1 (RR/US/BB) Published by Note This document has been printed on chlorine-free bleached paper. DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Contents I Contents 1 Introducing the Products 1.1 1.2 1-1 Introduction ................................................................................................................................... 1-1 Terms, Basic Principles ........................................................................................................... 1-1 Rexroth IndraDrive Hardware Platform ........................................................................................ 1-6 Drive Controllers ...................................................................................................................... 1-6 Motors and Measuring Systems .............................................................................................. 1-7 Master Communication............................................................................................................ 1-8 1.3 Rexroth IndraDrive Firmware Platform ......................................................................................... 1-8 Type Code ............................................................................................................................... 1-8 Functions Overview ................................................................................................................. 1-9 1.4 Rexroth IndraDyn Motors............................................................................................................ 1-12 Housing Motors...................................................................................................................... 1-12 Kit Motors............................................................................................................................... 1-12 1.5 Third-Party Motors at IndraDrive Controllers.............................................................................. 1-13 General Information on Third-Party Motors........................................................................... 1-13 Requirements on Third-Party Motors .................................................................................... 1-14 Requirements on the Encoder of the Third-Party Motor ....................................................... 1-17 Notes on Selection and Commissioning................................................................................ 1-17 1.6 Approval, Listing ......................................................................................................................... 1-18 Conformities........................................................................................................................... 1-18 C-UL-US-Listing..................................................................................................................... 1-18 2 Important Directions for Use 2.1 2-1 Appropriate Use............................................................................................................................ 2-1 Introduction .............................................................................................................................. 2-1 Areas of Use and Application .................................................................................................. 2-2 2.2 Inappropriate Use ......................................................................................................................... 2-2 3 Safety Instructions for Electric Drives and Controls 3.1 3-1 General Information ...................................................................................................................... 3-1 Using the Safety Instructions and Passing them on to Others................................................ 3-1 Instructions for Use.................................................................................................................. 3-1 Explanation of Warning Symbols and Degrees of Hazard Seriousness ................................. 3-3 Hazards by Improper Use........................................................................................................ 3-4 3.2 Instructions with Regard to Specific Dangers............................................................................... 3-5 Protection Against Contact with Electrical Parts ..................................................................... 3-5 Protection Against Electric Shock by Protective Low Voltage (PELV) .................................... 3-6 Protection Against Dangerous Movements ............................................................................. 3-7 DOK-INDRV*-FU*********-IB01-EN-P II Contents Rexroth IndraDrive Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting .................................................................................................................................. 3-9 Protection Against Contact with Hot Parts ............................................................................ 3-10 Protection During Handling and Mounting............................................................................. 3-11 Battery Safety ........................................................................................................................ 3-11 Protection Against Pressurized Systems .............................................................................. 3-12 4 Identification, Transport, Storage, Installation Conditions 4.1 4-1 Identification.................................................................................................................................. 4-1 Type Code ............................................................................................................................... 4-1 Type Plates.............................................................................................................................. 4-4 4.2 Transport and Storage.................................................................................................................. 4-6 Transport of the Devices ......................................................................................................... 4-6 Storage of the Devices ............................................................................................................ 4-6 4.3 Installation Conditions................................................................................................................... 4-7 Ambient and Operating Conditions.......................................................................................... 4-7 Compatibility with Foreign Matters .......................................................................................... 4-9 5 Electrical Data 5.1 5-1 Power Sections ............................................................................................................................. 5-1 Type Current and Connected Load ......................................................................................... 5-1 Control Voltage Supply............................................................................................................ 5-2 Power Voltage Supply- Mains Connection .............................................................................. 5-3 Limited Length of Motor Power Cables ................................................................................... 5-4 5.2 Control Sections ........................................................................................................................... 5-6 Relay Contact Type 1 .............................................................................................................. 5-6 Relay Contact Type 2 .............................................................................................................. 5-6 Relay Contact Type 3 .............................................................................................................. 5-7 Digital Inputs/Outputs .............................................................................................................. 5-7 Analog Inputs/Outputs ............................................................................................................. 5-9 5.3 Additional Components............................................................................................................... 5-15 Mains Filter HNF.................................................................................................................... 5-15 Mains Filter (-Combination) HNK........................................................................................... 5-16 Mains Choke HNL01.1E (feeding)......................................................................................... 5-16 Mains Choke HNL01.1E-****-S (Current-Compensated) ...................................................... 5-17 Braking Resistor HLR ............................................................................................................ 5-17 Motor Filter HMF.................................................................................................................... 5-26 6 Mounting and Installation 6.1 6-1 Mounting ....................................................................................................................................... 6-1 Dimensions – Power Sections................................................................................................. 6-1 Dimensions – Mains Filter HNF............................................................................................... 6-7 Dimensions – Mains Choke HNL01.1E (infeeding) ................................................................. 6-9 Dimensions – Standard Braking Resistors HLR01.1............................................................. 6-12 Dimensions – Reinforced Braking Resistors HLR01.1.......................................................... 6-14 Dimensions – Motor Filter HMF............................................................................................. 6-17 Combination of Drive Controllers of the Rexroth IndraDrive C Product Range .................... 6-22 DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Contents III Multiple-Line Arrangement of Drive Controllers .................................................................... 6-24 6.2 Electrical Installation ................................................................................................................... 6-25 Rules for Design of Installations with Drive Controllers in Compliance with EMC ................ 6-25 EMC-Optimal Installation in Facility and Control Cabinet...................................................... 6-26 Ground Connections.............................................................................................................. 6-32 Installing Signal Lines and Cables......................................................................................... 6-33 General Measures of Radio Interference Suppression for Relays, Contactors, Switches, Chokes, Inductive Loads....................................................................................... 6-34 Installing the 24V Supply ....................................................................................................... 6-35 Connection Diagram .............................................................................................................. 6-36 Connections and Connectors ................................................................................................ 6-38 Accessories HAS ................................................................................................................... 6-67 7 Commissioning and Parameterization 7.1 7-1 Basics ........................................................................................................................................... 7-1 Control Panels ......................................................................................................................... 7-1 Parameters .............................................................................................................................. 7-1 Master Communication Interfaces........................................................................................... 7-3 Parameterization Mode / Operating Mode .............................................................................. 7-4 Default Settings in the Motor Encoder Data Memory ("Load Defaults Procedure") ................ 7-9 7.2 Parameterization......................................................................................................................... 7-12 Control Panels ....................................................................................................................... 7-12 Menu Structure ...................................................................................................................... 7-16 7.3 Overview of Parameters – Base Package.................................................................................. 7-36 S-0-0000 – S-0-0100 ............................................................................................................. 7-36 S-0-0101 – S-0-0200 ............................................................................................................. 7-41 S-0-0201 – S-0-0300 ............................................................................................................. 7-45 S-0-0301 – S-0-0400 ............................................................................................................. 7-47 S-0-0401 – S-0-1000 ............................................................................................................. 7-50 P-0-0001 – P-0-0689 (General Functions) ............................................................................ 7-51 P-0-0690 – P-0-0899 (Synchronization Mode)...................................................................... 7-85 P-0-1100 – P-0-1299 (Velocity Control) ................................................................................ 7-87 P-0-1500 – P-0-1599 (General Device Parameters) ............................................................. 7-96 P-0-2000 – P-0-2999 (General Device Parameters .............................................................. 7-96 P-0-3600 – P-0-4095 (General Device Parameters) ............................................................. 7-97 7.4 Basic Functions ........................................................................................................................ 7-108 Serial Communication ......................................................................................................... 7-108 Master Communication........................................................................................................ 7-110 Profile Types........................................................................................................................ 7-114 Motor Control ....................................................................................................................... 7-117 Scaling of Physical Data...................................................................................................... 7-118 7.5 Voltage-Controlled Operation (Open-Loop U/f Control) ........................................................... 7-121 Overview.............................................................................................................................. 7-121 Automatic Setting of Motor Control Parameters.................................................................. 7-122 7.6 7.7 Closed-Loop Axis Control (Closed-Loop Operation) ................................................................ 7-131 Automatic Setting of Axis Control ........................................................................................ 7-136 Positioning Block Mode ............................................................................................................ 7-137 DOK-INDRV*-FU*********-IB01-EN-P IV Contents 8 Diagnostic and Service Functions 8.1 Rexroth IndraDrive 8-1 Diagnostic System ........................................................................................................................ 8-1 Diagnostic Status Messages ................................................................................................... 8-1 Diagnostic Command Messages............................................................................................. 8-1 Warnings.................................................................................................................................. 8-1 General Description of Error Messages and Error Reactions ................................................. 8-2 8.2 8.3 Recommended Actions for Operating States, Activities and Reactions of the Drive Controller ...................................................................................................................................... 8-5 Troubleshooting .......................................................................................................................... 8-21 Check Drive Components...................................................................................................... 8-21 Replacing Devices ................................................................................................................. 8-21 Cables.................................................................................................................................... 8-23 Replacing the Firmware......................................................................................................... 8-24 Firmware Release Update..................................................................................................... 8-25 Firmware Version Upgrade.................................................................................................... 8-29 Possible Problems during Firmware Replacement ............................................................... 8-35 8.4 Service and Maintenance ........................................................................................................... 8-36 Deactivation ........................................................................................................................... 8-36 Dismantling ............................................................................................................................ 8-36 Disposal ................................................................................................................................. 8-37 Environmental Protection ...................................................................................................... 8-37 9 Service & Support 9.1 9.2 9.3 9.4 9.5 9-1 Helpdesk ....................................................................................................................................... 9-1 Service-Hotline ............................................................................................................................. 9-1 Internet.......................................................................................................................................... 9-1 Vor der Kontaktaufnahme... - Before contacting us... .................................................................. 9-1 Kundenbetreuungsstellen - Sales & Service Facilities ................................................................. 9-2 10 Index 10-1 DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Introducing the Products 1-1 1 1.1 Introducing the Products Introduction Terms, Basic Principles Parameters Communication between master and drive takes place, with a few exceptions, by means of parameters. Parameters are used for: • determining the configuration • parameterizing the control loop • triggering and controlling drive functions and commands • transmitting command values and actual values (according to requirements, cyclically or acyclically) All operating data are mapped to parameters! The operating data stored in parameters can be identified by means of the IDN. They can be read and transferred, if required. The user write access to parameters depends on the properties of the respective parameter and the current communication phase. Specific parameter values (operating data) are checked for validity by the drive firmware. Data Storage and Parameter Handling Data Memory Several non-volatile data memories are available in an IndraDrive device: • in the controller • in the motor encoder (depending on motor type) In addition, a volatile data memory (working memory) is available in the controller. Condition As Supplied Condition as supplied of the Rexroth drive components: • The controller memory contains the drive firmware and the controllerspecific parameter values. • The motor encoder memory contains the encoder-specific and, depending on the motor type, the motor-specific parameter values. Storing the Application-Specific Parameter Values Saving Parameter Values The application-specific parameter values are stored in the controller. Due to the limited number of writing cycles of non-volatile storage media, application-specific parameter values can be stored in the working memory (volatile memory), too. Saving application-specific parameter values is required in the following cases: • after initial commissioning of the machine axis or the motor • before replacing the controller for servicing (if possible) Application-specific parameter values can be saved via: • "IndraWorks D" commissioning tool → saving the parameter values on external data carrier • control master → saving the parameter values on master-side data carrier • comfort control panel DOK-INDRV*-FU*********-IB01-EN-P 1-2 Introducing the Products Rexroth IndraDrive Parameter IDN Lists The drive supports master-side saving of parameter values by listing parameter identification numbers (IDNs). Using these lists guarantees complete storage of the application-specific parameter values. It is also possible to determine IDN lists defined by the customer. Loading parameter values is required in the following cases: • initial commissioning of the motor (loading basic parameter values and motor-specific parameter values) • serial commissioning of machine axes at series machines (loading the values saved after initial commissioning) • reestablishing a defined original status (repeated loading of the values saved after initial commissioning) • replacing the controller for servicing (loading the current parameter values saved before servicing) • Possibilities of loading parameter values to the controller: • motor encoder data memory → loading the parameter values by command or via the control panel during initial motor commissioning • "IndraWorks D" commissioning tool → loading the parameter values from external data carrier • control master → loading the parameter values from master-side data carrier Loading Parameter Values Checksum of Parameter Values By means of checksum comparison, the control master can determine whether the values of the application-specific parameter values currently active in the drive correspond to the values saved on the master side. Password IndraDrive controllers provide the possibility to protect parameter values against accidental or unauthorized change by means of a password. With regard to write protection, there are 3 groups of parameters that can be written: • Parameters that are write-protected as a standard, such as motor parameters, hardware code parameters, encoder parameters, error memory etc. ("administration parameters"). The values of these parameters guarantee correct function and performance of the drive. • Parameters the customer can combine in groups and protect them with a so-called customer password. This allows protecting parameter values, that are used for adjusting the drive to the axis, after having determined them. • All other parameters that can be written and are not contained in the above-mentioned groups. They are not write-protected. Kinds of Passwords The drive firmware allows activating and deactivating the write protection for parameter values by means of three hierarchically different passwords: • Customer password The parameter values of a parameter group combined by the customer can be protected. • Control password Parameters protected by a customer password can be written; "administration parameters" remain write-protected. • Master password All parameters that can be written, including "administration parameters" and parameters protected by a customer password, can be changed. DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Introducing the Products 1-3 Commands Commands are used to activate and control complex functions or monitoring features in the drive. The higher-level master can start, interrupt or clear commands. Each command is assigned to a parameter by means of which the execution of the command can be controlled. During the execution of the command the display of the control panel reads "Cx", "C" representing the diagnostic command message and "x" representing the number of the command. Note: Each command that was started must be actively cleared again. All commands available in the drive are stored in the S-0-0025, IDN-list of all procedure commands parameter. Kinds of Commands There are 3 different kinds of commands: • Drive control commands • can cause automatic drive motion, • can be started only when drive enable has been set, • deactivate the active operating mode during its execution. • Monitoring commands • activate or deactivate monitors or functions in the drive. • Administration commands • carry out administration tasks, • cannot be interrupted. See also "Command Processing" in chapter "Master Communication" Operating Modes The selection of operating modes defines which command values will be processed in which way, in order to lead to the desired drive motion. The operating mode does not determine how these command values are transmitted from the master to the slave. One of the four or eight (for SERCOS) operating modes defined in parameters is always active when the following conditions have been fulfilled: • control section and power section are ready for operation • drive enable signal sees a positive edge • drive follows command value • "Drive Halt" function has not been activated • no drive control command is active • no error reaction is carried out The display of the control panel reads "AF" when an operating mode was activated. Note: All implemented operating modes are stored in the S-0-0292, List of all operating modes parameter. See also chapter "Operating Modes" DOK-INDRV*-FU*********-IB01-EN-P 1-4 Introducing the Products Warnings Rexroth IndraDrive Depending on the active operating mode and the parameter settings, many monitoring functions are carried out. If a status is detected that still allows correct operation but in case this status persists will cause an error to occur and therefore cause the drive to be automatically switched off, the drive firmware generates a warning message. Note: Warnings do not cause automatic shutdown (exception: fatal warning). Warning Classes Warnings are classified in different warning classes which determine whether the drive, when the warning is generated, carries out an automatic reaction or not. Note: The warning class can be recognized by the diagnostic message. The following classes of warnings are distinguished: • without drive reaction → diagn. message no. E2xxx, E3xxx, E4xxx • with drive reaction Note: → diagn. message no. E8xxx Warnings cannot be cleared. They persist until the condition that activated the warning is no longer fulfilled. Errors Depending on the active operating mode and the parameter settings, many monitoring functions are carried out. If a status is detected that affects or prevents correct operation the drive firmware generates an error message. Error Classes Errors are classified in different error classes. There are 6 error classes with different drive error reactions. Note: The error class can be recognized by the diagnostic message number. Diagnostic message number F2xxx F3xxx F4xxx F6xxx F7xxx F8xxx F9xxx E-xxxx Fig. 1-1: Error class non-fatal error non-fatal safety technology error interface error travel range error safety technology error fatal error fatal system error fatal system error "processor exception" Overview of error classes Note: Apart from the mentioned error classes that can occur during operation, errors can occur when the devices are booted and DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Introducing the Products 1-5 during firmware download. These errors are not displayed at the control panel with a diagnostic message number of the "Fxxxx" pattern, but with a short text. Boot errors and firmware download errors are separately described in the documentation "Troubleshooting Guide" (diagnostic message description). Error Reactions of the Drive If the drive controller is in control and an error status is detected, the execution of a drive error reaction is automatically started. The diagnostic message number "Fxxxx" flashes on the display of the control panel. The drive reaction in the case of interface errors and non-fatal errors is determined in parameter P-0-0119, Best possible deceleration At the end of each error reaction, the drive is torque-free. See also "Error Reactions" in chapter "Drive Functions" Clearing Error Messages Error messages are not cleared automatically but by the following action: • activating the S-0-0099, C0500 Reset class 1 diagnostics command - or • actuating the "Esc" button on the control panel If the error status persists the error message is immediately generated again. Clearing Error Messages when Drive Enable Was Set If a drive error occurs while operating with drive enable having been set, the drive carries out an error reaction. The drive automatically deactivates itself at the end of each error reaction; in other words, the output stage is switched off and the drive switches from an energized to a de-energized state. To reactivate the drive: • clear the error message and • input a positive edge for drive enable again. Error Memory The diagnostic message numbers of occurring errors are written to an error memory. This memory contains the diagnostic message numbers of the last 50 errors that occurred and the time when they occurred. Errors caused by a shutdown of the control voltage (e.g. F8070 +24Volt DC error) are not stored in the error memory. The diagnostic message numbers in the error memory are mapped to the P-0-0192, Diagnostic numbers of error memory parameter and can be displayed by means of the control panel. By means of the "IndraWorks D" commissioning tool it is possible to display the diagnostic message numbers and the respective times at which the errors occurred. DOK-INDRV*-FU*********-IB01-EN-P 1-6 Introducing the Products Rexroth IndraDrive 1.2 Rexroth IndraDrive Hardware Platform Drive Controllers Overview The drive controller consists of two essential parts: • • Power section power section control section The power section incorporates the control section and has the following connections: • • • • • • mains voltage connection (at supply modules and HCS devices) motor connection (with optional motor holding brake and motor temperature monitor) 24 V control voltage DC bus connection module bus connection connection for external braking resistor (at HCS devices) Control section The control section is a separate component that is plugged into the power section. The drive controller is supplied complete with factoryinstalled (possibly configured) control section. Power Sections IndraDrive C 300 mm Design • HCS02.1E-W0012 • HCS02.1E-W0028 • HCS02.1E-W0054 • HCS02.1E-W0070 400 mm Design • HCS03.1E-W0070 • HCS03.1E-W0100 • HCS03.1E-W0150 • HCS03.1E-W0210 Control Sections • BASIC OPENLOOP (single axis; type CSB01.1N-FC-…) • BASIC PROFIBUS (single axis CSB01.1N-PB-…) Supported Control Section Configurations The configurable control sections differ with regard to the scope of their configurability. It basically depends on the control section type and the corresponding firmware variant. The following abbreviations are used: Options for master communication: • PB • FC → PROFIBUS-DP → FC Interface DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Introducing the Products 1-7 Motors and Measuring Systems Supported Motors The table below contains an overview of the Rexroth motors which can be operated at IndraDrive controllers. Housing motors synchronous asynchronous Kit motors synchronous MLF (IndraDyn L) MBS (Standard) MBSxx2 (IndraDyn H) MBT (IndraDyn T) LSF asynchr. 1MB MHD 2AD MKD ADF MKE MAD (IndraDyn A) MSK (IndraDyn S) MAF (IndraDyn A) MAL SF (Bosch) Fig. 1-2: Third party motors Appropriate Rexroth motors for IndraDrive Third party motors must meet the specified requirements. Supported Measuring Systems Motor Encoders and External Optional Encoders In addition to the encoders integrated in the Rexroth motors, the IndraDrive firmware can evaluate the following measuring systems as motor encoders or as external optional control encoders: • Bosch Rexroth GDS or GDM encoders (single-turn or multi-turn type) • resolvers according to Rexroth signal specification (single-turn or multi-turn type) • encoders with sine signals and EnDat2.1 interface (1 Vpp) • encoders with sine signals (1 Vpp) • encoders with square-wave signals (TTL) • Hall sensor box and encoder with sine signals (1 Vpp) • Hall sensor box and encoder with square-wave signals (TTL) • encoders with sine signals and HIPERFACE interface (1 Vpp) Measuring Encoders For measuring purposes the firmware can evaluate the following measuring systems (measuring encoders, no control encoders): • Bosch Rexroth GDS or GDM encoders (single-turn or multi-turn type) • encoders with sine signals and EnDat2.1 interface (1 Vpp) • encoders with sine signals (1 Vpp) • encoders with square-wave signals (TTL) • encoders with sine signals and HIPERFACE interface (1 Vpp) • motor encoders of MSK, MHD, 2AD, ADF, MAD, MAF motors • SSI encoders Note: Resolvers cannot be evaluated as measuring encoders! DOK-INDRV*-FU*********-IB01-EN-P 1-8 Introducing the Products Rexroth IndraDrive Master Communication PROFIBUS Interface General Features • cyclic data exchange of command and actual value (max. 32 byte each direction; min. cycle time of 500 ľs) • parameter channel for parameterization and diagnosing via field bus • safe process data channel (PROFIsafe), optional • free configuration of telegram contents possible (many cyclic configurable parameter IDN) 1.3 Rexroth IndraDrive Firmware Platform Type Code Structure of the Firmware Type Designation The individual functional packages can be combined to form the following firmware types that can be ordered: Base package of variant … (depending on control section) Open-/closedloop Alternative expansion packages IndraDrive-Firmware Basic single-axis FWA-INDRV* Fig. 1-3: -MPB- 04 VRS- D5- x- xxx- Basic structure of the firmware type designation Firmware Types That Can Be Ordered The following overview shows the available scope of functions of the respective base package: Open/closedloop IndraMotion MLD-S Control section Firmware range FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*- Alternative functional packages Language Base package Release Version Scope of functional packages base package (open-loop) base package (open-loop) + synchronization base package (open-loop) + main spindle base package (open-loop) + all altern. functions base package (open-loop) + IndraMotion MLD-S base package (open-loop) + *** + IndraMotion MLD-S MPBMPBMPBMPBMPBMPBMPBMPBMPBMPBMPBMPBMPB- 04 04 04 04 04 04 04 04 04 04 04 04 04 VRSVRSVRSVRSVRSVRSVRSVRSVRSVRSVRSVRSVRS- D5D5D5D5D5D5D5D5D5D5D5D5D5- 0000001111111- NNN SNC MSP ALL NNN *** NNN SRV SNC MSP ALL NNN *** -NN -NN -NN -NN -ML -ML -NN -NN -NN -NN -NN -ML -ML Basic single-axis FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*- base package (closed-loop) base package (closed-loop) + servo function base package (closed-loop) + synchronization base package (closed-loop) + main spindle base package (closed-loop) + all altern. functions base package (closed-loop) + IndraMotion MLD-S base package (closed-loop) + *** + IndraMotion MLD-S *** Fig. 1-4: selected option "alternative functional packages" according to availability Overview of firmware types and functional packages they are containing DOK-INDRV*-FU*********-IB01-EN-P Additive expansion packages Language Release Version xx Rexroth IndraDrive Introducing the Products 1-9 Functions Overview Supported Operating Modes The drive firmware supports the following operating modes: • torque/force control • velocity control • position control with cyclic command value input • drive-internal interpolation • drive-controlled positioning • positioning block mode • synchronization modes: • velocity synchronization with real/virtual master axis • phase synchronization with real/virtual master axis • electronic cam shaft with real/virtual master axis • electronic motion profile with real/virtual master axis Note: The operating modes supported by the firmware depend on the hardware and firmware and are contained in parameter S-0-0292, List of all operating modes. Drive Functions These are the most important drive functions of the MPX-04 firmware: • Drive Halt • establishing the position data reference • drive-controlled homing • setting absolute measuring • shifting the position data reference • drive error reactions • best possible deceleration • package reaction on error • NC reaction on error • E-Stop function • compensation functions/corrections • friction torque compensation • encoder correction • axis error correction • quadrant error correction • spindle positioning • drive-integrated command value generator • parameter set switching • probe function • encoder emulation • programmable position switch • drive-integrated PLC (IndraMotion MLD-S) • integrated safety technology DOK-INDRV*-FU*********-IB01-EN-P 1-10 Introducing the Products • monitoring functions • limitations that can be parameterized • output of control signals • numerous diagnostic possibilities Rexroth IndraDrive • drive-internal generation of diagnostic messages • analog output • status displays, status classes • oscilloscope function • monitoring function • patch function • code of optional card • parameter value check • operating hours counter, logbook function, error memory Performance Data Overview For the control performance of the IndraDrive range we basically distinguish three levels with regard to the clock rates (cycle times): • Basic performance → standard control performance by medium internal clock rates for the control loops and the signal processing of inputs/outputs or driveintegrated PLC (IndraMotion MLD-S) In this documentation the clock rate data refer to the following characteristic values: • current loop clock • velocity loop clock • position loop clock • cycle time of PLC (IndraMotion MLD-S) • cycle time of master communication TA_current TA_velocity TA_position TMLD-S TMastCom The table below contains an overview of the clock rates depending on the respective control performance. The detailed assignment of the clock rate to control section design, performance level and parameter setting is contained in the table in section "Control Section Design and Performance" (see below). Performance TA_Strom 62,5/83,3/125 ľs TA_Geschw 250 ľs TA_Lage 500 ľs TMLD-S TFKM Basic Fig. 1-5: Control section type/ firmware Functional packages all, except for "synchronization" and "IndraMotion" Perform. level 2000 ľs 500/1000 ľs Clock rates (depending on the available performance) Switching frequency 1) P-0-0556 bit 2 bit 5 TA_current TA_velocity TA_posit. TMLD-S TMastCom CSB01.1/MPB Basic 125 ľs 125 ľs 1) 250 ľs 250 ľs 500 ľs 500 ľs -- 1000 ľs 1000 ľs 4000 Hz 0 0 Basic -- 8000 Hz 0 0 : can be set via P-0-0001 P-0-0556: config word of axis controller Fig. 1-6: Performance depending on the control section design DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Introducing the Products 1-11 Selecting Performance via Parameter P-0-0556 For certain applications it is necessary to use the same clock rates in all axes so that the slowest drive sets the clock. It is therefore possible to specifically reduce the performance via bit 2 and bit 5 of parameter P-0-0556, Config word of axis controller. • For BASIC control sections it is possible to select the performance levels "Basic" or "Economy" via bit 5 of P-0-0556. See also Parameter Description "P-0-0556, Config word of axis controller" Note: The effective clock rates of the active performance level are contained in the table "Performance depending on the control section design" in section "Control Section Design and Performance" (see above). Restricted Performance with Certain Functional Packages If you use extensive and complex functions, the internal clock rates for BASIC control sections (CSB with firmware MPB and CDB with firmware MPD) are automatically reduced. This applies to the use of the following functional packages: • drive-integrated PLC "IndraMotion MLD-S" (functional package "ML") • expansion package "synchronization" (functional package "SNC") If you use one of these functional packages for BASIC control sections, the clock rates (position loop, velocity loop) are reduced to the lowest performance level "Economy!" DOK-INDRV*-FU*********-IB01-EN-P 1-12 Introducing the Products Rexroth IndraDrive 1.4 Rexroth IndraDyn Motors Housing Motors Type Code S Example MSK030B-0900-NN-S1-UG0-NNNN Housing design Windings code Holding brake MSK 030 B 0900 Fig. 1-7: NN S1 U G 0 NNNN Basic structure of type code Type Code IndraDyn A Example MAF130B-0150-FQ-M0-LH0-05-N1 Electrical Connection MAF 130 B 0150 FQ Fig. 1-8: M0 L H 0 05 N Basic structure of type code Kit Motors Type Code IndraDyn L Example MLP100A-0120-FS-N0CN-NNNN Windings code Encapsulation Cooling mode MLP 100 A 0120 Fig. 1-9: F S N0 CN NNNN Basic structure of type code DOK-INDRV*-FU*********-IB01-EN-P Other design Motor length Electrical Connection Motor size Encoder Product Vibration severity grade 1 Windings code Mounting style Holding brake Cooling mode Motor length Motor size Bearings Encoder Product Shaft Other design Motor length Electrical Connection Motor size Encoder Product Shaft Rexroth IndraDrive Introducing the Products 1-13 Type Code IndraDyn H Example 1 MRS102B-1N-0046-NNNN Internal diameter of the rotor Mounting style MRS 102 Fig. 1-10: Example 2 B 1N Basic structure of type code 0046 NNNN MSS102B-0800-FA-N0CN-NNNN Windings code Cooling mode Other design CN NNNN Other design Electrical connection Motor length Motor size Motor length Motor size Product Cooling connector MSS 102 B 0800 Fig. 1-11: F A N0 Basic structure of type code 1.5 Third-Party Motors at IndraDrive Controllers General Information on Third-Party Motors Why Use Third-Party Motors at IndraDrive? Today machine axes are mainly moved with electric drives. Motors of standard design are used in most cases as this is the most cost-efficient solution. Special Requirements Due to special requirements at machine axes, constructional or safetyrelated aspects, it may be necessary for the machine manufacturer to use a motor construction diverging from the standard. For these cases there is the demand on the drive supplier to realize, apart from the deliverable standard drive consisting of (standard) motor, controller, cable and, if required, machine control unit, drives with motors that are not included in his own product range due to the special design. At Rexroth controllers of the IndraDrive range it is also possible to use third-party motors. For this purpose, check whether the third-party motor complies with the requirements of use. Undeliverable Motor Design Check Before Using Third-Party Motors Which are the Important Directives? Additional Aspects to be Observed According to the legal requirements • of the EU directives EMC89/336/EEC and • the German EMC laws installations and machines have to be designed and built according to the present state of standardization. In order to comply with the machine directives regarding "electromagnetic compatibility (EMC)", a conformity test of the drive system (motor with controller and connection design) has DOK-INDRV*-FU*********-IB01-EN-P Encoder Product 1-14 Introducing the Products Rexroth IndraDrive to be carried out. The test of the drive system and compliance with the directives have to be guaranteed by the machine manufacturer. Third-Party Motors to be Controlled Motor Types The following motor types can be controlled: • asynchronous motors, rotary • asynchronous motors, linear • synchronous motors, rotary • synchronous motors, linear These motors can be operated within the scope of the technical data of the selected IndraDrive controller. If motors have been provided with a holding brake, it should be controlled via the controller. Make sure that the relevant technical data of the motor holding brake are complying with those of the holding brake output. Note: For third-party motors Bosch Rexroth, as a matter of principle, does not assume the guarantee for the power data at the motor shaft! Synchronous Motors In the case of synchronous motors, the commutation offset has to be set during commissioning. The drive firmware provides several methods for determining this offset so that it is possible to determine the value for different motor characteristics. Note: Observe the restrictions in conjunction with the commutation offset determination when using synchronous motors! See Functional Description of firmware "Motor Control: Commutation Setting" in chapter "Drive Control" Possibly available reluctance property cannot be used for synchronous third-party motors! For third-party motors it is impossible to determine failsafe motor parameter values for using the reluctance property; the respective bit of P-0-4014, Type of construction of motor therefore mustn't be set! Requirements on Third-Party Motors For successful and fail-safe use of a third-party motor check • whether the third-party motor to be controlled satisfies the voltage loads, • which controller, including supply, is suitable due to the motor power to be delivered, • whether the third-party motor has the required minimum inductance, • whether the motor can be protected against inadmissible temperature rise in the case of overload (temperature evaluation), • whether the mounted position measuring system can be evaluated by the controller or which position measuring system can be selected for kit motors. Voltage Load of the Third-Party Motor The voltage load of the insulation system of a motor occurring in practical application is mainly influenced by the following characteristics: • The output variables of the drive controller which is used (feed the transmission distance). DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Introducing the Products 1-15 • The cable parameters depending on cable design and length (determine the properties of the transmission distance, such as the attenuation). • The motor design regarding capacitive and inductive properties (form the end of the transmission distance). As a result of the variables, the insulation system of the third-party motor, as regards voltage, is loaded by the values • peak voltage Upp and • voltage change dv/dt. The occurring peak voltages at the motor are caused by reflections in the motor cable. The insulation of the motor is thereby loaded with other peak voltages and voltage changes than the ones occurring at the output of the power section. Note: Determine the occurring voltage load at the terminals of the third-party motor in the application with all involved components. Use of Voltage-Reducing Components, Motor Filter HMF Use voltage-reducing components (e.g. motor filter HMF), if one of the following criteria applies: • allowed voltage change (dv/dt) of third-party motor smaller than 5 kV/ľs • allowed peak voltage (crest value) of third-party motor between phasephase and phase-housing smaller than 1500 V • motor cable length smaller than 25 m • mains voltage greater than AC440V Note: Apart from the nominal current IN, especially take the maximum allowed switching frequency of the power output stage (fs) into account with which the motor filter HMF may be operated. Verify the success of the voltage-reducing measure. Minimum Inductance of Third-Party Motor Depending on the controller used, the motor has to have a minimum value for inductance. The actually available inductance of a motor can be measured directly between two motor terminals by means of an inductance measuring bridge. The measurement has to be made for a complete motor wired for normal operation but not yet connected. During the measurement one motor terminal remains open! For asynchronous motors the measured value can only be used if the rotor doesn't have closed slots! Controller type HCS with 3*AC230V HMS, HMD at HMV (3*AC400V) HMS, HMD at HCS (3*AC400V) HMS, HMD at HMV (3*AC480V) HMS, HMD at HCS (3*AC480V) ITyp: fs: Fig. 1-12: Minimum required motor inductance LU-V = 60* 4/(√2 * ITyp * fs) (in mH) LU-V = 80* 4/(√2 * ITyp * fs) (in mH) LU-V = 116* 4/( √2 * ITyp * fs) (in mH) maximum controller current acc. to type code (rms value) desired switching frequency in kHz Minimum inductances depending on controller data, supply units and supply voltage DOK-INDRV*-FU*********-IB01-EN-P 1-16 Introducing the Products Rexroth IndraDrive Use a three-phase choke in the motor feed wire, if the inductance of the third-party motor is smaller than indicated in the table above. This choke has to increase the inductance that can be measured between two motor terminals to the minimum value. Note: When the inductance is measured, different inductance values can be determined at different rotor positions within one pole pair distance of the motor. The average value is relevant for the check of the minimum value. Correct values can only be determined when the motor is in standstill! Available third-party motor Planned third-party motor Calculating the leakage inductance (asynchronous motor) or inductance (synchronous motor) of the third-party motor by means of the single-phase equivalent circuit diagram (manufacturer's specification!). Determine choke by means of calculation, if necessary. It is recommended to contact Rexroth! LU-Vmin LU-V U V W Motor 3x LDr LDr = 0,5 * (LU-Vmin - LU-V) (inductance measurement with 1 kHz) mounting of 3x LDr (three-phase choke) Requirements on the choke: - In_Dr ≥ In_Mot The rated current of the choke has to be greater than or equal to the rated motor current. - Depending on the maximum speed, the choke is loaded with the respective output frequency and the PWM frequency of the controller. - The insulation class has to correspond at least to that of the motor or has to be dimensioned for higher temperatures. - The voltage load of the choke depends on the controller used. Fig. 1-13: Data for possibly required choke Temperature Evaluation of Third-Party Motor Only operate such motors with incorporated temperature sensor at IndraDrive controllers so that the motor can be thermally monitored by the controller and protected against destruction by too high temperature rise (see P-0-0512, Temperature sensor). When, in exceptional cases, you want to operate third-party motors without temperature sensor at IndraDrive controllers, you must determine the thermal time constants of motor housing (P-0-4035) and motor winding (P-0-4034, P-0-4037). The firmware-internal motor temperature model can thereby reflect the cooling situation of the motor correctly. Note: In case the motor housing or blower is dirty, this worsens the cooling situation of the motor and protection against thermal overload is therefore insufficient! DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Introducing the Products 1-17 Requirements on the Encoder of the Third-Party Motor Motor Encoder of Asynchronous Third-Party Motor Asynchronous motors can also be controlled by IndraDrive controllers in "open-loop" operation (without motor encoder). In "closed-loop" operation (with motor encoder) a relative measuring system is sufficient for asynchronous motors. Motor Encoder of Synchronous Third-Party Motor For fail-safe drives with synchronous third-party motors at IndraDrive controllers the following possible combinations or restrictions have to be taken into account when selecting the measuring system: Drive range Motor measuring system absolute relative +… o… Synchronous thirdparty motor + o IndraDrive advantageous combination Combination is possible (restrictions specific to application), commissioning may be more complicated! Fig. 1-14: Possible combinations of synchronous third-party motor and motor measuring system Note: The control section integrated in the controller can evaluate measuring systems as a motor encoder if they are contained in P-0-0074, Encoder type 1 (motor encoder) (see also Project Planning Manual of the IndraDrive control sections). For information on absolute and relative measuring systems see section "Measuring Systems" of Functional Description of firmware! Notes on Selection and Commissioning Selecting the Controller as Regards Continuous Current The controller required for the respective motor and the supply unit are determined by comparing the motor data to the data of these devices (see documentation for HMS/HMD and HMV or HCS). Note: The continuous current of the controller should be greater than that of the motor, the continuous power of the supply must be greater than the sum of all average powers of the axes of the drive system! Selecting the Connection Technique The available power and encoder cables are described in the documentation "Connection Cables; Selection Data" (DOK-CONNECCABLE*STAND-AU...). Notes on Commissioning Note: For further information, notes on commissioning and supporting documents (e.g. forms for entering the required data) see Functional Description of firmware. DOK-INDRV*-FU*********-IB01-EN-P 1-18 Introducing the Products Rexroth IndraDrive 1.6 Approval, Listing Conformities Declaration of Conformity For Rexroth IndraDrive components there are declarations of conformity available. These declarations confirm that the components are designed according to valid EC directives. If required, you can ask your sales representative for these declarations. Low-Voltage Directive The Rexroth products of a drive system mentioned in this documentation comply with the requirements of the EC Directive 73/23/EEC (LowVoltage Directive), annex III B. EMC Directive The Rexroth products of a drive system mentioned in this documentation comply with the requirements of the EC Directive 89/336/EEC (EMC Directive) with the amendments 91/263/EEC and 93/68/EEC. CE Label CEf1.fh7 Fig. 1-15: CE label C-UL-US-Listing Devices approved by the UL agency carry the following label: Fig. 1-16: C-UL-US label DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Introducing the Products 1-19 Motors approved by the UL agency carry the following label: Fig. 1-17: C-UR-US label C-UL-US Listed Components Product HMS01.1NHMS02.1NHMD01.1NHCS02.1EHCS03.1EHMV01.1EHMV01.1RHMV02.1RHLB01.1CHLB01.1DHLC01.1CHLC01.1DNFD03.1- Component File Number W0020, W0036, W0054, W0070, W0150, E 134201 W0210 W0028, W0054 W0012, W0020, W0036 W0012, W0028, W0054, W0070 W0070, W0100, W0150, W0210 W0030-A-07, W0075-A-07, W0120-A-07 W0018-A-07, W0045-A-07, W0065-A-07 W0015 01K0-N06R0-A-007-NNN 02K0-N03R4-A-007-NNN 01M0-A-007, 02M4-A-007 05M0-A-007 -007, -016, -030, -055, -075, -130, -180 E 134201 E 134201 E 134201 Manufacturer REFU E254781 E 134201 E 134201 E 134201 E 134201 E 134201 E 134201 E 134201 E 172117 and CSA Cert. 1038841Master Contr. 171321 CSA Cert. 1492099Master Contr. 222887 E 134201 E 134201 E 134201 HNL01.1- ..... HNF01.1 HNK01.1 HLR01.1 Fig 1-18: In preparation In preparation In preparation C-UL-US listed Rexroth IndraDrive components Note: The components are listed by the file number of „Underwriters Laboratories Inc.Ž" (UL). The documented evidence of listing can be seen in the internet: http://www.ul.com, "Certifications", enter file number or "Company name: Rexroth. The control sections are included in the listing of the power sections. The control sections are not listed separately. DOK-INDRV*-FU*********-IB01-EN-P 1-20 Introducing the Products Rexroth IndraDrive DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Important Directions for Use 2-1 2 2.1 Important Directions for Use 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 products take 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. DOK-INDRV*-FU*********-IB01-EN-P 2-2 Important Directions for Use Rexroth IndraDrive Areas of Use and Application Drive controllers made by Bosch Rexroth are designed to control electrical motors and monitor their operation. Control and monitoring of the motors may require additional sensors and actors. Note: The drive controllers 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 Functional Descriptions. Every drive controller has to be programmed before commissioning, making it possible for the motor to execute the specific functions of an application. The drive controllers have been developed for use in single- and multiaxis drive and control tasks. To ensure an application-specific use, the drive controllers are available with different drive power and different interfaces. Typical applications of the drive controllers include: • handling and mounting systems, • packaging and food machines, • printing and paper processing machines and • machine tools. The drive controllers may only be operated under the assembly and installation conditions described in this documentation, in the specified position of normal use and under the ambient conditions as described (temperature, degree of protection, humidity, EMC, etc.). 2.2 Inappropriate Use Using the drive controllers outside of the operating conditions described in this documentation and outside of the indicated technical data and specifications is defined as "inappropriate use". Drive controllers must not be used, if • ... they are subject to operating conditions that do not meet the specified ambient conditions. This includes, for example, operation under water, under extreme temperature fluctuations or extremely high maximum temperatures. • Furthermore, the drive controllers must not be used in applications which have not been expressly authorized by Rexroth. • Please carefully follow the specifications outlined in the general Safety Instructions! DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-1 3 3.1 Safety Instructions for Electric Drives and Controls General Information Using the Safety Instructions and Passing them on to Others Do not attempt to install or commission this device without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation prior to working with the device. If you do not have the user documentation for the device, contact your responsible Bosch Rexroth sales representative. Ask for these documents to be sent immediately to the person or persons responsible for the safe operation of the device. If the device is resold, rented and/or passed on to others in any other form, then these safety instructions must be delivered with the device. WARNING Improper use of these devices, 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! Instructions for Use 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. • 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 device. • Only assign trained and qualified persons to work with electrical installations: Only persons who are trained and qualified for the use and operation of the device may work on this device 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 devices 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. DOK-INDRV*-FU*********-IB01-EN-P 3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive • The devices have been designed for installation in industrial machinery. • The ambient conditions given in the product documentation must be observed. • Only use safety-relevant applications that are clearly and explicitly approved in the Project Planning Manual. If this is not the case, they are excluded. Safety-relevant are all such applications which can cause danger to persons and material damage. • 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. • 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. DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-3 Explanation of Warning Symbols and Degrees of Hazard Seriousness The safety instructions describe the following degrees of hazard seriousness. The degree of hazard seriousness informs about the consequences resulting from non-compliance with the safety instructions: Warning symbol with signal word Degree of hazard seriousness according to ANSI Z 535 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 Z 535) DOK-INDRV*-FU*********-IB01-EN-P 3-4 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Hazards by Improper Use High electric voltage and high working current! Risk of death or severe bodily injury by electric shock! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! DANGER High electric voltage because of incorrect connection! Risk of death or bodily injury by electric shock! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! WARNING Hot surfaces on device housing! Danger of injury! Danger of burns! CAUTION CAUTION Risk of injury by improper handling! Risk of bodily injury by bruising, shearing, cutting, hitting, or improper handling of pressurized lines! Risk of injury by improper handling of batteries! CAUTION DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-5 3.2 Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts Note: This section only concerns devices and drive components with voltages of more than 50 Volt. Contact with parts conducting voltages above 50 Volts can cause personal danger and electric shock. When operating electrical equipment, it is unavoidable that some parts of the devices conduct dangerous voltage. High electrical voltage! Danger to life, electric shock and severe bodily injury! DANGER Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain and repair this equipment. Follow general construction and safety regulations when working on electrical power installations. Before switching on the device, the equipment grounding conductor must have been nondetachably connected to all electrical equipment in accordance with the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the equipment grounding conductor is not permanently connected to the mounting points of the components provided for this purpose. Before working with electrical parts with voltage potentials higher than 50 V, the device must be disconnected from the mains voltage or power supply unit. Provide a safeguard to prevent reconnection. With electrical drive and filter components, observe the following: Wait 30 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 device on. Before switching the equipment on, cover and safeguard live parts safely to prevent contact with those parts. A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device according to the relevant standards. Secure built-in devices from direct touching of electrical parts by providing an external housing, for example a control cabinet. European countries: according to EN 50178/ 1998, ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ DOK-INDRV*-FU*********-IB01-EN-P 3-6 Safety Instructions for Electric Drives and Controls section 5.3.2.3. Rexroth IndraDrive USA: See National Electrical Code (NEC), National Electrical Manufacturers' Association (NEMA), as well as local engineering regulations. The operator must observe all the above regulations at any time. With electrical drive and filter components, observe the following: High housing voltage and large leakage current! Risk of death or bodily injury by electric shock! ⇒ DANGER ⇒ ⇒ ⇒ Before switching on, the housings of all electrical equipment and motors must be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests. The equipment grounding conductor of the electrical equipment and the units must be non-detachably and permanently connected to the power supply unit at all times. The leakage current is greater than 3.5 mA. Over the total length, use copper wire of a cross 2 section of a minimum of 10 mm for this equipment grounding connection! Before start-up, also in trial runs, always attach the equipment grounding conductor or connect with the ground wire. Otherwise, high voltages may occur at the housing causing electric shock. Protection Against Electric Shock by Protective Low Voltage (PELV) All connections and terminals with voltages between 5 and 50 Volt at Rexroth products are protective extra-low voltage systems which are provided with touch guard according to the product standards. High electric voltage by incorrect connection! Risk of death or bodily injury by electric shock! ⇒ WARNING ⇒ To all connections and terminals with voltages between 0 and 50 Volt, only devices, electrical components, and conductors may be connected which are equipped with a PELV (Protective ExtraLow Voltage) system. Connect only voltages and circuits which are safely isolated from dangerous voltages. Safe isolation is achieved for example by isolating transformers, safe optocouplers or battery operation without mains connection. DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-7 Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of 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 harm 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. DOK-INDRV*-FU*********-IB01-EN-P 3-8 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! ⇒ DANGER For the above reasons, ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. They have to be provided for by the user according to the specific conditions within the installation and a hazard and fault analysis. The safety regulations applicable for the installation have to be taken into consideration. Unintended machine motion or other malfunction is possible if safety devices are disabled, bypassed or not activated. To avoid accidents, bodily harm and/or material damage: ⇒ 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. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don’t operate the device if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a safety related starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Additionally 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 or - 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! ⇒ ⇒ ⇒ ⇒ ⇒ DOK-INDRV*-FU*********-IB01-EN-P 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 devices 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. ⇒ Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious personal danger to those with heart pacemakers, metal implants and hearing aids. Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! WARNING ⇒ Persons with heart pacemakers and metal implants are not permitted to enter following areas: - Areas in which electrical equipment and parts are mounted, being operated or commissioned. - Areas in which parts of motors with permanent magnets are being stored, repaired or mounted. If it is necessary for somebody with a pacemaker to enter such an area, a doctor must be consulted prior to doing so. The interference immunity of present or future implanted heart pacemakers differs greatly, so that no general rules can be given. Those with metal implants or metal pieces, as well as with hearing aids must consult a doctor before they enter the areas described above. Otherwise health hazards may occur. ⇒ ⇒ DOK-INDRV*-FU*********-IB01-EN-P 3-10 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Protection Against Contact with Hot Parts Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of burns! CAUTION ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Do not touch surfaces of device housings and chokes in the proximity of heat sources! Danger of burns! Do not touch housing surfaces of motors! Danger of burns! According to operating conditions, temperatures can be higher than 60 °C, 140 °F during or after operation. Before accessing motors after having switched them off, let them cool down for a sufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated, the time required for cooling down is five times the thermal time constant specified in the Technical Data. After switching drive controllers or chokes off, wait 15 minutes to allow them to cool down before touching them. Wear safety gloves or do not work at hot surfaces. For certain applications, the manufacturer of the end product, machine or installation, according to the respective safety regulations, has to take measures to avoid injuries caused by burns in the end application. These measures can be, for example: warnings, guards (shielding or barrier), technical documentation. DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-11 Protection During Handling and Mounting In unfavorable conditions, handling and assembling certain parts and components in an improper way can cause injuries. Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting! CAUTION ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Observe the general construction and safety regulations on handling and assembly. Use suitable devices for assembly and transport. Avoid jamming and bruising by appropriate measures. Always use suitable tools. Use special tools if specified. Use lifting equipment and tools in the correct manner. If necessary, use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Do not stand under hanging loads. Immediately clean up any spilled liquids because of the danger of skidding. Battery Safety Batteries consist of active chemicals enclosed in a solid housing. Therefore, improper handling can cause injury or damages. Risk of injury by improper handling! ⇒ CAUTION ⇒ ⇒ ⇒ ⇒ Do not attempt to reactivate low batteries by heating or other methods (risk of explosion and cauterization). Do not recharge the batteries as this may cause leakage or explosion. Do not throw batteries into open flames. Do not dismantle batteries. Do not damage electrical parts installed in the devices. Note: Environmental protection and disposal! The batteries installed in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations. Dispose of used batteries separate from other waste. Observe the local regulations in the country of assembly. DOK-INDRV*-FU*********-IB01-EN-P 3-12 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Protection Against Pressurized Systems According to the information given in the Project Planning Manuals, motors cooled with liquid and compressed air, as well as drive controllers, can be partially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids, and cooling lubricating agents. In these cases, improper handling of external supply systems, supply lines, or connections can cause injuries or damages. Risk of injury by improper handling of pressurized lines! Do not attempt to disconnect, open, or cut pressurized lines (risk of explosion). Observe the respective manufacturer's operating instructions. Before dismounting lines, relieve pressure and empty medium. Use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Immediately clean up any spilled liquids from the floor. CAUTION ⇒ ⇒ ⇒ ⇒ ⇒ Note: Environmental protection and disposal! The agents used to operate the product might not be economically friendly. Dispose of ecologically harmful agents separate from other waste. Observe the local regulations in the country of assembly. DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-1 4 Identification, Transport, Storage, Installation Conditions Identification 4.1 Type Code Firmware MPB-04 Open/closedloop IndraMotion MLD-S Alternative functional packages Control section Firmware range FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*- Language Base package Release Version Scope of functional packages base package (open-loop) base package (open-loop) + synchronization base package (open-loop) + main spindle base package (open-loop) + all altern. functions base package (open-loop) + IndraMotion MLD-S base package (open-loop) + *** + IndraMotion MLD-S MPBMPBMPBMPBMPBMPBMPBMPBMPBMPBMPBMPBMPB- 04 04 04 04 04 04 04 04 04 04 04 04 04 VRSVRSVRSVRSVRSVRSVRSVRSVRSVRSVRSVRSVRS- D5D5D5D5D5D5D5D5D5D5D5D5D5- 0000001111111- NNN SNC MSP ALL NNN *** NNN SRV SNC MSP ALL NNN *** -NN -NN -NN -NN -ML -ML -NN -NN -NN -NN -NN -ML -ML Basic single-axis FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*FWA-INDRV*- base package (closed-loop) base package (closed-loop) + servo function base package (closed-loop) + synchronization base package (closed-loop) + main spindle base package (closed-loop) + all altern. functions base package (closed-loop) + IndraMotion MLD-S base package (closed-loop) + *** + IndraMotion MLD-S Power Sections HCS Examples HCS02.1E-W0012-A-03-NNNV (with integrated 24V supply); HCS03.1E-W0100-A-05-NNBV (with integrated brake transistor) Mains connecting voltage Maximum current Protection mode Cooling mode Power supply HCS 02 1 E Fig. 4-1: W 0012 A 03 NNNV Basic structure of type code DOK-INDRV*-FU*********-IB01-EN-P Other design Product Design Line 4-2 Identification, Transport, Storage, Installation Conditions Control Sections BASIC CSB01.1N Example Rexroth IndraDrive CSB01.1.N-FC-NNN-NNN-NN-C-NN-FW Master communication Configuration option CSB 01 1 N FC Fig. 4-2: NNN NNN NN C NN Basic structure of type code Additional Components Mains Choke HNL Example HNL01.1E-0980-N0026-A-480-NNNN Degree of protection Nominal inductance Mains connecting voltage Additional option Nominal current Supply system HNL 01 1 E Fig. 4-3: 0980 N 0026 A 480 NNNN Basic structure of type code Mains Filter HNF, HNK Example HNF01.1A-F240-R0094-A-480-NNNN Mains connecting voltage Nominal current Supply system EMC-area per DIN 61800-3 HNF HNK 01 01 1 1 A A Fig. 4-4: F240 A075 R E 0094 0050 A A 480 500 NNNN NNNN Basic structure of type code DOK-INDRV*-FU*********-IB01-EN-P Other design Applications Degree of protection Product Design Line Other design Product Design Line Firmware (to be ordered extra) FW Safety option Other design Option 1 Option 2 Product Display Design Line Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-3 Motor Filter HMF Example HMF01.1A-N1K5-E0070-A-500-NNNN Degree of protection Switching frequency Motor frequency Nominal current Mounting style Voltage rating HMF 01 1 A Fig. 4-5: N 1K5 E 0070 A 500 NNNN Basic structure of type code Braking Resistor HLR Example HLR01.1N-1K08-N05R0-A-007-NNNN Degree of protection Continuous output Additional option DC bus nominal voltage Mounting style HLR 01 1 N Fig. 4-6: 1K08 N 05R0 A 007 NNNN Basic structure of type code Accessories HAS01.1 Example HAS01.1-050-048-NN Other design NN Device width HAS 01 Fig. 4-7: 1 050 Basic structure of type code 048 DOK-INDRV*-FU*********-IB01-EN-P Bus-bar Product Design Line Other design Resistance Product Design Line Other design Filter class Product Design Line 4-4 Identification, Transport, Storage, Installation Conditions HAS02.1 Example Rexroth IndraDrive HAS02.1-001-NNN-NN Device assignment Other feature HAS 02 Fig. 4-8: 1 001 Basic structure of type code NNN NN Type Plates Each drive component is marked by a type designation. There is a type plate attached to all devices. Type Plates at the Drive Controller 1 2 3 DG000023v01_nn.FH9 1: Power section type plate 2: Control section type plate 3: Firmware type plate Fig. 4-9: Type plates at the drive controller DOK-INDRV*-FU*********-IB01-EN-P Other design Product Design Line Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-5 Type Plates at the Control Section Control Section Type Plate Type CSH01.1C-SE-EN1-EN2-MA1-L1-S-NN-FW MNR: R911293808 FD: 05W24 (7260) Part number Production week SN:CSH011-00123 0A01 0S01 Example: 05W24 means year 2005, week 24 Serial number Barcode Hardware index DG000022v01_de.FH9 Fig. 4-10: Control section type plate Firmware Type Plate Type Barcode MPH02V12D51 SRVNN (7260) 05W24 R911 297901-04432 Production week Example: 05W24 means year 2005, week 24 Serial number DG000024v01_en.fh9 Fig. 4-11: Firmware type plate (example) DOK-INDRV*-FU*********-IB01-EN-P 4-6 Identification, Transport, Storage, Installation Conditions Rexroth IndraDrive 4.2 Transport and Storage Transport of the Devices Conditions temperature relative humidity absolute humidity moisture condensation icing shock test out of operation according to EN 60068-2-27 Fig. 4-12: Conditions for transport -25…70 °C 5…95%; climatic category 2K3 1…60 g/m climatic category 2K3 not allowed not allowed half sine in 3 axes: 10g / 11ms 3 Storage of the Devices Conditions temperature relative humidity absolute humidity moisture condensation icing Fig. 4-13: Conditions for storage -25…55 °C 5…95%; climatic category 1K3 1…29 g/m climatic category 1K3 not allowed not allowed 3 Extended Storage Some devices contain electrolytic capacitors which may deteriorate during storage. Note: When storing these devices for a longer period of time, operate them once a year for at least 1 hour with power ON: • devices HCS with mains voltage ULN DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-7 4.3 Installation Conditions Ambient and Operating Conditions The drive controllers and their additional components are designed for control cabinet mounting! Note: The user must check that the ambient conditions, in particular the control cabinet temperature, are complied with by calculating the heat levels in the control cabinet and making the corresponding measurements. In the Technical Data the power dissipation is indicated as an input value for calculating the heat levels. Designation degree of protection ambient temperature ambient temperature with power reduction temperature during storage temperature during transport installation altitude with nominal data installation altitude with power reduction * maximum installation altitude * relative humidity (operation) absolute humidity climatic category degree of dirt contamination dust, steam sine vibration during operation according to EN 60068-2-6 Data IP20 according to IEC529 0…+40 °C 0…+55 °C; see characteristic in Fig. 4-15 see section 4.2 Transport and Storage see section 4.2 Transport and Storage <1000 m above sea level see characteristic in Fig. 4-16 4000 m (upper temperature level reduced to 40 °C instead of 55 °C) 5%…95% Cl.3K5 with restriction, as not –5 °C 1…29 g/m 3 Cl. 3K3 according to IEC721 degree of dirt contamination 2 in accordance with EN50178 allowed according to EN 50178, table A.2 amplitude and frequency: acceleration and frequency: tolerance: 0.15 mm (peak-peak) at 10…57 Hz 1 g at 57…150 Hz ą15 % 20…150 Hz 0.005 g /Hz ą 3 dB 1.0 g 2 noise vibration (random) during operation according to IEC 68-2-36 frequency: spectral acceleration density amplitude: tolerance: rms value of the total acceleration: * Fig. 4-14: For installation altitudes of more than 2000 m, an overvoltage limiter for transient overvoltage 1.2/50 ľs 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. Ambient and operating conditions DOK-INDRV*-FU*********-IB01-EN-P 4-8 Identification, Transport, Storage, Installation Conditions Capacity Utilization Rexroth IndraDrive Where installation conditions differ, the following performance data are reduced in accordance with the diagrams (see "Fig. 4-15: " and "Fig. 4-16: "): drive controller: • allowed continuous DC bus power • continuous power of braking resistor • continuous current motor: • power • continuous torque at standstill • S1 continuous torques • short-time service torque MKB If differing ambient temperatures and higher installation altitudes occur simultaneously, both capacity utilization factors must be multiplied. The installation altitude must only be taken into account once, deviating ambient temperatures must be taken into account separately for motor and drive controller. 1 Load factor 0,7 5 40 45 50 55 Ambient temperature in °C DK000073v01_en Fig. 4-15: Capacity utilization at higher ambient temperature DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-9 1 0,9 Load factor 0,8 0,7 0,6 0 1000 2000 3000 4000 Installation altitude above sea level in meters DK000074v01_en Fig. 4-16: Capacity utilization at higher installation altitude Compatibility with Foreign Matters All Rexroth controls and drives are developed and tested according to the state-of-the-art 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. DOK-INDRV*-FU*********-IB01-EN-P 4-10 Identification, Transport, Storage, Installation Conditions Rexroth IndraDrive DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Electrical Data 5-1 5 5.1 Electrical Data Power Sections Unless otherwise specified, the following data apply to • Ta = Tamax • ULN = 3AC400V • use of HNL and HNK mains chokes Type Current and Connected Load Compact converter Type current Attached mains choke HNL, HNK Nominal motor power (2) Connected load Mains input contin. current IL_cont [A] 6 13 19 30 50 80 106 146 Nominal fuse current / fuse type characteristic gL Type [A] 10 20 25 35 3NA6820-4 3NA6824-4 3NA6832-4 3NA6836-4 Contin. current (1) Peak current (1) SLN [kW] HCS02 HCS02 HCS02 HCS02 HCS03 HCS03 HCS03 HCS03 W0012 W0028 W0054 W0070 W0070 W0100 W0150 W0210 HNL01.1E-1000-N0012 HNL01.1E-1000-N0012 HNL01.1E-1000-N0020 HNL01.1E-0600-N0032 HNL01.1E-0571-N0050 HNK01.1A-A075-E0080 HNL01.1E-0362-N0080; HNK01.1A-A075-E0080 HNL01.1E-0240-N0106 HNK01.1A-A075-E0106 HNL01.1E-0170-N0146 HNK01.1A-A075-E0146 (1) (2) Fig. 5-1: 1,5 4,0 7,5 11 18,5 30 45 75 [kVA] 3,5 7,3 13,3 18,5 35 55,2 72,9 99,3 Iout_cont1 [A] 4 11 22 28 45 73 95 145 Iout_max [A] 12 28 54 70 70 100 150 210 at fs = 4 kHz; without overload for standard motor, when using mains choke HNL01; at 3 AC 400 V variable torque, low overload Type current and connected load DOK-INDRV*-FU*********-IB01-EN-P 5-2 Electrical Data Rexroth IndraDrive Control Voltage Supply Note: The control sections are supplied via the terminal connectors 24V and 0V at the power section (24V supply). Note: The isolated inputs/outputs at X31 and X32 are not supplied via the connections of the 24V supply of the power section. A separate voltage supply is required for these inputs/outputs. Note: Overvoltage of more than 33 V has to be discharged by means of the appropriate electrical equipment of the machine or installation. This equipment includes: • 24V power supply units that reduce incoming overvoltages to the allowed value. • Overvoltage limiters at the control cabinet input that limit existing overvoltage to the allowed value. This, too, applies to long 24V lines that have been run in parallel to power cables and mains cables and can absorb overvoltages by inductive or capacitive coupling. Designation 24V control voltage supply HCS02.1E; HCS03.1E Symbol Unit • • 24 ą 20% (if no motor holding brake has to be supplied) If motor holding brakes are to be supplied, observe the data of the motor documentation. The following values are normally sufficient: 24 ą 5% at motor cable length < 50 m 26 ą 5% at motor cable length > 50 m UN3 V max. ripple content max. allowed overvoltage w UN3max V mustn't exceed the control voltage range 33 (max. 1 ms) Power consumption of power sections 1) HCS02.1E-W0012 HCS02.1E-W0028 HCS02.1E-W0054 HCS02.1E-W0070 HCS03.1E-W0070 HCS03.1E-W0100 HCS03.1E-W0150 HCS03.1E-W0210 PN3 PN3 PN3 PN3 PN3 PN3 PN3 PN3 W W W W W W W W 12 14 23 23 23 25 25 30 Power consumption of control sections 2) CSB01.1N-FC… CSB01.1N-PB… Typ. inrush current of control sections PN3 PN3 W W 7,5 7,5 DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Electrical Data 5-3 CSB01.1N-FC… CSB01.1N-PB… IEIN3 IEIN3 A A 1,5 (pulse width tEIN3lade ca. 120 ms) 5 (pulse width tEIN3lade ca. 40 ms) Power consumption of optional modules according to type code 3), 4) C EN1 EN2 ENS MA1 MD1 S PN3 PN3 PN3 PN3 PN3 PN3 PN3 1) 2) 3) 4) Fig. 5-2: W W W W W W W 1,0 6,0 5,5 5,5 2,0 1,0 1,0 plus control section with optional modules plus optional modules code from the control section type code at max. allowed output load without circuits to be supplied externally Control voltage Power Voltage Supply- Mains Connection Designation allowed range of mains input voltage, three-phase; TN-S, TN-C, TT mains allowed range of mains input voltage, three-phase; IT mains allowed range of mains input voltage, single-phase rotary field allowed range of mains frequency max. allowed mains frequency change fLN d fLN /t Fig. 5-3: Hz Hz/s Extended range of power voltage Symbol Unit HCS02.1E HCS03.1E ULN V 3 * AC (200…500) +-10% 3 * AC (200…230) +-10% 1 * AC (200…250) +-10% 3 * AC (400…500) +10% -15% ULN V not allowed ULN V not allowed no rotary field condition (50…60) + - 2 2% * fLN Note: When using HCS02 and HCS03 devices in the mains voltage range up to 3 * AC 500 V, make sure the additional components you use may be operated in this mains voltage range. NFD mains filters, for example, can only be used up to 3 * AC 480 V. DOK-INDRV*-FU*********-IB01-EN-P 5-4 Electrical Data Rexroth IndraDrive Limited Length of Motor Power Cables Keep in mind, that the allowed maximum motor cable length is depending on the switching frequency of the power output stage. On principle, the higher the switching frequency, the shorter the allowed cable length (in order to protect the drive controllers against overload). Note: Always use switching frequencies supported by the components of your drive system. Observe the technical data of the drive controllers and motors. See also Parameter Description "P-0-0001, Switching frequency of the power output stage". Limited Lengths of Motor Power Cables The lengths indicated in the table below are recommended as guide values (at an ambient temperature of ≤ 40 °C in accordance with EN 60 204). Allowed line lengths for motor connection without filter measures at motor output: PWM frequency [kHz] 2 2) Max. allowed line length [m] Shielded line 100 75 38 25 18 Unshielded line 175 150 150 not allowed not allowed 1) 4 8 12 16 1) 2) Fig. 5-4: only allowed at HCS drive controllers depending on the drive controller Line lengths Operation with unshielded motor cables of up to 150 m • aims at applications with "operation without encoder" (Open Loop) • does not include the control voltage lines to the motor • requires additional measures with regard to EMC on the part of the operating company Allowed line lengths for motor connection with additional components HMF or HML: PWM frequency [kHz] 4 1) 2) Fig. 5-5: 2) Max. allowed line length [m] Shielded line 75 Unshielded line 200 1) only allowed at HCS03 drive controllers higher PWM frequencies are not allowed Line lengths Documentation Motor Power Cables The documentation "Rexroth Connection Cables; Selection Data" is available for selecting the motor power cables and other connections, such as encoder cables. Rexroth IndraDrive drive systems have to be equipped with shielded motor power cables of the RKL line. DOK-INDRV*-FU*********-IB01-EN-P Rexroth IndraDrive Electrical Data 5-5 Third-Party Motor Power Cables Requirements on third-party motor power cables: Maximum allowed cable length at A1, A2, A3: • see description above Maximum allowed capacitance per unit length at A1, A2, A3: • • against ground, each: 0.5 nF/m against each other: 0.5 nF/m Maximum allowed inductance per unit length at A1, A2, A3: • 100 nH/m each If you use third-party motor power cables not corresponding to the requirements, Rexroth's guarantee for the drive system will expire. Use ready-made Rexroth cables. Note: DOK-INDRV*-FU*********-IB01-EN-P 5-6 Electrical Data Rexroth IndraDrive 5.2 Control Sections Relay Contact Type 1 Data current load capacity voltage load capacity minimum contact load contact resistance at minimum current switching actions at max. time constant of load number of mechanical switching cycles time constant of load pick up delay drop out delay Fig. 5-6: Relay contacts type 1 ms ms ms Unit A V mA mOhm 100.000 6 Min. Typ. Max. DC 1 AC 2 DC 30 AC 250 10 1000 1 * 10 50 10 10 Relay Contact Type 2 Data current load capacity voltage load capacity minimum contact load contact resistance at minimum current switching actions at max. time constant of load number of mechanical switching cycles time constant of load pick up delay drop out delay Fig.
HCS02 - IndraDrive C - Accionamientos (Drivers) - Tecnología de Accionamientos. MIRO SEGURIDAD MANUAL - Con control de dos manos; MIRO SEGURIDAD - de paso seguro;.
