Bosch Rexroth IndraDrive M Technical manual

R911295014
Edition 01
Rexroth IndraDrive M
Drive Controllers
Power Sections
Project Planning Manual
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics

About this Documentation IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P
IndraDrive M
Drive Controllers
Power Sections
Project Planning Manual
DOK-INDRV*-HMS+HMD****-PR01-EN-P
Document number 120-2400-B302-01/EN
Description Release
Date
Notes
DOK-INDRV*-HMS+HMD****-PR01-EN-P 11.2003 project planning manual;
first edition
2003 Bosch Rexroth AG
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
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 Lohr a. Main
Telephone [phone] •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.de/
Dept. EDY3/EDY1 (GB/US)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revisions
Copyright
Validity
Published by
Note

Rexroth IndraDrive M Contents I
DOK-INDRV*-HMS+HMD****-PR01-EN-P
Contents
1 Introduction 1-1
1.1 About this documentation ............................................................................................................. 1-1
Purpose of documentation....................................................................................................... 1-1
1.2 Introducing the Devices................................................................................................................. 1-2
Features and Fields of Appliction ............................................................................................ 1-2
Basic Structure......................................................................................................................... 1-3
Drive System............................................................................................................................ 1-4
Tests and Certifications ........................................................................................................... 1-5
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 Introduction ................................................................................................................................... 3-1
3.2 Explanations.................................................................................................................................. 3-1
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 During Handling and Mounting .................................................................................. 3-10
3.11 Battery Safety.............................................................................................................................. 3-11
3.12 Protection Against Pressurized Systems.................................................................................... 3-11
4 Identifying and Checking the Delivered Components 4-1
4.1 Delivery of Components................................................................................................................ 4-1
Packaging ................................................................................................................................ 4-1
Accompanying Documents ...................................................................................................... 4-1
4.2 Scope of Delivery.......................................................................................................................... 4-1
Overview .................................................................................................................................. 4-1
Checking the Delivered Components ......................................................................................4-1
4.3 Component Designation................................................................................................................ 4-2
4.4 Device Types ................................................................................................................................ 4-3

II Contents Rexroth IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P
Type Code................................................................................................................................ 4-3
5 Transport and Storage 5-1
5.1 Transporting the Devices .............................................................................................................. 5-1
Conditions ................................................................................................................................ 5-1
5.2 Storing the Devices....................................................................................................................... 5-1
Conditions ................................................................................................................................ 5-1
In Case of Long Storage Periods............................................................................................. 5-1
6 Mechanical Mounting 6-1
6.1 Mounting Conditions ..................................................................................................................... 6-1
Ambient and Operating Conditions.......................................................................................... 6-1
Duty Capacity........................................................................................................................... 6-2
6.2 Mechanical Technical Data........................................................................................................... 6-4
Dimensions .............................................................................................................................. 6-4
Weight.................................................................................................................................... 6-11
Installation Orientation ........................................................................................................... 6-11
Arrangement of Components in the Control Cabinet............................................................. 6-12
6.3 Cooling and Cooling Units .......................................................................................................... 6-14
Power Dissipation .................................................................................................................. 6-14
Power Dissipation of Power Section...................................................................................... 6-14
Mounting Cooling Units..........................................................................................................6-21
7 Electrical Installation 7-1
7.1 General Information ...................................................................................................................... 7-1
7.2 10 rules for EMC-correct installation of drives ..............................................................................7-2
7.3 Electrical Data ............................................................................................................................... 7-4
Power Section (HMS01.1N-W0020, HMD01.1N-W0012…W0020) ........................................ 7-4
Power Section (HMS01.1N-W0036…0070, HMD01.1N-W0036)............................................ 7-6
Power Section (HMS01.1N-W0150…0210) ............................................................................ 7-8
Control Voltage ...................................................................................................................... 7-10
7.4 Drive System - Overview............................................................................................................. 7-11
7.5 Connecting Cables and Rails...................................................................................................... 7-12
Complete Connection Diagram.............................................................................................. 7-12
Connections on power section............................................................................................... 7-13
Control Voltage (+24 V, 0 V).................................................................................................. 7-19
DC Bus (L+, L-) ...................................................................................................................... 7-20
X5, Motor Connection (1, 2, 3, Ground)................................................................................. 7-21
Ground Connection, Power Supply Unit and Neighboring Device ........................................ 7-25
X1, Bus Module...................................................................................................................... 7-26
X6, Motor Temperature Monitoring and Motor Holding Brake............................................... 7-27
7.6 XS1, Shield Connection .............................................................................................................. 7-30
7.7 Touch Guard ............................................................................................................................... 7-31
Cutouts................................................................................................................................... 7-31
Mounting ................................................................................................................................ 7-32

Rexroth IndraDrive M Contents III
DOK-INDRV*-HMS+HMD****-PR01-EN-P
8 Replacing Devices 8-1
8.1 General Information ...................................................................................................................... 8-1
8.2 How to Proceed When Replacing Devices ................................................................................... 8-1
Replacing the Drive Controller................................................................................................. 8-1
Replacing the Motor................................................................................................................. 8-2
Replacing Cables..................................................................................................................... 8-2
Fault Report ............................................................................................................................. 8-4
9 Disposal and Environmental Protection 9-1
9.1 Disposal ........................................................................................................................................ 9-1
Products ................................................................................................................................... 9-1
Packaging Materials................................................................................................................. 9-1
9.2 Environmental Protection.............................................................................................................. 9-1
No Release of Hazardous Substances.................................................................................... 9-1
Materials Contained in the Products........................................................................................ 9-1
Recycling.................................................................................................................................. 9-2
10 Appendix 10-1
10.1 Accessories................................................................................................................................. 10-1
Shielding Plate for Shield Connection of the Motor Cable..................................................... 10-1
10.2 Connection of Supply Unit by Wires ......................................................................................... 10-11
Supply Unit to the Left of the Drive Controller ..................................................................... 10-11
Supply Unit to the Right of the Drive Controller................................................................... 10-12
10.3 Stacked Drive Controllers ......................................................................................................... 10-13
Anticlockwise Cable Routing................................................................................................ 10-13
Clockwise Cable Routing..................................................................................................... 10-14
11 Service & Support 11-1
11.1 Helpdesk ..................................................................................................................................... 11-1
11.2 Service-Hotline............................................................................................................................ 11-1
11.3 Internet ........................................................................................................................................ 11-1
11.4 Vor der Kontaktaufnahme... - Before contacting us.................................................................... 11-1
11.5 Kundenbetreuungsstellen - Sales & Service Facilities ............................................................... 11-2
12 Index 12-1

IV Contents Rexroth IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P

Rexroth IndraDrive M Introduction 1-1
DOK-INDRV*-HMS+HMD****-PR01-EN-P
1 Introduction
1.1 About this documentation
Purpose of documentation
This documentation describes
•planning the mechanical control cabinet construction
•planning the electrical control cabinet construction
•logistical handling of the equipment
Note: Only the power section is described in this manual
"Rexroth IndraDrive M, Drive Controllers: Power Sections,
Project Planning Manual" (DOK-INDRV*-HMS+HMD****-PR**-
EN-P; Part no.: 295014).
Note: The control section is described in a separate document:
"Rexroth IndraDrive, Drive Controllers: Control Sections,
Project Planning Manual" (DOK-INDRV*-CSH********-PR**-
EN-P; Part no.: 295012).

1-2 Introduction Rexroth IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P
1.2 Introducing the Devices
Features and Fields of Appliction
The intelligent digital drive controller is the high performance solution with
high functionality for single-axis and multiple-axis drive and control tasks.
The drive controller can be used for carrying out a large number of drive
tasks in the most varied applications. Various types of device are
available with graduated drive performance.
Typical applications are:
•Printing presses
•Machine tools
•Handling systems
•Packaging machines
•Assembly systems

Rexroth IndraDrive M Introduction 1-3
DOK-INDRV*-HMS+HMD****-PR01-EN-P
Basic Structure
lt_rtf2.fh7
1
2
1: Power section
2: Control section
Fig. 1-1: Basic structure
The drive controller consists of two essential parts:
•Power section
•Control section
Power Section
The following are connected to the power section:
•Power supply unit (DC bus voltage)
•24 V power supply
•Motor
•Bus module (for cross communication with other devices connected to
the DC bus)
Control Section
The control section is a separate section which is inserted into the power
section. The drive controller is supplied ex works complete with control
section.

1-4 Introduction Rexroth IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P
Drive System
The following figure shows 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. 1-2: Drive system

Rexroth IndraDrive M Introduction 1-5
DOK-INDRV*-HMS+HMD****-PR01-EN-P
Tests and Certifications
CEf1.fh7
Fig. 1-3: CE mark
In accordance with UL508 C.
The devices are C-UL-US listed under the item "Rexroth".
Insulation-high-voltage test 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. 1-4: Tests
CE Mark
C-UL-US Listing
Tests

1-6 Introduction Rexroth IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P
Notes

Rexroth IndraDrive M Important Directions for Use 2-1
DOK-INDRV*-HMS+HMD****-PR01-EN-P
2 Important Directions for Use
2.1 Appropriate Use
Introduction
Rexroth products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note: Rexroth, as manufacturer, is not liable for any damages
resulting from inappropriate use. In such cases, the guarantee
and the right to payment of damages resulting from
inappropriate use are forfeited. The user alone carries all
responsibility of the risks.
Before using Rexroth products, make sure that all the pre-requisites for
an appropriate use of the products are satisfied:
•Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
•If the product takes the form of hardware, then they must remain in
their original state, in other words, no structural changes are permitted.
It is not permitted to decompile software products or alter source
codes.
•Do not mount damaged or faulty products or use them in operation.
•Make sure that the products have been installed in the manner
described in the relevant documentation.

2-2 Important Directions for Use Rexroth IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P
Areas of Use and Application
Drive controllers made by 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 function descriptions.
Every drive controller has to be programmed before starting it up, making
it possible for the motor to execute the specific functions of an application.
The drive controllers are designed for use in single or multiple-axis drive
and control applications.
To ensure an application-specific use, the drive controllers are available
with differing drive power and different interfaces.
Typical applications of drive controllers are:
•handling and mounting systems,
•packaging and foodstuff machines,
•printing and paper processing machines and
•machine tools.
The drive controllers 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 drive controllers outside of the above-referenced areas of
application or under operating conditions other than described in the
document and the technical data specified is defined as “inappropriate
use".
Drive controllers may not be used if
•they are subject to operating conditions that do not meet the above
specified ambient conditions. This includes, for example, operation
under water, in the case of extreme temperature fluctuations or
extremely high maximum temperatures or if
•Rexroth has not specifically released them for that intended purpose.
Please note the specifications outlined in the general safety
instructions!

Rexroth IndraDrive M Safety Instructions for Electric Drives and Controls 3-1
DOK-INDRV*-HMS+HMD****-PR01-EN-P
3 Safety Instructions for Electric Drives and Controls
3.1 Introduction
Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these
safety instructions at all times.
Do not attempt to install or start up this equipment without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation of the equipment prior to
working with the equipment at any time. If you do not have the user
documentation for your equipment, contact your local Rexroth
representative to send this documentation immediately to the person or
persons responsible for the safe operation of this equipment.
If the equipment is resold, rented or transferred or passed on to others,
then these safety instructions must be delivered with the equipment.
WARNING
Improper use of this equipment, failure to follow
the safety instructions in this document or
tampering with the product, including disabling
of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
3.2 Explanations
The safety instructions describe the following degrees of hazard
seriousness in compliance with ANSI Z535. The degree of hazard
seriousness informs about the consequences resulting from non-
compliance with the safety instructions.
Warning symbol with signal
word
Degree of hazard seriousness according
to ANSI
DANGER
Death or severe bodily harm will occur.
WARNING
Death or severe bodily harm may occur.
CAUTION
Bodily harm or material damage may occur.
Fig. 3-1: Hazard classification (according to ANSI Z535)

3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P
3.3 Hazards by Improper Use
DANGER
High voltage and high discharge current!
Danger to life or severe bodily harm by electric
shock!
DANGER
Dangerous movements! Danger to life, severe
bodily harm or material damage by
unintentional motor movements!
WARNING
High electrical voltage due to wrong
connections! Danger to life or bodily harm by
electric shock!
WARNING
Health hazard for persons with heart
pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
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, shearing, cutting and
mechanical shock or incorrect handling of
pressurized systems!
CAUTION
Risk of injury due to incorrect handling of
batteries!

Rexroth IndraDrive M Safety Instructions for Electric Drives and Controls 3-3
DOK-INDRV*-HMS+HMD****-PR01-EN-P
3.4 General Information
•Bosch Rexroth AG is not liable for damages resulting from failure to
observe the warnings provided in this documentation.
•Read the operating, maintenance and safety instructions in your
language before starting up the machine. If you find that you cannot
completely understand the documentation for your product, please ask
your supplier to clarify.
•Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this equipment.
•Only persons who are trained and qualified for the use and operation
of the equipment may work on this equipment or within its proximity.
•The persons are qualified if they have sufficient knowledge of the
assembly, installation and operation of the equipment as well as an
understanding of all warnings and precautionary measures noted in
these instructions.
•Furthermore, they must be trained, instructed and qualified to
switch electrical circuits and equipment on and off in accordance
with technical safety regulations, to ground them and to mark them
according to the requirements of safe work practices. They must
have adequate safety equipment and be trained in first aid.
•Only use spare parts and accessories approved by the manufacturer.
•Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
•The equipment is designed for installation in industrial machinery.
•The ambient conditions given in the product documentation must be
observed.
•Use only safety features and applications that are clearly and explicitly
approved in the Project Planning Manual.
For example, the following areas of use are not permitted: construction
cranes, elevators used for people or freight, devices and vehicles to
transport people, medical applications, refinery plants, transport of
hazardous goods, nuclear applications, applications sensitive to high
frequency, mining, food processing, control of protection equipment
(also in a machine).
•The information given in the documentation of the product with regard
to the use of the delivered components contains only examples of
applications and suggestions.
The machine and installation manufacturer must
•make sure that the delivered components are suited for his
individual application and check the information given in this
documentation with regard to the use of the components,
•make sure that his application complies with the applicable safety
regulations and standards and carry out the required measures,
modifications and complements.
•Startup of the delivered components is only permitted once it is sure
that the machine or installation in which they are installed complies
with the national regulations, safety specifications and standards of the
application.

3-4 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P
•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.

Rexroth IndraDrive M Safety Instructions for Electric Drives and Controls 3-5
DOK-INDRV*-HMS+HMD****-PR01-EN-P
3.5 Protection Against Contact with Electrical Parts
Note: This section refers to equipment and drive components with
voltages above 50 Volts.
Touching live parts with voltages of 50 Volts and more with bare hands or
conductive tools or touching ungrounded housings can be dangerous and
cause electric shock. In order to operate electrical equipment, certain
parts must unavoidably have dangerous voltages applied to them.
DANGER
High electrical voltage! Danger to life, severe
bodily harm by electric shock!
⇒Only those trained and qualified to work with or on
electrical equipment are permitted to operate, maintain
or repair this equipment.
⇒Follow general construction and safety regulations when
working on high voltage installations.
⇒Before switching on power the ground wire must be
permanently connected to all electrical units according
to the connection diagram.
⇒Do not operate electrical equipment at any time, even
for brief measurements or tests, if the ground wire is not
permanently connected to the points of the components
provided for this purpose.
⇒Before working with electrical parts with voltage higher
than 50 V, the equipment must be disconnected from
the mains voltage or power supply. Make sure the
equipment cannot be switched on again unintended.
⇒The following should be observed with electrical drive
and filter components:
⇒Wait five (5) minutes after switching off power to allow
capacitors to discharge before beginning to work.
Measure the voltage on the capacitors before beginning
to work to make sure that the equipment is safe to
touch.
⇒Never touch the electrical connection points of a
component while power is turned on.
⇒Install the covers and guards provided with the
equipment properly before switching the equipment on.
Prevent contact with live parts at any time.
⇒A residual-current-operated protective device (RCD)
must not be used on electric drives! Indirect contact
must be prevented by other means, for example, by an
overcurrent protective device.
⇒Electrical components with exposed live parts and
uncovered high voltage terminals must be installed in a
protective housing, for example, in a control cabinet.

3-6 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive M
DOK-INDRV*-HMS+HMD****-PR01-EN-P
To be observed with electrical drive and filter components:
DANGER
High electrical voltage on the housing!
High leakage current! Danger to life, danger of
injury by electric shock!
⇒Connect the electrical equipment, the housings of all
electrical units and motors permanently with the safety
conductor at the ground points before power is
switched on. Look at the connection diagram. This is
even necessary for brief tests.
⇒Connect the safety conductor of the electrical
equipment always permanently and firmly to the
supply mains. Leakage current exceeds 3.5 mA in
normal operation.
⇒Use a copper conductor with at least 10 mm²cross
section over its entire course for this safety conductor
connection! The cross section must not be smaller
than the cross section of a phase of the mains supply
wire.
⇒Prior to startups, even for brief tests, always connect
the protective conductor or connect with ground wire.
Otherwise, high voltages can occur on the housing
that lead to electric shock.
3.6 Protection Against Electric Shock by Protective Low
Voltage (PELV)
All connections and terminals with voltages between 0 and 50 Volts on
Rexroth products are protective low voltages designed in accordance with
international standards on electrical safety.
WARNING
High electrical voltage due to wrong
connections! Danger to life, bodily harm by
electric shock!
⇒Only connect equipment, electrical components and
cables of the protective low voltage type (PELV =
Protective Extra Low Voltage) to all terminals and
clamps with voltages of 0 to 50 Volts.
⇒Only electrical circuits may be connected which are
safely isolated against high voltage circuits. Safe
isolation is achieved, for example, with an isolating
transformer, an opto-electronic coupler or when
battery-operated.