Rexroth IndraDrive Supply Units - Indramat USA

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IndustrialHydraulicsElectric Drivesand ControlsLinear Motion andAssembly ulicsRexroth IndraControl VCP 20Rexroth IndraDriveSupply UnitsProject Planning ManualR911299229Edition 03

About this DocumentationTitleRexroth IndraDriveRexroth IndraDriveSupply UnitsType of DocumentationDocument TypecodeInternal File ReferenceRecord of RevisionsCopyrightProject Planning ManualDOK-INDRV*-HMV-*******-PR03-EN-PDocument number 120-2400-B312-03/ENDescriptionRelease ect Planning Manual;first onDOK-INDRV*-HMV-*******-PR03-EN-P01.06Revision Bosch Rexroth AG, 2006Copying this document, giving it to others and the use or communicationof the contents thereof without express authority, are forbidden. Offendersare liable for the payment of damages. All rights are reserved in the eventof the grant of a patent or the registration of a utility model or design(DIN 34-1).ValidityPublished byThe specified data only serve to describe the product. No statementsconcerning a certain condition or suitability for a certain application can bederived from our information. The given information does not release theuser from the obligation of own judgement and verification. It must beremembered that our products are subject to a natural process of wearand aging.Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 2 D-97816 Lohr a. MainTelephone 49 (0)93 52/40-0 Tx 68 94 21 Fax 49 (0)93 52/40-48 85http://www.boschrexroth.de/Dept. BRC/EDY1 (RR, US)NoteThis document has been printed on chlorine-free bleached paper.DOK-INDRV*-HMV-*******-PR03-EN-P

Rexroth IndraDriveContents IContents1Introduction1.11-1About this Documentation. 1-1Purpose of Documentation . 1-1Documentations - Overview . 1-21.22Basic Structure . 1-3Important Directions for Use2.12-1Appropriate Use. 2-1Introduction . 2-1Areas of Use and Application . 2-22.23Inappropriate Use . 2-2Safety Instructions for Electric Drives and Controls3.13-1General Information . 3-1Using the Safety Instructions and Passing them on to Others. 3-1Instructions for Use. 3-1Explanation of Warning Symbols and Degrees of Hazard Seriousness . 3-3Hazards by Improper Use. 3-43.2Instructions with Regard to Specific Dangers. 3-5Protection Against Contact with Electrical Parts . 3-5Protection Against Electric Shock by Protective Low Voltage (PELV) . 3-6Protection Against Dangerous Movements . 3-7Protection Against Magnetic and Electromagnetic Fields During Operation andMounting . 3-9Protection Against Contact with Hot Parts . 3-10Protection During Handling and Mounting. 3-11Battery Safety . 3-11Protection Against Pressurized Systems . 3-124Identifying and Checking the Delivered Components4.14-1Device Types . 4-1Type Code . 4-1Type Plate on the Unit . 4-24.25Scope of Delivery. 4-2Mechanical Data5-15.1Dimensions, Weight. 5-15.2Dimensions, Mass HMV01.1R-W0120 with External Blower Unit. 5-2Mounting the External Blower Unit HAB01 to HMV01. 5-3DOK-INDRV*-HMV-*******-PR03-EN-P

II Contents6Rexroth IndraDriveElectrical Data6-16.1HMV01.1E-W0030, -W0075, -W0120 . 6-16.2HMV01.1R-W0018, -W0045, -W0065, -W0120 . 6-36.1Control Voltage . 6-56.2Load Cycles . 6-6HMV01.1R . 6-6HMV01.1E with Mains Choke. 6-9HMV01.1E without Mains Choke. 6-116.3Connections . 6-13Connection Diagram . 6-13Overview. 6-14Control Voltage ( 24 V, 0 V). 6-18DC Bus (L , L-). 6-20Equipment Grounding Conductor . 6-21X1, Module Bus . 6-23X2, RS232 . 6-24X3, Mains Connection . 6-25X13, Connection for External Blower . 6-26X14, Mains Voltage Synchronization. 6-27X31, Connection for Messages . 6-29X32, Mains Contactor Control, DC Bus Short Circuit, Braking Resistor Threshold . 6-31X33, Acknowledge Messages of Mains Contactor . 6-33X34, Contact for Controlling the External Mains Contactor. 6-3578Touch Guard7-17.1Cutouts. 7-17.2Mounting . 7-2Control Panel8-18.1Brief Description . 8-18.2Functional Description . 8-1Displays . 8-1Priorities of Display. 8-3Complete Diagnostic Message Text. 8-3Extended Displays . 8-4Setting the Language . 8-59Troubleshooting9-19.1Fault Diagnostics and Resetting Faults . 9-19.2Checking and Repairing the Unit. 9-29.3Replacing the Unit . 9-39.4Diagnostic Display . 9-410 Service & Support10-110.1 Helpdesk . 10-110.2 Service-Hotline . 10-1DOK-INDRV*-HMV-*******-PR03-EN-P

Rexroth IndraDriveContents III10.3 Internet. 10-110.4 Vor der Kontaktaufnahme. - Before contacting us. . 10-110.5 Kundenbetreuungsstellen - Sales & Service Facilities . 10-211 Appendix11-111.1 Chronological Sequence when Switching ON and OFF. 11-1When Switching On . 11-1When Switching Off . 11-212 IndexDOK-INDRV*-HMV-*******-PR03-EN-P12-1

IV ContentsRexroth IndraDriveDOK-INDRV*-HMV-*******-PR03-EN-P

Introduction 1-1Rexroth IndraDrive1Introduction1.1About this DocumentationPurpose of DocumentationThis documentation basically contains the technical data of the RexrothIndraDrive supply units.Personal injury and property damage caused byincorrect project planning for applications,machines and installations!WARNING Take the content of the Project Planning Manual"Rexroth IndraDrive Drive System" (DOK-INDRV*SYSTEM*****-PRxx-EN-P; part no. R911309636)into account.For complete project planning of a Rexroth IndraDrive drive system youneed, in any case, the Project Planning Manual "Rexroth IndraDrive DriveSystem" (DOK-INDRV*-SYSTEM*****-PRxx-EN-P; part no. R911309636).This Project Planning Manual, among other things, contains: specifications for the components of the drive system configuration of the drive system components arrangement of the components in the control cabinet electromagnetic compatibility (EMC) types of mains connection requirements to the mains connection control circuits for the mains connection connections of the components in the drive system fusing and selecting the mains contactor accessories in the drive system calculations (determining appropriate drive controller; mainsconnection; leakage capacitance; operating data of mains filters;selecting the 24V supply; braking behavior when using a DC busresistor unit)DOK-INDRV*-HMV-*******-PR03-EN-P

1-2 IntroductionRexroth IndraDriveDocumentations - Overview1)TitleType of DocumentationDocument TypecodeRexroth IndraDriveDrive SystemProject Planning ManualDOK-INDRV*-SYSTEM*****-PRxx-EN-PRexroth IndraDriveDrive ControllersControl SectionsProject Planning ManualDOK-INDRV*-CSH********-PRxx-EN-PRexroth IndraDrive MDrive ControllersPower SectionsProject Planning ManualDOK-INDRV*-HMS HMD****-PRxx-EN-PRexroth IndraDrive CDrive ControllersPower Sections HCS02.1Project Planning ManualDOK-INDRV*-HCS02.1****-PRxx-EN-PRexroth IndraDrive CDrive ControllersPower Sections HCS03.1Project Planning ManualDOK-INDRV*-HCS03.1****-PRxx-EN-PRexroth IndraDriveSupply UnitsProject Planning ManualDOK-INDRV*-HMV-*******-PRxx-EN-PRexroth IndraDriveIntegrated Safety TechnologyFunctional and EN-PConnecting cablesSelection DataDOK-CONNEC-CABLE*STAND-AUxx-EN-PSafety Instructions for Electrical DrivesSafety h IndraDriveAdditional ComponentsProject Planning ManualDOK-INDRV*-ADDCOMP****-PRxx-EN-PRexroth IndraDriveFirmware for Drive ControllersFunctional DescriptionDOK-INDRV*-MP*-02VRS**-FKxx-EN-PRexroth IndraDriveFirmware for Drive ControllersFunctional DescriptionDOK-INDRV*-MP*-03VRS**-FKxx-EN-PRexroth IndraDriveFirmware for Drive ControllersFunctional DescriptionDOK-INDRV*-MP*-04VRS**-FKxx-EN-PRexroth IndraDriveFirmware for Drive ControllersParameter DescriptionDOK-INDRV*-GEN-**VRS**-PAxx-EN-PRexroth IndraDriveFirmware for Drive ControllersTroubleshooting GuideDOK-INDRV*-GEN-**VRS**-WAxx-EN-PRexroth IndraDyn SSynchronous Motors MSKProject Planning ManualDOK-MOTOR*-MSK********-PRxx-EN-PRexroth IndraDyn AAsynchronous Motors MAD/MAFProject Planning ManualDOK-MOTOR*-MAD/MAF****-PRxx-EN-PRexroth IndraDyn TSynchronous Torque Motors MBTProject Planning ManualDOK-MOTOR*-MBT********-PRxx-EN-PRexroth IndraDyn HSynchronous Kit –Spindle Motors MBS-HProject Planning ManualDOK-MOTOR*-MBS-H******-PRxx-EN-PRexroth IndraDyn LSynchronous Linear Motors MLFProject Planning ManualDOK-MOTOR*-MLF********-PRxx-EN-PThird Party MotorsProject Planning Manualand . 1-1:in the document type codes "xx" designates replacement charactersfor the update edition of the documentation (Example: "PR01" is thefirst edition of a project planning manual)Documentations - OverviewDOK-INDRV*-HMV-*******-PR03-EN-P

Introduction 1-3Rexroth IndraDrive1.2Basic Structure123hmv aufbau.fh71:2:3:Fig. 1-2:Signal processingControl panel (Display)Power connections and control voltage connectionBasic structureControl PanelThe control panel is a separate part which is plugged on the supply unit.The supply unit is supplied ex works complete with control panel.The handling of the control panel is described in chapter 8.DOK-INDRV*-HMV-*******-PR03-EN-P

1-4 IntroductionRexroth IndraDriveNotesDOK-INDRV*-HMV-*******-PR03-EN-P

Important Directions for Use 2-1Rexroth IndraDrive2Important Directions for Use2.1Appropriate UseIntroductionRexroth products represent state-of-the-art developments andmanufacturing. They are tested prior to delivery to ensure operating safetyand reliability.The products may only be used in the manner that is defined asappropriate. If they are used in an inappropriate manner, then situationscan develop that may lead to property damage or injury to personnel.Note:Rexroth as manufacturer is not liable for any damagesresulting from inappropriate use. In such cases, the guaranteeand the right to payment of damages resulting frominappropriate use are forfeited. The user alone carries allresponsibility of the risks.Before using Rexroth products, make sure that all the pre-requisites foran appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must firstread and understand the relevant safety instructions and be familiarwith appropriate use. If the products take the form of hardware, then they must remain intheir original state, in other words, no structural changes are permitted.It is not permitted to decompile software products or alter sourcecodes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the mannerdescribed in the relevant documentation.DOK-INDRV*-HMV-*******-PR03-EN-P

2-2 Important Directions for UseRexroth IndraDriveAreas of Use and ApplicationDrive controllers made by Bosch Rexroth are designed to controlelectrical motors and monitor their operation.Control and monitoring of the motors may require additional sensors andactors.Note:The drive controllers may only be used with the accessoriesand parts specified in this document. If a component has notbeen specifically named, then it may not be either mounted orconnected. The same applies to cables and lines.Operation is only permitted in the specified configurations andcombinations of components using the software and firmwareas 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 anapplication.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 availablewith 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 andinstallation conditions described in this documentation, in the specifiedposition of normal use and under the ambient conditions as described(temperature, degree of protection, humidity, EMC, etc.).2.2Inappropriate UseUsing the drive controllers outside of the operating conditions described inthis documentation and outside of the indicated technical data andspecifications is defined as "inappropriate use".Drive controllers must not be used, if . they are subject to operating conditions that do not meet thespecified ambient conditions. This includes, for example, operationunder water, under extreme temperature fluctuations or extremely highmaximum temperatures. Furthermore, the drive controllers must not be used in applicationswhich have not been expressly authorized by Rexroth. Please carefully follow the specifications outlined in the general P

Safety Instructions for Electric Drives and Controls 3-1Rexroth IndraDrive3Safety Instructions for Electric Drives and Controls3.1General InformationUsing the Safety Instructions and Passing them on to OthersDo not attempt to install or commission this device without first reading alldocumentation provided with the product. Read and understand thesesafety instructions and all user documentation prior to working with thedevice. If you do not have the user documentation for the device, contactyour responsible Bosch Rexroth sales representative. Ask for thesedocuments to be sent immediately to the person or persons responsiblefor the safe operation of the device.If the device is resold, rented and/or passed on to others in any otherform, then these safety instructions must be delivered with the device.WARNINGImproper use of these devices, failure to followthe safety instructions in this document ortampering with the product, including disablingof safety devices, may result in materialdamage, bodily harm, electric shock or evendeath!Instructions for UseRead these instructions before the initial startup of the equipment in orderto eliminate the risk of bodily harm or material damage. Follow thesesafety instructions at all times. Bosch Rexroth AG is not liable for damages resulting from failure toobserve the warnings provided in this documentation. Read the operating, maintenance and safety instructions in yourlanguage before starting up the machine. If you find that you cannotcompletely understand the documentation for your product, pleaseask your supplier to clarify. Proper and correct transport, storage, assembly and installation aswell as care in operation and maintenance are prerequisites foroptimal and safe operation of this device. Only assign trained and qualified persons to work with electricalinstallations: Only persons who are trained and qualified for the use andoperation of the device may work on this device or within itsproximity. The persons are qualified if they have sufficientknowledge of the assembly, installation and operation of theequipment as well as an understanding of all warnings andprecautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified toswitch electrical circuits and devices on and off in accordance withtechnical safety regulations, to ground them and to mark themaccording to the requirements of safe work practices. They musthave adequate safety equipment and be trained in first aid.DOK-INDRV*-HMV-*******-PR03-EN-P Only use spare parts and accessories approved by the manufacturer. Follow all safety regulations and requirements for the specificapplication as practiced in the country of use.

3-2 Safety Instructions for Electric Drives and ControlsRexroth IndraDrive The devices have been designed for installation in industrialmachinery. The ambient conditions given in the product documentation must beobserved. Only use safety-relevant applications that are clearly and explicitlyapproved in the Project Planning Manual. If this is not the case, theyare excluded.Safety-relevant are all such applications which can cause danger topersons and material damage. The information given in the documentation of the product with regardto the use of the delivered components contains only examples ofapplications and suggestions.The machine and installation manufacturer must make sure that the delivered components are suited for hisindividual application and check the information given in thisdocumentation with regard to the use of the components, make sure that his application complies with the applicablesafety regulations and standards and carry out the requiredmeasures, modifications and complements. Startup of the delivered components is only permitted once it is surethat the machine or installation in which they are installed complieswith the national regulations, safety specifications and standards ofthe application. Operation is only permitted if the national EMC regulations for theapplication are met. The instructions for installation in accordance with EMC requirementscan be found in the documentation "EMC in Drive and ControlSystems". The machine or installation manufacturer is responsible forcompliance with the limiting values as prescribed in the nationalregulations. Technical data, connections and operational conditions are specifiedin the product documentation and must be followed at all times.DOK-INDRV*-HMV-*******-PR03-EN-P

Safety Instructions for Electric Drives and Controls 3-3Rexroth IndraDriveExplanation of Warning Symbols and Degrees of Hazard SeriousnessThe safety instructions describe the following degrees of hazardseriousness. The degree of hazard seriousness informs about theconsequences resulting from non-compliance with the safety instructions:Warning symbol with signalwordDegree of hazard seriousness accordingto ANSI Z 535Death or severe bodily harm will occur.DANGERDeath or severe bodily harm may occur.WARNINGBodily harm or material damage may occur.CAUTIONFig. 3-1:DOK-INDRV*-HMV-*******-PR03-EN-PHazard classification (according to ANSI Z 535)

3-4 Safety Instructions for Electric Drives and ControlsRexroth IndraDriveHazards by Improper UseHigh electric voltage and high working current!Risk of death or severe bodily injury by electricshock!DANGERDangerous movements! Danger to life, severebodily harm or material damage byunintentional motor movements!DANGERHigh electric voltage because of incorrectconnection! Risk of death or bodily injury byelectric shock!WARNINGHealth hazard for persons with heartpacemakers, metal implants and hearing aids inproximity to electrical equipment!WARNINGHot surfaces on device housing! Danger ofinjury! Danger of burns!CAUTIONCAUTIONRisk of injury by improper handling! Risk ofbodily injury by bruising, shearing, cutting,hitting, or improper handling of pressurizedlines!Risk of injury by improper handling of batteries!CAUTIONDOK-INDRV*-HMV-*******-PR03-EN-P

Safety Instructions for Electric Drives and Controls 3-5Rexroth IndraDrive3.2Instructions with Regard to Specific DangersProtection Against Contact with Electrical PartsNote:This section only concerns devices and drive components withvoltages of more than 50 Volt.Contact with parts conducting voltages above 50 Volts can causepersonal danger and electric shock. When operating electrical equipment,it is unavoidable that some parts of the devices conduct dangerousvoltage.High electrical voltage! Danger to life, electricshock and severe bodily injury! DANGER DOK-INDRV*-HMV-*******-PR03-EN-POnly those trained and qualified to work with or onelectrical equipment are permitted to operate,maintain and repair this equipment.Follow general construction and safety regulationswhen working on electrical power installations.Before switching on the device, the equipmentgrounding conductor must have been nondetachably connected to all electrical equipment inaccordance with the connection diagram.Do not operate electrical equipment at any time,even for brief measurements or tests, if theequipment grounding conductor is not permanentlyconnected to the mounting points of the componentsprovided for this purpose.Before working with electrical parts with voltagepotentials higher than 50 V, the device must bedisconnected from the mains voltage or powersupply unit. Provide a safeguard to preventreconnection.With electrical drive and filter components, observethe following:Wait 30 minutes after switching off power to allowcapacitors to discharge before beginning to work.Measure the voltage on the capacitors beforebeginning to work to make sure that the equipment issafe to touch.Never touch the electrical connection points of acomponent while power is turned on.Install the covers and guards provided with theequipment properly before switching the device on.Before switching the equipment on, cover andsafeguard live parts safely to prevent contact withthose parts.A residual-current-operated circuit-breaker or r.c.d.cannot be used for electric drives! Indirect contactmust be prevented by other means, for example, byan overcurrent protective device according to therelevant standards.Secure built-in devices from direct touching ofelectrical parts by providing an external housing, forexample a control cabinet.

3-6 Safety Instructions for Electric Drives and ControlsRexroth IndraDriveEuropean countries: according to EN 50178/ 1998,section 5.3.2.3.USA: See National Electrical Code (NEC), NationalElectrical Manufacturers' Association (NEMA), as well aslocal engineering regulations. The operator must observeall 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 electricalequipment and motors must be connected orgrounded with the equipment grounding conductor tothe grounding points. This is also applicable beforeshort tests.The equipment grounding conductor of the electricalequipment and the units must be non-detachablyand permanently connected to the power supply unitat all times. The leakage current is greater than3.5 mA.Over the total length, use copper wire of a cross2section of a minimum of 10 mm for this equipmentgrounding connection!Before start-up, also in trial runs, always attach theequipment grounding conductor or connect with theground wire. Otherwise, high voltages may occur atthe housing causing electric shock.Protection Against Electric Shock by Protective Low Voltage (PELV)All connections and terminals with voltages between 5 and 50 Volt atRexroth products are protective extra-low voltage systems which areprovided 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 voltagesbetween 0 and 50 Volt, only devices, electricalcomponents, and conductors may be connectedwhich are equipped with a

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