Bosch Rexroth BA1N Technical manual

BA1N
Kinetic Energy Buffer
Project Planning Manual
R911393264
Edition 01

BA1N
Kinetic Energy Buffer
Project Planning Manual
DOK-MOTOR*-BA1N*******-PR01-EN-P
RS-7a6f81cba34b0fabc0a80286678bea65-1-en-US-4
This documentation ...
● explains product features and applications, technical data as well as
conditions and limits for operation and
● provides information regarding product selection, handling and opera‐
tion.
Record of revisions Edition 01
See tab. 1-1 "Record of revisions" on page 2
Copyright © Bosch Rexroth AG 2019
All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial prop‐
erty rights.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this docu‐
mentation and the availability of the product.
Published by Bosch Rexroth AG
Electric Drives and Controls
Dept. DC-AE/EPI5 (fs)
Buergermeister-Dr.-Nebel-Strasse 2
97816 Lohr, Germany
Tel. [phone] / Fax [phone]
http://www.boschrexroth.com/electrics
Note This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
BA1N Kinetic Energy Buffer

Table of Contents
Page
1 Introduction to the product............................................................................................. 1
1.1 General................................................................................................................................................... 1
1.2 About this documentation....................................................................................................................... 2
1.2.1 Editions of this documentation............................................................................................................. 2
1.2.2 Document structure............................................................................................................................. 2
1.2.3 Information presentation...................................................................................................................... 2
1.2.4 Further documentation........................................................................................................................ 3
1.2.5 Standards............................................................................................................................................ 4
1.2.6 Additional components........................................................................................................................ 4
1.2.7 Your feedback..................................................................................................................................... 4
2 Important instructions for use......................................................................................... 5
2.1 Intended use........................................................................................................................................... 5
2.1.1 Introduction.......................................................................................................................................... 5
2.1.2 Areas of use and application............................................................................................................... 5
2.2 Inappropriate use.................................................................................................................................... 6
3 Safety instructions for electric drives and controls......................................................... 7
3.1 Definitions of terms................................................................................................................................. 7
3.2 General information................................................................................................................................ 8
3.2.1 Using the Safety instructions and passing them on to others.............................................................. 8
3.2.2 Requirements for safe use.................................................................................................................. 8
3.2.3 Hazards by improper use.................................................................................................................... 9
3.3 Instructions with regard to specific dangers.......................................................................................... 10
3.3.1 Protection against contact with electrical parts and housings........................................................... 10
3.3.2 Protective extra-low voltage as protection against electric shock .................................................... 11
3.3.3 Protection against dangerous movements........................................................................................ 12
3.3.4 Protection against electromagnetic and magnetic fields during operation and mounting.................. 13
3.3.5 Protection against contact with hot parts........................................................................................... 14
3.3.6 Protection during handling and mounting.......................................................................................... 14
3.3.7 Battery safety..................................................................................................................................... 14
3.3.8 Protection against pressurized systems............................................................................................ 15
3.4 Explanation of signal words and the Safety alert symbol..................................................................... 16
4 Technical data.............................................................................................................. 17
4.1 Operating behavior............................................................................................................................... 17
4.1.1 Description of the specified parameters............................................................................................ 17
4.2 Technical data...................................................................................................................................... 18
4.2.1 Data sheet BA1N16........................................................................................................................... 18
4.2.2 Forced ventilation – BA1N16 fan data............................................................................................... 19
4.2.3 Water cooling – Technical data......................................................................................................... 19
4.2.4 BA1N16 characteristic curves........................................................................................................... 20
BA1N Kinetic Energy Buffer I
Table of Contents
R911393264_Edition 01 Bosch Rexroth AG

Page
5 Dimension sheets........................................................................................................ 21
5.1 BA1N16 Frame size with cooling mode “forced ventilation”................................................................. 21
5.2 BA1N16 Frame size with cooling mode “water cooling”....................................................................... 22
6 Type codes.................................................................................................................. 23
6.1 Type codes BA1N16............................................................................................................................. 23
7 Accessories.................................................................................................................. 25
8 Connection technique.................................................................................................. 27
8.1 Notes.................................................................................................................................................... 27
8.2 Electrical connection............................................................................................................................. 28
8.2.1 Device connector on the BA1N energy storage device..................................................................... 28
8.2.2 Selection tables for ready-made connection cables.......................................................................... 29
8.3 Plug-in connector with threaded connection......................................................................................... 29
8.4 SpeedCon connectors.......................................................................................................................... 30
8.5 Temperature sensor ............................................................................................................................ 31
8.6 Cooling.................................................................................................................................................. 31
8.6.1 Fan connection.................................................................................................................................. 31
8.6.2 Coolant connection ........................................................................................................................... 32
8.6.3 Coolant input pressure ..................................................................................................................... 33
9 Application notes.......................................................................................................... 35
9.1 Operating conditions............................................................................................................................. 35
9.1.1 Installation altitude and ambient temperature.................................................................................... 35
9.2 Humidity................................................................................................................................................ 36
9.3 Vibration and shock.............................................................................................................................. 36
9.3.1 Vibration............................................................................................................................................ 36
9.3.2 Shock................................................................................................................................................. 37
9.4 Degree of protection............................................................................................................................. 37
9.5 Frame shape and installation position ................................................................................................. 38
9.5.1 General.............................................................................................................................................. 38
9.6 Paint...................................................................................................................................................... 38
9.7 Compatibility test.................................................................................................................................. 39
9.8 Cooling.................................................................................................................................................. 39
9.8.1 Forced ventilation (IC416)................................................................................................................. 39
9.8.2 Water cooling (IC3W7)...................................................................................................................... 40
9.9 Thermal winding protection................................................................................................................... 43
9.10 Encoder................................................................................................................................................ 44
9.10.1 Technical data................................................................................................................................... 44
9.10.2 Encoder connection........................................................................................................................... 44
9.11 Bearings................................................................................................................................................ 45
9.11.1 Hybrid bearings (with re-lubrication option)....................................................................................... 45
9.12 Run-down and follow-up time of the rotor............................................................................................. 45
II
Table of Contents
BA1N Kinetic Energy Buffer
Bosch Rexroth AG R911393264_Edition 01

Page
9.13 Acceptances and approvals.................................................................................................................. 45
9.13.1 CE mark............................................................................................................................................. 45
10 Handling and transport................................................................................................. 47
10.1 Delivery status ..................................................................................................................................... 47
10.1.1 General.............................................................................................................................................. 47
10.1.2 Factory test ....................................................................................................................................... 47
10.1.3 Customer test ................................................................................................................................... 47
10.2 Identification.......................................................................................................................................... 47
10.3 Identification.......................................................................................................................................... 48
10.4 Transport and storage.......................................................................................................................... 49
10.4.1 General notes.................................................................................................................................... 49
10.4.2 Transport instructions........................................................................................................................ 49
10.4.3 Storage instructions........................................................................................................................... 51
11 Installation.................................................................................................................... 53
11.1 Safety.................................................................................................................................................... 53
11.2 Mechanical attachment......................................................................................................................... 53
11.2.1 Attachment........................................................................................................................................ 53
11.2.2 Preparing assembly........................................................................................................................... 55
11.2.3 Mounting the BA1N energy storage device....................................................................................... 55
11.3 Electrical connection ............................................................................................................................ 55
11.3.1 General.............................................................................................................................................. 55
12 Operation of BA1N energy storage device.................................................................. 57
12.1 Commissioning..................................................................................................................................... 57
12.1.1 General.............................................................................................................................................. 57
12.1.2 Preparation........................................................................................................................................ 57
12.1.3 Procedure.......................................................................................................................................... 57
12.2 Shutdown.............................................................................................................................................. 58
12.3 Disassembly......................................................................................................................................... 58
12.4 Maintenance......................................................................................................................................... 59
12.4.1 General.............................................................................................................................................. 59
12.4.2 Measures........................................................................................................................................... 59
12.4.3 Re-lubrication of the hybrid bearings................................................................................................. 60
12.4.4 Fan ................................................................................................................................................... 61
12.4.5 Coolant supply .................................................................................................................................. 63
12.5 Troubleshooting ................................................................................................................................... 63
12.5.1 General information........................................................................................................................... 63
12.5.2 Temperature on the housing is too high............................................................................................ 63
12.5.3 High energy storage device values, but housing temperature is normal........................................... 64
12.5.4 Energy storage device or machine table generates vibrations.......................................................... 64
12.6 Environmental protection and disposal ................................................................................................ 65
12.6.1 Environmental protection................................................................................................................... 65
12.6.2 Disposal............................................................................................................................................. 65
BA1N Kinetic Energy Buffer III
Table of Contents
R911393264_Edition 01 Bosch Rexroth AG

Page
13 Service and support..................................................................................................... 67
Index............................................................................................................................ 69
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Table of Contents
BA1N Kinetic Energy Buffer
Bosch Rexroth AG R911393264_Edition 01

1 Introduction to the product
1.1 General
BA1N are kinetic energy storage devices by Rexroth. The energy storage de‐
vice is based on an asynchronous machine with squirrel-cage rotor. Currently
available designs:
●BA1N16 in "forced ventilation" design
Fig. 1-1: BA1N16 "forced ventilation"
●BA1N16 in "water cooling" design
Fig. 1-2: BA1N16 "water cooling"
BA1N energy storage devices are ideal for IndraDrive controllers and their
technology functions for energy and power management of drive systems. In‐
formation on technology functions can be found in the Application Manual un‐
der “MLD Technology Function - Kinetic Buffering, R911397139" in the
Rexroth media directory (see chapter 1.2.4 "Further documentation" on page
3).
Example applications ● Power failure buffering
● Mains-side peak power reduction
● Mains quality improvement
● Reduction of connection power
● Increase of energy efficiency in feeding systems with braking resistor
● Booster for increasing the peak power at limited connection power
Advantages ● High energy and power density
● High dynamism, quick rise time
● Useful life optimized by hybrid bearings with re-lubrication
● Intrinsically safe, completely encapsulated
BA1N Kinetic Energy Buffer 1/73
Introduction to the product
R911393264_Edition 01 Bosch Rexroth AG

1.2 About this documentation
1.2.1 Editions of this documentation
Edition Release
date Notes
01 2019-07 First edition
Tab. 1-1: Record of revisions
1.2.2 Document structure
This documentation includes safety-related guidelines, technical data and
operating instructions. The following table provides an overview of the con‐
tents of this documentation.
Chap‐
ter Title Content
1 Introduction Introduction to the product and reading
instructions
2 Important instructions for use
Important safety instructions
3 Safety
4 Technical data
Product description
for designers and
project developers
5 Dimensional sheets
6 Type codes
7 Accessories
8 Connection technology
Practice
9 Application instructions
10 Handling and transport for operating and
maintenance per‐
sonnel
11 Installation
12 Operation
13 Service & support
Additional information
14 Index
Tab. 1-2: Chapter structure
1.2.3 Information presentation
Safety instructions The safety instructions in this documentation include signal words (danger,
warning, caution, note) and a signal symbol (acc. to ANSI Z535.6-2006).
The signal word is intended to draw your attention to the safety instructions
and describes the seriousness of the danger. The warning triangle with excla‐
mation mark indicates the danger for persons.
DANGER
Non-compliance with this safety instructions will result in death or severe per‐
sonal injury.
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Introduction to the product
BA1N Kinetic Energy Buffer
Bosch Rexroth AG R911393264_Edition 01

WARNING
Non-compliance with this safety instructions can result in death or severe
personal injury.
CAUTION
Non-compliance with this safety instructions can result in moderate or minor
personal injury.
NOTICE
Non-compliance with this safety instructions can result in material damage.
Safety symbols The following internationally standardized safety symbols and graphic sym‐
bols are used in this documentation. The meaning of the symbols is descri‐
bed in the table.
Safety symbols Significance
Warning against dangerous electric voltage
Warning against hot surfaces
Warning against overhead load
Electrostatic sensitive devices
No access for persons with cardiac pacemakers or implanted defibrilla‐
tors.
Do not carry along metal parts or clocks.
Tab. 1-3: Meaning of safety signs
Markup The following markups are used for a user-friendly text information represen‐
tation:
Reference to supplementary documentation
This note gives important information, which must be observed.
● Listings on the first level contain a bullet point
– Listings on the second level contain a dash
1. Handling instructions are specified in numbered lists. Please comply
with the order of the handling instructions.
1.2.4 Further documentation
For the project planning of drive systems with energy storage devices of the
BA1N series, you will require further documentation such as "MLD Technolo‐
gy Function - Kinetic Buffering, R911397139".
BA1N Kinetic Energy Buffer 3/73
Introduction to the product
R911393264_Edition 01 Bosch Rexroth AG

Rexroth provides the complete product documentation in PDF format in the
following Bosch Rexroth media directory:
http://www.boschrexroth.com/various/utilities/mediadirectory/index.jsp
1.2.5 Standards
This documentation refers to German, European and international technical
standards. Documents and sheets on standards are subject to copyright pro‐
tection and may not be passed on to third parties by Rexroth. If need be,
please contact the authorized sales outlets or, in Germany, directly:
BEUTH Verlag GmbH
Burggrafenstraße 6
10787 Berlin, Germany
Tel. [phone]
Fax [phone]
Internet: http://www.din.de/beuth
Email: [email protected]
1.2.6 Additional components
Documentation for external systems which are connected to Bosch Rexroth
components are not included in the scope of delivery and must be ordered
directly from the corresponding manufacturers.
1.2.7 Your feedback
Your experiences are an essential part of the improvement process of prod‐
uct and documentation.
Please send your feedback to:
Bosch Rexroth AG
Dept. DC-AE/EPI5 (fs)
Buergermeister-Dr.-Nebel-Straße 2
97816 Lohr am Main, Germany
E-Mail: [email protected]
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Introduction to the product
BA1N Kinetic Energy Buffer
Bosch Rexroth AG R911393264_Edition 01