Bosch Rexroth IndraDrive HMV01.1E-W0030, Project Planning Manual

Page 1: ...229 Edition 01 Rexroth IndraDrive Supply Units Project Planning Manual Industrial Hydraulics Electric Drives and Controls Linear Motion and Assembly Technologies Pneumatics Service Automation Mobile Hydraulics ...

Page 2: ...served in the event of the grant of a patent or the registration of a utility model or design DIN 34 1 The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract All rights are reserved with respect to the content of this documentation and the availability of the product Bosch Rexroth AG Bgm Dr Nebel Str 2 D 97816 L...

Page 3: ... 3 Hazards by Improper Use 3 2 3 4 General Information 3 3 3 5 Protection Against Contact with Electrical Parts 3 5 3 6 Protection Against Electric Shock by Protective Low Voltage PELV 3 6 3 7 Protection Against Dangerous Movements 3 7 3 8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting 3 9 3 9 Protection Against Contact with Hot Parts 3 10 3 10 Protection Duri...

Page 4: ...6 8 7 Electrical Installation 7 1 7 1 General Information 7 1 7 2 Interference Elimination and EMC 7 2 Interference Elimination 7 2 10 Rules for EMC Correct Installation of Drives 7 3 Optimal EMC Installation 7 5 7 3 Electrical Data 7 7 HMV01 1E W0030 W0075 W0120 7 7 HMV01 1R W0018 W0045 W0065 7 8 Control Voltage 7 9 7 4 Complete Connection Diagram 7 10 7 5 Connecting Cables and Rails 7 11 Connect...

Page 5: ...lling the Supply Unit with Emergency Stop Relays 9 1 With DC Bus Dynamic Brake 9 1 Without DC Bus Dynamic Brake 9 4 9 3 Control via NC Controller 9 6 10 Troubleshooting 10 1 10 1 General 10 1 10 2 Fault Diagnostics and Resetting Faults 10 1 10 3 Checking and Repairing the Unit 10 2 10 4 Replacing the Unit 10 3 10 5 Diagnostic Display 10 4 11 Disposal and Environmental Protection 11 1 11 1 Disposal...

Page 6: ... 3 Clockwise Cable Routing 13 4 13 3 Mains Connection 13 5 General 13 5 Mains Supply Requirements 13 6 HMV01 1E 13 7 HMV01 1R 13 9 Fusing with Direct Mains Supply 13 13 13 4 Grounding the Power Supply System 13 13 13 5 Fault Current Protective Device 13 14 13 6 Earth Leakage Monitor 13 14 13 7 Chronological Sequence when Switching ON and OFF 13 15 When Switching On 13 15 When Switching Off 13 16 1...

Page 7: ... controllers communicates with the drive controllers via a module bus The supply units can be used for realizing a multitude of drive tasks in most diverse applications For these purposes there are 2 different device types regenerative non regenerative with graduated supply power available Main Features design with regeneration back to the mains HMV01 1R Wxxxx and without regeneration back to the ...

Page 8: ...plugged on the supply unit The supply unit is supplied ex works complete with control panel Esc Enter 01 F4002 Fig 1 2 Standard control panel with sample display and control elements Operating status command and error diagnoses and warnings for problems requiring attention are shown in the display Using the four buttons the commissioning operator or service engineer can opt in addition to master c...

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

Page 10: ...st in accordance with EN50178 Routine testing with DC 2230 V 1 min resp Routine testing with AC 1575 V 1 min Power supply with 0 1 A short circuit current Separation between control and power voltage circuits Safe separation in accordance with EN50178 Air gaps and leakage distances In accordance with EN50178 Fig 1 5 Tests CE Mark C UL US Listing Tests ...

Page 11: ...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 fa...

Page 12: ...n descriptions The supply units may only be operated under the assembly installation and ambient conditions as described here temperature system of protection humidity EMC requirements etc and in the position specified 2 2 Inappropriate Use Using the supply units outside of the above referenced areas of application or under operating conditions other than described in the document and the technica...

Page 13: ...on or persons responsible for the safe operation of this equipment If the equipment is resold rented or transferred or passed on to others then these safety instructions must be delivered with the equipment WARNING Improper use of this equipment failure to follow the safety instructions in this document or tampering with the product including disabling of safety devices may result in material dama...

Page 14: ...WARNING High electrical voltage due to wrong connections Danger to life or bodily harm by electric shock WARNING Health hazard for persons with heart pacemakers metal implants and hearing aids in proximity to electrical equipment CAUTION Surface of machine housing could be extremely hot Danger of injury Danger of burns CAUTION Risk of injury due to improper handling Bodily harm caused by crushing ...

Page 15: ...nd accessories approved by the manufacturer Follow all safety regulations and requirements for the specific application as practiced in the country of use The equipment is designed for installation in industrial machinery The ambient conditions given in the product documentation must be observed Use only safety features and applications that are clearly and explicitly approved in the Project Plann...

Page 16: ...ructions 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 ...

Page 17: ...ven for brief measurements or tests if the ground wire is not permanently connected to the points of the components provided for this purpose Before working with electrical parts with voltage higher than 50 V the equipment must be disconnected from the mains voltage or power supply Make sure the equipment cannot be switched on again unintended The following should be observed with electrical drive...

Page 18: ...t be smaller than the cross section of a phase of the mains suppy wire Prior to startups even for brief tests always connect the protective conductor or connect with ground wire Otherwise high voltages can occur on the housing that lead to electric shock 3 6 Protection Against Electric Shock by Protective Low Voltage PELV All connections and terminals with voltages between 0 and 50 Volts on Rexrot...

Page 19: ...nents software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble free operation The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives Regarding personal safety especially the danger of bodily injury and material damage this alone cannot be relied upo...

Page 20: ...st maximum possible momentum especially if there is a possibility of loose parts flying off Mount the emergency stop switch in the immediate reach of the operator Verify that the emergency stop works before startup Don t operate the machine if the emergency stop is not working Isolate the drive power connection by means of an emergency stop circuit or use a starting lockout to prevent unintentiona...

Page 21: ...ng conductors and permanent magnets in motors represent a serious health hazard to persons with heart pacemakers metal implants and hearing aids WARNING Health hazard for persons with heart pacemakers metal implants and hearing aids in proximity to electrical equipment Persons with heart pacemakers hearing aids and metal implants are not permitted to enter the following areas Areas in which electr...

Page 22: ...ting Under certain conditions incorrect handling and mounting of parts and components may cause injuries CAUTION Risk of injury by incorrect handling Bodily harm caused by crushing shearing cutting and mechanical shock Observe general installation and safety instructions with regard to handling and mounting Use appropriate mounting and transport equipment Take precautions to avoid pinching and cru...

Page 23: ...corresponding to the information in the respective Project Planning Manual must be provided with pressurized media such as compressed air hydraulic oil cooling fluid and cooling lubricant supplied by external systems Incorrect handling of the supply and connections of pressurized systems can lead to injuries or accidents In these cases improper handling of external supply systems supply lines or c...

Page 24: ...3 12 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive DOK INDRV HMV PR01 EN P Notes ...

Page 25: ...ote in duplicate can be found in an envelope on one of the packages supplied No other accompanying documents are provided The total number of containers supplied is recorded on the delivery note or consignment note 4 2 Scope of Delivery Overview as standard optional touch guard rails for connecting the DC bus grounding bracket rails for connecting the control voltage connector X31 X32 X33 safety i...

Page 26: ...ts including the motor A label cable marker is wrapped round the ready made cable The type designation and length are indicated on this label The designation for the cable itself without connector is printed on the cable sheath The identification of accessories packed in bags is either printed on the bag or indicated in an accompanying note Type Plates on the Unit hmv_typenschild fh7 Fig 4 2 Type ...

Page 27: ... 6 7 8 9 4 0 5 Example Abbrev Column H M V 0 1 1 E W 0 0 3 0 A 0 7 N N N N 1 Product 1 1 HMV HMV 2 Line 2 1 1 01 3 Design 3 1 1 1 4 Power supply 4 1 feeded E 4 2 regenerative R 5 Cooling mode 5 1 Air internal through integrated blower W 6 Rated output Rated output Power supply Code KW E R with choke 30 X 0030 45 X 0045 7 Protection mode 7 1 IP 20 A 8 DC bus nominal voltage 8 1 DC 700V 07 9 Other d...

Page 28: ...4 4 Identifying and Checking the Delivered Components Rexroth IndraDrive DOK INDRV HMV PR01 EN P Notes ...

Page 29: ... 2 27 Halve sine in 3 axis 10g 11ms Fig 5 1 Conditions for transport 5 2 Storing the Devices Conditions temperature 25 55 C relative humidity 5 95 climatic category 1K3 absolute humidity 1 29 g m 3 climatic category 1K3 moisture condensation not allowed icing not allowed Fig 5 2 Conditions for storage In Case of Long Storage Periods The power supply units contain sensitive electrolytic capacitors ...

Page 30: ...5 2 Transport and Storage Rexroth IndraDrive DOK INDRV HMV PR01 EN P Notes ...

Page 31: ...2000 m see characteristic in Fig 6 3 Maximum mounting altitude 4000 m upper temperature limit falls to 40 C instead of 55 C Relative humidity operation 5 to 95 Cl 3K5 with reservation as not 5 C Absolute humidity 1 to 29 g m 3 Climatic class Cl 3K5 Contamination level Contamination level 2 in accordance with EN50178 Vibration sinus in operation according to EN 60068 2 6 Amplitude and frequency 0 1...

Page 32: ...velopment 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 Compatibility...

Page 33: ...er mounting altitudes occur simultaneously both duty factors must be multiplied The mounting altitude must be taken into account just once differing ambient temperatures must be considered separately for the motor and drive controller DG0006F1 FH7 Ambient temperature in C 0 7 1 40 45 50 55 5 Degree of utilization at higher ambient temperatures Load factor Fig 6 2 Duty capacity at higher ambient te...

Page 34: ...nd HMV01 1R W00 maszblatt_hmv fh7 A A 7 L1 L 480 440 466 25 7 262 100 300 A minimum mounting clearance Fig 6 4 Dimensional drawing for HMV01 1E W0 and HMV01 1R W00 Device L mm L1 mm HMV01 1E W0030 150 100 HMV01 1E W0075 250 200 HMV01 1E W0120 350 300 HMV01 1R W0018 175 125 HMV01 1R W0045 250 200 HMV01 1R W0065 350 300 Fig 6 5 L and L1 dimensions ...

Page 35: ...ents in the Control Cabinet Power dependent Arrangement versorg_antrieb_sym FH7 supply unit drive controllers high power low power high power low power drive controllers Fig 6 7 Example of an arrangement Arrange the drive controllers with higher power needs and high currents as close to the supply unit as possible Ideally the drive controllers should be distributed equally to the left and right si...

Page 36: ...ng air guides are to be allowed for with ventilators specially inserted for this purpose For example air baffle Additional fan Discharge direction of the warmed air in the flow off area Discharge direction of the warmed air in the flow off area Entry area of the cooling air for the upper device line Entry area of the cooling air for the lower device line Exhaust air from the air conditioner Supply...

Page 37: ...n of the mains connecting unit the power dissipation of each drive controller and the power dissipation of additional units e g DC bus resistor unit or DC bus capacitor unit The power dissipation of a supply unit is composed of power dissipation of the control voltage supply unit current related power dissipation of rectifier HMV01 1E resp inverter HMV01 1R wiring and mains contactor power dissipa...

Page 38: ... condensation water is formed when cooling units are used For this reason please observe the following information Always position cooling units in such a way that condensation water cannot drip onto electrical equipment in the control cabinet Position the cooling unit so that the ventilator for the cooling unit does not spray accumulated condensation water onto electrical equipment electronic equ...

Page 39: ... temperature so that the interior temperature of the control cabinet is no lower than the temperature of the surrounding air Set the temperature delimitation to the maximum surrounding temperature Only use well sealed control cabinets so that condensation cannot arise as a result of warm and moist external air entering the cabinet In the event that control cabinets are operated with the doors open...

Page 40: ...6 10 Mechanical Mounting Rexroth IndraDrive DOK INDRV HMV PR01 EN P Notes ...

Page 41: ...ts may only be stored or dispatched in conductive packaging Note Rexroth connection diagrams are only to be used for producing installation connection diagrams The machine manufacturer s installation connection diagrams must be used for wiring the installation Lay signal lines separately from the load resistance lines because of the occurrence of interference Feed analog signals e g command values...

Page 42: ...ning the mains filter arrangement apply above all to the HMV01 1E The line filter is already included in the combining filter To maintain class B limit values interference suppression N as per EN 55011 3 91 at the machine required in residential and light industrial areas suitable interference suppression filters must be installed in the mains supply line in the machine The motor power cable shoul...

Page 43: ...et but as close as possible to the cabinet itself and the mounting panels This is also true for reserve cables Incremental encoders must be connected using shielded cables The shield must be connected at the incremental encoder and at the drive controller through the largest possible surface area The shield may not be interrupted e g using intermediate terminals The shields of signal cables must b...

Page 44: ...onnection between the motor terminal box and the motor housing has a low impedance Otherwise use an additional grounding strap between them Never use plastic motor terminal boxes The shield between the motor and drive controller may not be interrupted by installing components such as output reactors sinusoidal filters motor filters fuses contactors The components must be mounted on mounting panels...

Page 45: ...e area drive components is advisable See the next figure in this respect HMV01 1E Wxxxx mains PE mains filter load earth rail to the motors power connection shielded control cabinet compartment or intermediate panel control cabinet connecting clamps main switch distributor clamps fuse HMVE_emv fh7 supply unit drive controller drive controller mains choke Fig 7 1 HMV01 1E Separation of interference...

Page 46: ...control cabinet compartment or intermediate panel control cabinet connecting clamps main switch distributor clamps fuse HMVR_emv fh7 filter power connection mains choke shielded cable ground connection supply unit drive controller drive controller Fig 7 2 HMV01 1R Separation of interference free and interference susceptible areas ...

Page 47: ...ut choke PDC cont kW 18 45 72 continuous DC bus power depending on mains input voltage at ULN 400 V 1 power reduction per 4 V at ULN 400 V 1 power increasing per 4 V peak DC bus power for max 0 3 s with a preload of 0 6 x ILN cont and 40 C ambient temperature PDC peak kW 45 112 180 braking resistor switch on threshold UDC R_DC On V constant 820V or variable 80V 2 ULN continuous brake power kW 1 5 ...

Page 48: ...limit shutdown threshold UDC limit max V 900 lower DC bus voltage limit shutdown threshold UDC limit min V 0 75 2 ULN continuous DC bus power at ULN 400V PDC cont kW 18 45 65 continuous DC bus power depending on mains input voltage at ULN 400 V 1 power reduction per 4 V at ULN 400 V no power increasing DC bus peak power for max 0 3 s with a preload of 0 6 x ILN cont and 40 C ambient temperature PD...

Page 49: ...01 1E W0030 7 A HMV01 1E W0075 16 A HMV01 1E W0120 15 A HMV01 1R W0018 6 A HMV01 1R W0045 8 A HMV01 1R W0065 14 A Max pulse duration of IEIN3 tEIN3Lade ms HMV01 1E W0120 50 all other devices 15 Max input capacity CN3 mF 10 Power consumption HMV01 1 1E W0030 PN3 W 24 preliminary HMV01 1 1E W0075 PN3 W 38 preliminary HMV01 1 1E W0120 PN3 W 41 preliminary HMV01 1 1R W0018 PN3 W 27 preliminary HMV01 1...

Page 50: ...or interface ready for operation DC bus ok prewarning temp bleeder mains connection module bus mains contactor ON mains contactor OFF 24V 0V L L HMV 01 1x Wxxxx X3 24V control voltage DC bus mains connection for synchronization braking resistor threshold fixed variable PE PE 4 3 2 1 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 3 2 1 X33 X32 X31 X2 X1 only for HMV01 1R Wxxxx X14 on...

Page 51: ...age supply C Supply unit D Drive controller 1 PE connection of mains supply 2 Mains connection 3 PE connection to drive controller If cables are used for ground connection they must have a cross section of at least 10 mm 2 4 Module bus X1 5 Control voltage connection 24V 0V If connection with contact isn t possible you can also use wires 6 DC bus connection L L If connection with contact isn t pos...

Page 52: ... 24 V 0 V L L control voltage DC bus mains PE PE X2 control panel X1 X33 X32 X31 Fig 7 8 HMV01 1E W0030 and HMV01 1E W0075 Description of connections Connection See page control voltage 7 15 DC bus 7 17 mains voltage X5 7 22 PE connection power supply unit resp neighboring device 7 20 X1 7 21 X2 7 21 X3 7 27 X6 7 29 X7 7 25 ...

Page 53: ...us mains PE connection to drive controller PE PE connection to drive controller PE X33 X32 X31 X2 X1 control panel Fig 7 9 HMV01 1E W0120 Description of connections Connection See page control voltage 7 15 DC bus 7 17 mains voltage X5 7 22 PE connection power supply unit resp neighboring device 7 20 X1 7 21 X2 7 21 X3 7 27 X6 7 29 X7 7 25 ...

Page 54: ...4 V 0 V control voltage DC bus mains PE PE X2 X14 control panel X33 X32 X31 Fig 7 10 HMV01 1R W0018 W0045 W0065 Description of connections Connection See page control voltage 7 15 DC bus 7 17 mains voltage X5 7 22 PE connection power supply unit resp neighboring device 7 20 X1 7 21 X2 7 21 X3 7 27 X6 7 29 X7 7 25 X14 7 30 ...

Page 55: ...aused by brakeless motor coasting to stop in the event of an interruption to the control voltage supply Do not stay within the motional range of the machine Possible measures to prevent personnel accidentally accessing the machine protective fencing protective grid protective cover light barrier Fencing and covers must be adequately secured against the maximum possible force of movement The extern...

Page 56: ...7 16 Electrical Installation Rexroth IndraDrive DOK INDRV HMV PR01 EN P schienen_steuerspg B A A cables to the source of control voltage B contact rails Fig 7 11 Contact rails 6 Nm Tightening Torque ...

Page 57: ...the width of the drive controllers schienen_zwkreis Fig 7 12 Contact rails 6 Nm If in special cases it is not possible to use the DC bus rails provided to make the connection the connection must be made using the shortest possible twisted wires Length of the twisted wire max 2 m Wire cross section min 10 mm however no less than the cross section of the power input line Wire protection by means of ...

Page 58: ...K INDRV HMV PR01 EN P CAUTION Risk of voltage arcing If devices are stacked in the control cabinet the connections for the DC buses between the drive controllers have to be correctly made There is otherwise a risk of voltage arcing see page 13 3 onward ...

Page 59: ...0065 HMV01 1E W0120 hmv_erdanschluss_netz_30 fh7 hmv_erdanschluss_netz_120 fh7 Abb 7 13 PE connection of power supply The ground wire is fixed to the supply unit with screws HMV01 1E W0030 W0075 HMV01 1R W0018 W0045 W0065 HMV01 1E W0120 M6 x 25 M10 HMV01 1E W0030 W0075 HMV01 1R W0018 W0045 W0065 HMV01 1E W0120 6 Nm 18 Nm Design Tightening Torque ...

Page 60: ...a shared bare metal surface Note You must use the grounding bracket on the front for ground connection in any case The rear panel of the device can be used in addition erdungslasche_hmv 1 1 Grounding bracket for ground connection Fig 7 14 PE connection to supply unit resp neighboring device Note If cables are used for PE connection they must have a cross section of at least 10 mm 2 The cross secti...

Page 61: ... exchange between the supply unit and the drive controllers X1_hmv Fig 7 15 X1 Type Number of poles Type of design Flat line connector 8 Connector on device Fig 7 16 Design Note If extension leads are used the leads must be shielded Their total length must not exceed a maximum of 40 m Graphic Representation Design ...

Page 62: ...h7 1 2 3 4 5 6 7 8 Fig 7 17 X2 Type Number of poles Type of design MiniDIN 8 socket on device Fig 7 18 Design Cross section single wire mm Cross section multiwire mm Cross section in AWG Gauge No 0 25 0 5 Fig 7 19 Connection cross section n c 1 n c 2 RS232_TxD 3 GND 4 RS232_RxD 5 n c 6 n c 7 n c 8 GND is connected to the housing Graphic Representation Design Connection cross section Connection ...

Page 63: ...f poles Type of design W0018 Terminal block 3 Threaded terminal end W0045 Terminal block 3 Threaded terminal end W0065 Terminal block 3 Threaded terminal end Fig 7 21 Design HMV01 1E Cross section single wire mm Cross section multiwire mm Cross section in AWG W0030 16 16 6 W0075 50 50 0 W0120 120 120 0000 HMV01 1R Cross section single wire mm Cross section multiwire mm Cross section in AWG W0018 6...

Page 64: ...th IndraDrive DOK INDRV HMV PR01 EN P HMV01 1E Torque W0030 6 W0075 6 W0120 6 HMV01 1R Torque W0018 6 W0045 6 W0065 6 Fig 7 23 Tightening torques Note See chapter 13 3 onward for further information on mains connection Tightening Torque ...

Page 65: ...UD warning signal for bleeder overload and overtemperature WARN hmv_X31 6 5 4 3 2 1 Fig 7 24 X31 Type Number of poles Type of design LK06 1M WIN R3 5 series 0734 6 Bushing on device Fig 7 25 Design Cross section single wire mm Cross section multiwire mm Cross section in AWG Gauge No 0 14 1 5 0 14 1 5 28 16 Fig 7 26 Connection cross section Description Graphic Representation Design Connection cross...

Page 66: ...closes if no error is present contact opens if error is present UD_1 4 UD_2 3 power supply ok contact load DC 30V 1A inrush current max 5A contact closes if DC bus voltage is within the specified range contact opens if DC bus voltage is too low resp in case of mains failure WARN_1 2 WARN_2 1 warning signal for bleeder overload and overtemperature contact load DC 30V 1A inrush current max 5A contac...

Page 67: ... for braking resistor threshold Note See chapter 9 onward for further information on mains contactor control hmv_X32 9 8 7 6 5 4 3 2 1 Fig 7 28 X32 Type Number of poles Type of design LK09 1M WIN R3 5 series 0734 9 Bushing on device Fig 7 29 Design Cross section single wire mm Cross section multiwire mm Cross section in AWG Gauge No 0 14 1 5 0 14 1 5 28 16 Fig 7 30 Connection cross section Descrip...

Page 68: ...a external contact OFF1 7 OFF2 6 switching off mains contactor 24V for switching mains contactor on pins 6 7 jumpered via N O ON1 5 ON2 4 switching on mains contactor 24V switching mains contactor on by closing pins 4 5 for longer than 200 ms pushbutton braking resistor threshold 3 switching signal for braking resistor threshold 24V for HMV01 1E switching between braking resistor threshold fixed v...

Page 69: ...re mm Cross section multiwire mm Cross section in AWG Gauge No 0 14 1 5 0 14 1 5 28 16 Fig 7 34 Connection cross section hmv_X33_schalt feedback contact mains contactor ON feedback contact mains contactor OFF 4 3 2 1 X33 Name Pin no Description Level Notes MAINS_ON1 4 MAINS_ON2 3 feedback contact mains contactor ON N O contact load DC 30V 1A inrush current max 5A MAINS_OFF1 2 MAINS_OFF2 1 feedback...

Page 70: ...G 3 Connector on device Fig 7 37 Design Cross section single wire mm Cross section multiwire mm Cross section in AWG Gauge No 1 5 4 1 5 4 16 12 Fig 7 38 Connection cross section Pin no Description Level Notes 3 mains connection phase L3 before choke max 900V current load max 5A 2 mains connection phase L2 before choke max 900V current load max 5A 1 mains connection phase L1 before choke max 900V c...

Page 71: ... at the touch guard WARNING Lethal electric shock caused by live parts with more than 50 V You have to provide the best possible protection against contact Therefore keep the cutouts at the touch guard as small as possible Only break off the cutouts if necessary If the DC bus and the control voltage are connected by means of contact rails only the cutout C see picture may be broken off the touch g...

Page 72: ... each other there mustn t any cutout be broken off at the outer side of the touch guard Mounting The touch guard must always be mounted following connection work hmv_beruehrschutz Fig 7 41 Touch guard Note Risk of damage to the touch guard The maximum tightening torque for the fixing screw for the touch guard is 2 8 Nm 2 8 Nm Tightening Torque ...

Page 73: ...ich will be used It is advisable to carry out calculations in accordance with the following chapters in order to make sure that the layout of the mains supply is correct 8 2 DC Bus Continuous Power The DC bus continuous power is calculated from the mechanical power and based on the efficiency of motor and controller as well as coincidence factors 9550 n M kW P or 60 n 2 M M W P m m π ω Pm mechanic...

Page 74: ...3 t4 t Abb 8 3 Speed cycle influence of accel and decel time is not taken into consideration Accel and decel times with short cycle times must be taken into consideration in such dynamic applications as is the case with rollers and nibble machines 2 B 1 H B 1 H av t t t t t 2 n t n t 2 n n nav average motor speed min 1 n motor speed min 1 t time s tH accel time s tB decel time s Fig 8 4 Average sp...

Page 75: ...r for typical NC feed axes on tool machines it has proven in practice that a so called coincidence factor is included Number of Axes 1 2 3 4 5 6 Coincidence factor FG 1 1 15 1 32 1 75 2 0 2 25 Fig 8 8 Coincidence factors G mSen 2 mSe 1 mSe F 25 1 P P P P PZWSe DC bus continuous power for servo drives kW PmSe1 PmSen cont mech power for servo drives kW FG coincidence factor 1 25 constant for motor a...

Page 76: ...r spindle and servo drives in machine tools 8 3 DC Bus Peak Power The DC bus peak power is demanded of the power supply unit when e g several axes of a machine tool simultaneously accelerate to rapid traverse and then go to a workpiece after a tool change CAUTION Damages due to overloaded power supply unit Damages to the power supply unit can be avoided if the sum of the peak power of all drives d...

Page 77: ...se speed min 1 JG inertia of motor and load inertia reduced to shaft kgm Fig 8 14 Regenerated energy per drive MAX rot W W Wrot rotary energy Ws WMAX max permissible regenerated energy of the power supply module kWs Fig 8 15 Sum of regenerated energies In servo drive applications with numerous accel and decel procedures as is the case for example with nibble machines and rollers it is advisable to...

Page 78: ...sum of the continuous regenerated power of all drives may not exceed the continuous regenerated power in the HMV01 1R or the continuous bleeder power in the HMV01 1E Note For operation with continuous power an additional load caused by DC bus short circuit is no longer allowed The processing time in servo drive applications given a typical NC machine tool is relatively long in terms of the entire ...

Page 79: ...generated power usually arises when an Emergency Stop signal has been released and all the axes brake simultaneously CAUTION Property damages due to longer braking periods paths Choose the power supply unit such that the sum of the peak regenerated power of the all drives does not exceed the bleeder peak power of the power supply unit The peak regenerated power of the servo drives is listed in the...

Page 80: ...nctional principle of the power supply unit 15 1 P S KD choke mains with 0120 W 0075 W E 1 01 HMV for 5 1 P S 0030 W E 1 01 HMV for 7 1 P S KD choke mains without ZW 1 N ZW 1 N ZW 1 N SN1 connected load kVA PZW DC bus continuous power kW Fig 8 23 Connected load for power supply units of the HMV01 1E line 05 1 P S ZW 1 N SN1 connected load kVA PZW DC bus continuous power kW Fig 8 24 Connected load ...

Page 81: ...us voltage is short circuited If the drive electronics is interfered and the DC bus voltage is not short circuited then the motors with energized permanent magnet will slow down uncontrolled Braking with Emergency Stop or Power Failure In an emergency stop or power failure situation drives are generally shutdown by the drive control Given an emergency stop or with actuation of the drive internal m...

Page 82: ...t are connected in series with the CNC contact in the E Stop circuit the DC bus dynamic brake is only triggered in the case of a supply unit error In an emergency stop situation or with actuation of the monitor in the supply unit e g power failure the drives are shutdown by the drive electronics in the manner set for the specific error reaction WARNING Property damages due to uncontrolled axis mov...

Page 83: ...or message of control use only contacts that do not open with E stop switch is open K1 mains contactor in power supply unit K4 drive enable signal control RF drive enable signal of the control S1 Emergency stop S2 axis end position S4 power OFF S5 power ON S11 S12 safety door monitor AF AF AF S2 CNC S5 K1 1 1 bleeder control 2 1 K1 control if no emergency stop switch is used 2 unregulated rectifie...

Page 84: ...re then the drives are shutdown by the drive electronics as per the set error reaction The mains contactor in the supply unit immediately falls off when the emergency stop sequence is initiated The drive enable is removed by the emergency stop relay or by an auxiliary contact of the mains contactor The drives are shutdown depending on the set error reaction CAUTION Machine damages due to brakeless...

Page 85: ...ready drive system Bb drive controllers ready CNC lag error message of control use only contacts that do not open with E stop switch is open K1 mains contactor in power supply unit K4 drive enable signal control RF drive enable signal of the control S1 Emergency stop S2 axis end position S4 power OFF S5 power ON S11 S12 safety door monitor 24V 5 L L HMV01 1E HMV01 1R 24 V 5 0 V ON delay approx 1 5...

Page 86: ...turn motion The parameter Activating NC reactions with a fault must be programmed in the drive controller P 0 0117 bit 0 1 Given an emergency stop or the actuation of the supply unit monitor e g power failure the drives are shutdown position controlled by the position controller Upon initiating the emergency stop sequence or with the actuation of the monitor in the supply unit e g power failure th...

Page 87: ...its ready drive system Bb drive controllers ready CNC lag error message of control use only contacts that do not open with E stop switch is open K1 mains contactor in power supply unit K4 drive enable signal control RF drive enable signal of the control S1 Emergency stop S2 axis end position S4 power OFF S5 power ON S11 S12 safety door monitor 24V 5 L L 24 V 5 0 V ON delay approx 1 5 seconds 4 min...

Page 88: ...9 8 Control Mains Contactor Rexroth IndraDrive DOK INDRV HMV PR01 EN P Notes ...

Page 89: ...ng key Esc on the control panel display switching the control voltage off or generating the reset command of the drive controller via the bus module CAUTION Destruction of the power supply module if the power is switched on to a faulty drive controller Upon RESET of an over current fault and after replacement of a defective supply module the fault memories of the drive controllers must be read out...

Page 90: ...we would like to ask you to provide the following information so that a quick and precise assistance can be assured type designations and serial numbers of units and motors the status of the fault any diagnostic displays and software status if necessary You ll find the telephone number of our service hotline in the chapter Service Support ...

Page 91: ...ate measuring device check whether the installation is power free Wait the discharge time 3 Motors must be standing still 4 Secure vertical axes against motion 5 Release all connections from the defective unit 6 Release the fixing bolts and remove the unit from the control cabinet Use the lifting device if necessary 7 Hang replacement unit into mounting rails Use the lifting device if necessary 8 ...

Page 92: ...10 4 Troubleshooting Rexroth IndraDrive DOK INDRV HMV PR01 EN P 10 5 Diagnostic Display Concerning error diagnoses displayed on the control panel see Troubleshooting Guide of firmware documentation ...

Page 93: ...raße 2 D 97816 Lohr am Main Packaging Materials The packaging materials consist of cardboard wood and polystyrene They can be easily recycled For ecological reasons you should not return the empty packages to us 11 2 Environmental Protection No Release of Hazardous Substances Our products do not contain any hazardous substances that they can release in the case of appropriate use Normally there ar...

Page 94: ...omponents can be recycled In order to recycle the metal in the best possible way it is necessary to disassemble the products into individual modules The metals contained in the electric and electronic modules can also be recycled by means of specific separation processes The synthetic materials remaining after these processes can be thermally recycled ...

Page 95: ...n Sie bitte zuerst Kontakt mit unserem für Sie nächstgelegenen Ansprechpartner auf Die Angaben in der vorliegenden Dokumentation können seit Drucklegung überholt sein At www boschrexroth com you may find additional notes about service repairs and training in the Internet as well as the actual addresses of our sales and service facilities figuring on the following pages sales agencies offices provi...

Page 96: ...üd Germany South Bosch Rexroth AG Landshuter Allee 8 10 80637 München Tel 49 0 89 127 14 0 Fax 49 0 89 127 14 490 Vertriebsgebiet West Germany West Bosch Rexroth AG Regionalzentrum West Borsigstrasse 15 40880 Ratingen Tel 49 0 2102 409 0 Fax 49 0 2102 409 406 49 0 2102 409 430 Gebiet Südwest Germany South West Bosch Rexroth AG Service Regionalzentrum Süd West Siemensstr 1 70736 Fellbach Tel 49 0 7...

Page 97: ...th S p A Via Paolo Veronesi 250 10148 Torino Tel 39 011 224 88 11 Fax 39 011 224 88 30 Italy Italien Bosch Rexroth S p A Via Mascia 1 80053 Castellamare di Stabia NA Tel 39 081 8 71 57 00 Fax 39 081 8 71 68 85 Italy Italien Bosch Rexroth S p A Via del Progresso 16 Zona Ind 35020 Padova Tel 39 049 8 70 13 70 Fax 39 049 8 70 13 77 Italy Italien Bosch Rexroth S p A Via Isonzo 61 40033 Casalecchio di ...

Page 98: ...8 061 847 64 62 63 Fax 48 061 847 64 02 Romania Rumänien East Electric S R L Bdul Basarabia no 250 sector 3 73429 Bucuresti Tel Fax 40 0 21 255 35 07 40 0 21 255 77 13 Fax 40 0 21 725 61 21 eastel rdsnet ro Romania Rumänien Bosch Rexroth Sp zo o Str Drobety nr 4 10 app 14 70258 Bucuresti Sector 2 Tel 40 0 1 210 48 25 40 0 1 210 29 50 Fax 40 0 1 210 29 52 Russia Russland Bosch Rexroth OOO Wjatskaja...

Page 99: ...oth India Ltd Electric Drives Controls Advance House II Floor Ark Industrial Compound Narol Naka Makwana Road Andheri East Mumbai 400 059 Tel 91 22 28 56 32 90 91 22 28 56 33 18 Fax 91 22 28 56 32 93 singh op boschrexroth co in India Indien Bosch Rexroth India Ltd S 10 Green Park Extension New Delhi 110016 Tel 91 11 26 56 65 25 91 11 26 56 65 27 Fax 91 11 26 56 68 87 koul rp boschrexroth co in Ind...

Page 100: ...hrexroth ca Canada West Kanada West Bosch Rexroth Canada Corporation 5345 Goring St Burnaby British Columbia Canada V7J 1R1 Tel 1 604 205 5777 Fax 1 604 205 6944 Hotline 1 604 205 5777 david gunby boschrexroth ca Mexico Bosch Rexroth Mexico S A de C V Calle Neptuno 72 Unidad Ind Vallejo 07700 Mexico D F Tel 52 55 57 54 17 11 Fax 52 55 57 54 50 73 mariofelipe hernandez boschrexroth com m x Mexico B...

Page 101: ...n see page 7 17 The connection depends on the cable routing to the left or to the right of the supply unit The following figure shows the correct DC bus connection of the drive controller to the supply unit The illustrated way of connection keeps bare wire sections from being situated directly vis à vis This avoids voltage arcing Supply Unit to the Left of the Drive Controller DC bus nach links zu...

Page 102: ...PR01 EN P Supply Unit to the Right of the Drive Controller DC bus nach rechts zum versorger drive controller DC bus connection correct incorrect supply unit Fig 13 2 Connection of supply unit by wires to the DC bus connection of the drive controller ...

Page 103: ...ing clockwise or counterclockwise The following figures show the correct DC bus connection for stacked devices The illustrated way of connection keeps bare wire sections from being situated directly vis à vis This avoids voltage arcing Counterclockwise Cable Routing DC bus nach links_hmv correct device 1 DC bus connection device 2 DC bus connection device 1 DC bus connection device 2 DC bus connec...

Page 104: ...V HMV PR01 EN P Clockwise Cable Routing DC bus nach rechts_hmv device 1 DC bus connection device 2 DC bus connection device 1 DC bus connection device 2 DC bus connection correct incorrect Fig 13 4 DC bus connection for clockwise cable routing ...

Page 105: ... be connected to grounded three phase without the need of a transformer Concerning electrical data of the mains see chapter 7 3 For more information about the subject Mains fuse protection with direct mains connection read the recommendations in chapter Fusing with Direct Mains Supply on page 13 13 A transformer is needed if the mains voltage is smaller than 380 V or greater than 480 V The require...

Page 106: ...nnected load These values are from a directive of german energy supply companies and are applicable only to european mains supplies If you need the values for different mains supplies you have to contact your energy supply company Supply units HMV01 1E and HMV01 1R tolerance mains supply failures up to a duration of 10 ms When the supply voltage falls below its minimal value see technical data for...

Page 107: ...rence suppression we recommend a line filter HFD supply unit HMV01 1E HMVE_NFD_anschluss fh7 mains filter L1 L2 L3 PE 1 2 mains choke 3 1 Like mains wires but not smaller than 10 mm 2 2 Twist main wires cable selections according to EN 60 204 3 Whether a mains choke is necessary or not depnds on the continuous DC bus power see electrical data Fig 13 6 Direct mains connection via mains filter Direc...

Page 108: ... a transformer HMVE_spartrafo_NFD_anschluss fh7 autotransformer 1 Like main wires but not smaller than 10 mm2 2 Twist main wires cable selections according to EN 60 204 supply unit HMV01 1E mains filter L1 L2 L3 PE 1 2 mains choke Fig 13 7 Mains connection via autotransformer Connecting the mains via autotransformer with mains voltages 3 AC x 380 V e g 3 AC x 480 V ...

Page 109: ...E L1 1 L2 1 L3 1 to the central ground connection HFD combining filter 3 x AC 380 480 V 50 60 Hz KDxx mains choke drive controller twisted HMVR_Netzanschluss fh7 mains input L L 24V 0V twisted to the central ground connection X14 1 2 3 F2 L1 L2 L3 Fig 13 8 Mains connection via mains choke and combining filter Basically the HFD combining filters to be provided for the mains connection of the power ...

Page 110: ...onics fn on the mains voltage will lead to a temperature rise of the dielectric material of the capacitors built in the filters You can calculate the temperature rise using the following formula K U U x 10 T 2 Gn 2 Mn n UMn measured voltage value at frequency fn UGn voltage limit value for frequency fn Tn calculated temperature rise of the dielectric material for frequency fn Fig 13 9 Calculating ...

Page 111: ...ains choke have a connected voltage of high amplitude and frequency This can result in a possible interference of sensitive units in the control cabinet Therefore the connection cables need to be kept as short as possible and absolutely twisted here it would also be better to use shielded cables If a transformer is used it is possible to connect HMV01 1R supply modules to networks with mains volta...

Page 112: ...uss FH7 F2 1 L2 1 L3 1 L1 L2 L3 1 Use a motor circuit breaker F2 e g PKZM6 3 or fuses 6 3 A to protect X14 Fig 13 12 Synchronizing voltage HMV01 1R Details of the Mains Choke The mains chokes are equipped with a temperature contact which opens at T 150 C connections a b The contact can be evaluated by a controller and is used for example for a regulated shutdown of the unit should the control cabi...

Page 113: ...rom three phase systems with grounded neutral points or phases without control to load isolation With ungrounded mains IT mains there is the increased danger that unacceptably high overvoltages could occur between the phase and the housing Both the HMV01 1E and HMV01 1R can be protected against unacceptable overvoltages if they are connected via an isolating transformer the star point of the outpu...

Page 114: ...r to avoid faulty releases when inductive loads and capacitance interference suppression filters transformers contactors magnetic valves are switched on it is necessary to provide an isolating transformer in the mains supply line ahead of the power supply unit of the drive system The over current protective device must be matched to the impedance of the fault loop so that a shutdown is effected if...

Page 115: ...UD contact closes t1 5 2 s time for internal booting until Bb1 contact closes t2 time can be set by the user t3 400 ms time for internal test routine before loading the DC bus t4 time depends on DC bus capacitance internal external and supply voltage The approximate time can be calculated t4 0 7 x UMains x CDC bus t5 500 ms delay time until mains contactor closes t6 max 200 ms depends on device ON...

Page 116: ...ff t hmv_ausschalt_verlauf FH7 t1 t2 Control voltage OFF Bb1 contact opens Power OFF UD contact opens Acknowledge Power OFF t1 max 200 ms depends on device OFF delay of mains contactor t2 time can be set by the user Fig 13 15 Chronological sequence when shutting down the unit ...

Page 117: ...295 180 122 8 x 12 24 KD 33 265 152 350 215 126 15 x 11 33 Fig 13 16 Mechanical Data Mains choke Pdcont kW ILN cont at UNetz 400V Aeff ILN max for 0 3s Aeff LN Rated inductance µH Lmin at ILN max Cross section mm Device KD 31 30 51 77 3 x 400 50 of LN 16 a b 2 5 HMV01 1E W0030 KD 35 75 125 188 3 x 200 50 of LN 70 a b 2 5 HMV01 1E W0075 KD 33 120 202 303 3 x 100 50 of LN 150 a b 2 5 HMV01 1E W0120 ...

Page 118: ...0 174 55 385 290 132 11 x 15 65 Fig 13 19 Mechanical Data Mains choke Pdcont kW ILN cont at ULN 400V Aeff ILN max for 0 3s Aeff LN Rated inductance µH Lmin at ILN max C µF Cross section mm Device KD 34 C 18 26 65 3 x 980 80 von LN 3 x 10 16 a b 2 5 HMV01 1 R W0018 KD 32 C 45 65 163 3 x 590 80 von LN 3 x 20 35 a b 2 5 HMV01 1 R W0045 KD 36 C 65 94 235 3 x 540 80 von LN 3 x 20 70 C 16 a b 2 5 HMV01 ...

Page 119: ...ontrollers to ensure interference suppression according to EN61800 3 class A group 2 and 1 type to ensure interference suppression according to EN61800 3 class B group 1 Type 1 For max 6 axis with a total motor cable length of 240 m Type 2 For max 15 axis with a total motor cable length of 900 m Type 3 For max 6 axis with a total motor cable length of 100 m For IndraDrive C drive controllers you o...

Page 120: ...0030 65 class B group 1 curve 4 1 4 2 HFD03 2 480 0094 3 HMV01 1R W0065 94 class B group 1 curve 4 1 4 2 1 see following figure Fig 13 22 Versions Limit values for line based disturbances DIN EN 55011 DIN EN 61800 3 A11 1 1 1 2 2 1 3 1 4 1 2 2 3 2 4 2 1 1 1 2 2 1 2 2 3 1 3 2 4 1 4 2 130 120 100 90 79 66 56 125 115 86 76 60 56 46 115 105 73 50 60 70 class A group 2 QSP I 100A second environment cla...

Page 121: ...Rexroth IndraDrive Appendix 13 21 DOK INDRV HMV PR01 EN P Dimensions Fig 13 24 HFD0x 2 480 0065 ...

Page 122: ...13 22 Appendix Rexroth IndraDrive DOK INDRV HMV PR01 EN P Fig 13 25 HFD01 2 480 0026 ...

Page 123: ...Rexroth IndraDrive Appendix 13 23 DOK INDRV HMV PR01 EN P Fig 13 26 HFD02 2 480 0026 ...

Page 124: ... INDRV HMV PR01 EN P hfd02_2_480_0202 fh7 Beschriftung Netz Line 250 150 13 6 5 12 9 7 480 466 440 7 6 5 4x45 67 150 mm2 25 30 Nm PE M10x30 25 50 70 96 83 Last Load Netz Line 262 138 115 96 83 50 25 250 12 440 67 Fig 13 27 HFD02 2 480 0202 ...

Page 125: ...ching on and off 13 15 Compatibility with foreign matters 6 2 Component designation 4 2 Condensation 6 9 Condition as supplied 4 1 Conditions ambient 6 1 mounting 6 1 operating 6 1 storing 5 1 transporting 5 1 Connected load of supply unit 8 8 Connection mains 13 5 mains 7 23 Connection diagram 7 10 Control cabinet arrangement of components 6 6 multiple line structure 6 6 power dependent arrangeme...

Page 126: ... compatibility 7 2 EMC 7 2 correct installation of drives 7 3 optimal installation 7 5 Emergency stop relays 9 1 F Fault current protective device 13 14 Fusing with direct mains supply 13 13 G Ground connection 7 19 Grounding power supply system 13 13 Grounding bracket 7 20 H Hazards by Improper Use 3 2 HFD 13 19 HMV01 1E power supply 13 7 type code 4 3 HMV01 1R power supply 13 9 synchronizing to ...

Page 127: ...ternal mains contactor 7 29 Bb1 UD WARN 7 25 Mounting 6 1 N NC controller 9 6 O Operating conditions 6 1 P Packaging labels 4 1 material 4 1 units 4 1 Panel 1 2 PE connection neighboring device 7 20 connection power supply 7 19 Power dissipation 6 7 Power supply HMV01 1E 13 7 HMV01 1R 13 9 Protection against contact with electrical parts 3 5 against contact with hot parts 3 10 against dangerous mo...

Page 128: ...ion by wires instead of rails 13 1 device types 4 3 inappropriate use 2 2 main features 1 1 repairing 10 2 storing 5 1 transport 5 1 type code 4 3 Switching On Off chronological sequence 13 15 Synchronization mains voltage 7 30 Synchronizing to the mains 13 12 T Technical data electrical 7 7 mechanical 6 4 Tests 1 4 Touch guard 7 31 Transporting 5 1 Troubleshooting 10 1 Type code 4 3 Type plate 4 ...

Page 129: ...Rexroth IndraDrive Index 14 5 DOK INDRV HMV PR01 EN P X14 7 30 X2 7 22 X3 7 23 X31 7 25 X32 7 27 X33 7 29 ...

Page 130: ...14 6 Index Rexroth IndraDrive DOK INDRV HMV PR01 EN P Notes ...

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Page 132: ... EN P R911299229 Bosch Rexroth AG Electric Drives and Controls Postfach 13 57 97803 Lohr Deutschland Bgm Dr Nebel Str 2 97816 Lohr Deutschland Tel 49 0 93 52 40 50 60 Fax 49 0 93 52 40 49 41 service svc boschrexroth de www boschrexroth com ...