Bosch Rexroth IndraDrive Mi Technical manual
Rexroth IndraDrive Mi
Drive Systems with KCU02
KSM02, KMS02/03, KMV03, KNK03
Project Planning Manual
R911335703
Edition 03
Rexroth IndraDrive Mi
Drive Systems with KCU02
KSM02, KMS02/03, KMV03, KNK03
Project Planning Manual
DOK-INDRV*-KCU02+KSM02-PR03-EN-P
RS-447a9cdbb5102eb30a6846a001f6e846-3-en-US-4
Edition Release Date Notes
03 2016-03 3rd edition; changes in
comparison to edi‐
tion 02: See index entry
"Editions"
02 2014-02 2nd edition; changes in
comparison to edi‐
tion 01: See index entry
"Editions"
01 2012-03 First edition
Copyright © Bosch Rexroth AG 2016
This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth AG. It may not be re‐
produced or given to third parties without its consent.
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.
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revision
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-P
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
Table of Contents
Page
1 System presentation.................................................................................................... 11
1.1 Introduction........................................................................................................................................... 11
1.1.1 Rexroth IndraDrive Mi........................................................................................................................ 11
1.1.2 Features............................................................................................................................................ 12
KSM02 motor-integrated servo drive.............................................................................................. 12
KMS02 near motor servo drive....................................................................................................... 13
KNK03 mains filter, KMV03 supply unit, KMS03 near motor servo drive....................................... 14
Maximum number of drives per drive line....................................................................................... 15
1.2 Rexroth IndraDrive Mi drive system...................................................................................................... 16
1.2.1 Components...................................................................................................................................... 16
Cabinet-bound, distributed drive technology.................................................................................. 16
Cabinet free, distributed drive technology...................................................................................... 17
Series............................................................................................................................................. 17
1.2.2 Firmware............................................................................................................................................ 18
1.2.3 System structure................................................................................................................................ 18
1.2.4 Overview of functions........................................................................................................................ 21
Firmware functions (functional packages)...................................................................................... 21
1.3 Type code............................................................................................................................................. 22
1.3.1 Introduction........................................................................................................................................ 22
1.3.2 KSM02 motor-integrated servo drive................................................................................................. 23
KSM02 type code........................................................................................................................... 23
1.3.3 KMS02 near motor servo drive.......................................................................................................... 25
KMS02 type code........................................................................................................................... 25
1.3.4 KMS03 near motor servo drive.......................................................................................................... 26
KMS03 type code........................................................................................................................... 26
1.3.5 KCU02 drive connection box............................................................................................................. 27
KCU02.2 type code........................................................................................................................ 27
1.3.6 KMV03 supply unit............................................................................................................................. 28
KMV03 type code........................................................................................................................... 28
1.3.7 KNK03 mains filter............................................................................................................................. 29
KNK03 type code............................................................................................................................ 29
1.3.8 Firmware............................................................................................................................................ 29
1.4 About this documentation..................................................................................................................... 30
1.4.1 Editions.............................................................................................................................................. 30
1.4.2 Documentations................................................................................................................................. 31
Drive systems, system components............................................................................................... 31
Motors............................................................................................................................................. 31
Cables............................................................................................................................................ 32
Firmware......................................................................................................................................... 32
1.4.3 Your feedback................................................................................................................................... 34
2 Important directions for use......................................................................................... 35
2.1 Appropriate use.................................................................................................................................... 35
2.1.1 Introduction........................................................................................................................................ 35
DOK-INDRV*-KCU02+KSM02-PR03-EN-P Bosch Rexroth AG I/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
Table of Contents
Page
2.1.2 Areas of use and application............................................................................................................. 35
2.2 Inappropriate use.................................................................................................................................. 36
3 Safety instructions for electric drives and controls....................................................... 37
3.1 Definitions of terms............................................................................................................................... 37
3.2 General information.............................................................................................................................. 38
3.2.1 Using the Safety instructions and passing them on to others............................................................ 38
3.2.2 Requirements for safe use................................................................................................................ 38
3.2.3 Hazards by improper use.................................................................................................................. 39
3.3 Instructions with regard to specific dangers.......................................................................................... 40
3.3.1 Protection against contact with electrical parts and housings........................................................... 40
3.3.2 Protective extra-low voltage as protection against electric shock .................................................... 41
3.3.3 Protection against dangerous movements........................................................................................ 42
3.3.4 Protection against electromagnetic and magnetic fields during operation and mounting.................. 43
3.3.5 Protection against contact with hot parts........................................................................................... 43
3.3.6 Protection during handling and mounting.......................................................................................... 44
3.3.7 Battery safety..................................................................................................................................... 44
3.3.8 Protection against pressurized systems............................................................................................ 45
3.4 Explanation of signal words and the Safety alert symbol..................................................................... 46
4 General data and specifications................................................................................... 47
4.1 Acceptance tests and approvals........................................................................................................... 47
4.2 Transport and storage.......................................................................................................................... 49
4.2.1 Transporting the components............................................................................................................ 49
4.2.2 Storing the components..................................................................................................................... 49
4.3 Installation conditions........................................................................................................................... 51
4.3.1 Ambient and operating conditions..................................................................................................... 51
4.3.2 Control cabinet design and cooling................................................................................................... 58
4.3.3 Mounting position.............................................................................................................................. 60
Mounting positions of components................................................................................................. 60
Mounting Positions of Motor-Integrated Servo Drives.................................................................... 61
4.3.4 Compatibility with foreign matters...................................................................................................... 61
4.3.5 Motor Paint........................................................................................................................................ 61
4.4 Voltage testing and insulation resistance testing.................................................................................. 61
4.5 Control voltage (24V supply) ............................................................................................................... 62
5 Technical data of the components............................................................................... 63
5.1 Explanation of terms and definitions..................................................................................................... 63
5.2 KSM02 motor-integrated servo drive.................................................................................................... 67
5.2.1 KSM02 without motor holding brake, data sheet............................................................................... 67
5.2.2 KSM02 with motor holding brake, data sheet.................................................................................... 69
5.2.3 KSM02 characteristics....................................................................................................................... 71
5.2.4 Dimensions and technical design...................................................................................................... 74
Dimensions..................................................................................................................................... 74
Technical design............................................................................................................................. 79
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-PII/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
Table of Contents
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5.2.5 Bearing load and shaft load............................................................................................................... 80
5.3 KMS02 near motor servo drive............................................................................................................. 82
5.3.1 KMS02 data sheet............................................................................................................................. 82
5.3.2 KMS02 dimensional drawing............................................................................................................. 84
5.4 KCU02 drive connection box................................................................................................................ 85
5.4.1 Brief description and use................................................................................................................... 85
5.4.2 KCU02 data sheet............................................................................................................................. 86
5.4.3 KCU02 dimensional drawing............................................................................................................. 89
5.5 KMV03 supply unit................................................................................................................................ 90
5.5.1 Ambient and operating conditions..................................................................................................... 90
5.5.2 Mechanics and mounting................................................................................................................... 91
KMV03 dimensions......................................................................................................................... 91
Dimensions, mass, insulation, sound pressure level...................................................................... 92
Power dissipation, mounting position, cooling, distances............................................................... 93
5.5.3 Basic data.......................................................................................................................................... 94
Control voltage............................................................................................................................... 94
Mains voltage................................................................................................................................. 95
DC bus............................................................................................................................................ 97
Braking resistor............................................................................................................................... 98
5.6 KNK03 mains filter................................................................................................................................ 99
5.6.1 KNK03 data sheet............................................................................................................................. 99
5.6.2 KNK03 dimensional drawing........................................................................................................... 100
5.7 KMS03 near motor servo drive........................................................................................................... 101
5.7.1 KMS03 data sheet........................................................................................................................... 101
5.7.2 KMS03 dimensional drawing........................................................................................................... 104
5.8 RKH hybrid cable................................................................................................................................ 106
5.8.1 RKH hybrid cable incl. communication, technical data.................................................................... 106
5.8.2 Hybrid cable without communication, technical data....................................................................... 108
5.8.3 Selecting hybrid cable incl. communication for appropriate connection.......................................... 110
5.8.4 Selecting hybrid cable without communication for appropriate connection..................................... 113
5.8.5 Interconnection diagrams for ready-made hybrid cables incl. communication................................ 115
KCU - KSM/KMS.......................................................................................................................... 115
KSM/KMS - KSM/KMS................................................................................................................. 117
Flexible cable tracks..................................................................................................................... 119
RHS0014 terminal connector....................................................................................................... 120
5.8.6 Interconnection diagrams for ready-made hybrid cables without communication........................... 121
KCU - KSM/KMS.......................................................................................................................... 121
KSM/KMS - KSM/KMS................................................................................................................. 122
5.8.7 Interconnection diagrams for ready-made hybrid cables used for mains connection...................... 123
KNK03 - KMV03 (RKH0800)........................................................................................................ 123
KNK03 - KMV03 (RKH0801)........................................................................................................ 124
6 Connection points...................................................................................................... 125
6.1 System connection points................................................................................................................... 125
6.1.1 Connection point of equipment grounding conductor...................................................................... 125
Cabinet-bound drive systems....................................................................................................... 125
DOK-INDRV*-KCU02+KSM02-PR03-EN-P Bosch Rexroth AG III/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
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Cabinet free drive systems........................................................................................................... 126
6.1.2 Ground connection.......................................................................................................................... 127
6.2 KCU02 connection points................................................................................................................... 128
6.2.1 Position of connection points........................................................................................................... 128
6.2.2 X1, Module Bus............................................................................................................................... 129
6.2.3 X29.1, X29.2, Multi-Ethernet........................................................................................................... 130
6.2.4 X49, L3 - Safe Torque Off............................................................................................................... 132
Data.............................................................................................................................................. 132
Pin Assignment, Function............................................................................................................. 132
6.2.5 X50, E-Stop Input............................................................................................................................ 133
6.2.6 X52, Status Messages..................................................................................................................... 134
6.2.7 X53, Control Voltage Output............................................................................................................ 135
6.2.8 X54, DC Bus, Equipment Grounding Conductor Output KSM02/KMS02........................................ 136
6.2.9 DC Bus Connection L+, L-............................................................................................................... 137
6.2.10 Control Voltage Supply +24V, 0V.................................................................................................... 140
6.3 KSM02 connection points................................................................................................................... 142
6.3.1 Position of connection points........................................................................................................... 142
6.3.2 X37, X38, digital inputs/outputs....................................................................................................... 143
6.3.3 X103.1, X103.2, hybrid cable connection point............................................................................... 147
6.3.4 X107, programming module............................................................................................................ 149
6.3.5 X108, X109, communication output coupling.................................................................................. 151
6.3.6 X118, X119, external communication.............................................................................................. 154
6.3.7 X141, Safe Torque Off safety technology and "release brake" service input.................................. 155
6.3.8 X141, Safe Motion safety technology and "release brake" service input........................................ 158
6.3.9 Second connection point of equipment grounding conductor.......................................................... 160
6.4 KMS02 connection points................................................................................................................... 162
6.4.1 Position of connection points........................................................................................................... 162
6.4.2 X37, X38, digital inputs/outputs....................................................................................................... 162
6.4.3 X103.1, X103.2, hybrid cable connection point............................................................................... 162
6.4.4 X104, connection for motor encoder............................................................................................... 163
6.4.5 X107, programming module............................................................................................................ 163
6.4.6 X108, X109, communication output coupling.................................................................................. 163
6.4.7 X118, X119, external communication.............................................................................................. 163
6.4.8 X141, safety technology.................................................................................................................. 163
6.4.9 X156, Motor Connection.................................................................................................................. 165
6.4.10 Second connection point of equipment grounding conductor.......................................................... 165
6.5 KMS03 connection points................................................................................................................... 166
6.5.1 Position of connection points........................................................................................................... 166
6.5.2 Motor cable and encoder cable connection..................................................................................... 167
Condition as supplied................................................................................................................... 167
Connection cover: Mounting options............................................................................................ 168
Connecting the cables.................................................................................................................. 169
6.5.3 XD3, motor connection.................................................................................................................... 171
6.5.4 XG3, motor temperature monitoring and motor holding brake ....................................................... 172
6.5.5 XG4, digital motor encoder connection........................................................................................... 175
6.5.6 XG8, analog motor encoder connection.......................................................................................... 176
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-PIV/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
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6.5.7 X37, X38, digital inputs/outputs....................................................................................................... 177
6.5.8 X103.1, X103.2, hybrid cable connection point............................................................................... 177
6.5.9 X107, programming module............................................................................................................ 177
6.5.10 X108, X109, communication output coupling.................................................................................. 177
6.5.11 X118, X119, external communication.............................................................................................. 177
6.5.12 X141, safety technology.................................................................................................................. 178
6.5.13 Second connection point of equipment grounding conductor.......................................................... 178
6.6 KMV03 connection points................................................................................................................... 179
6.6.1 Position of connection points........................................................................................................... 179
6.6.2 X37, X38, digital inputs/outputs....................................................................................................... 180
6.6.3 X103.1, X103.2, hybrid cable connection point............................................................................... 180
6.6.4 X108, X109, communication............................................................................................................ 180
6.6.5 X118, X119, external communication.............................................................................................. 180
6.6.6 X141, safety technology.................................................................................................................. 180
6.6.7 Second connection point of equipment grounding conductor.......................................................... 180
6.6.8 XD1, mains voltage......................................................................................................................... 181
6.6.9 XD10, control voltage...................................................................................................................... 182
6.6.10 XG3, mains choke temperature contact.......................................................................................... 183
6.6.11 XG14, mains voltage synchronization............................................................................................. 184
6.6.12 XG34, mains contactor control and feedback contacts (KNK03).................................................... 185
6.6.13 Connection cover: Mounting options............................................................................................... 186
6.7 KNK03 connection points................................................................................................................... 187
6.7.1 Position of connection points........................................................................................................... 187
6.7.2 Second connection point of equipment grounding conductor.......................................................... 187
6.7.3 XD1, mains voltage......................................................................................................................... 188
6.7.4 XD1.2, supply unit........................................................................................................................... 189
6.7.5 XG14, mains voltage synchronization............................................................................................. 190
6.7.6 XG3, mains choke temperature contact.......................................................................................... 191
6.7.7 XG34, mains contactor control and feedback contacts................................................................... 192
6.7.8 Connection cover: Mounting options............................................................................................... 193
7 Notes on project planning.......................................................................................... 195
7.1 Combining the individual components................................................................................................ 195
7.1.1 Power supply................................................................................................................................... 195
7.1.2 Power supply by HMV01, HMV02, HCS02 or HCS03..................................................................... 195
Supply units.................................................................................................................................. 195
7.1.3 Power supply by HCS01.................................................................................................................. 196
7.1.4 Power supply by KMV03 and KNK03.............................................................................................. 196
KMV03 supply unit, KNK03 mains filter........................................................................................ 196
7.1.5 Control voltage power requirement 42 V......................................................................................... 197
7.1.6 KCU02 drive connection box........................................................................................................... 198
General information...................................................................................................................... 198
Control voltage supply.................................................................................................................. 198
Power supply to KSM/KMS (KCU)............................................................................................... 200
7.1.7 Hybrid cable length.......................................................................................................................... 205
Length of hybrid cable incl. communication ................................................................................. 205
DOK-INDRV*-KCU02+KSM02-PR03-EN-P Bosch Rexroth AG V/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
Table of Contents
Page
Length of hybrid cable without communication ............................................................................ 207
Hybrid cable length vs. KCU performance................................................................................... 208
Hybrid cable length vs. KMV03 performance............................................................................... 211
7.1.8 Zone setup....................................................................................................................................... 214
Safety zones................................................................................................................................. 214
E-Stop function............................................................................................................................. 217
7.1.9 Motor fan for KSM02....................................................................................................................... 219
7.1.10 Evaluation of motor encoders at KMS............................................................................................. 219
7.1.11 Length of motor cables and encoder cables at KMS....................................................................... 220
7.1.12 Operation with standard motors...................................................................................................... 220
7.2 Notes on electrical project planning.................................................................................................... 222
7.2.1 Address Selector Switch ................................................................................................................. 222
7.2.2 IP configuration................................................................................................................................ 223
7.2.3 Current limitation............................................................................................................................. 223
7.2.4 Motor temperature........................................................................................................................... 224
7.2.5 Switching frequency........................................................................................................................ 225
7.3 Notes on mechanical project planning................................................................................................ 225
7.3.1 Mounting clearance......................................................................................................................... 225
7.3.2 Output shaft..................................................................................................................................... 225
Plain shaft..................................................................................................................................... 225
Output shaft with key.................................................................................................................... 225
Output shaft with shaft sealing ring.............................................................................................. 226
7.3.3 Bearings and shaft load................................................................................................................... 227
General information...................................................................................................................... 227
Radial load, axial load.................................................................................................................. 228
Bearing service life....................................................................................................................... 229
7.3.4 Holding brakes................................................................................................................................. 230
Brake control and supply.............................................................................................................. 230
Safety requirements..................................................................................................................... 230
Sizing holding brakes................................................................................................................... 231
7.3.5 Mechanical attachment of driving elements.................................................................................... 232
General information...................................................................................................................... 232
Redundant bearings..................................................................................................................... 232
Gear attachment........................................................................................................................... 233
Coupling attachment..................................................................................................................... 233
Bevel gear pinions or skew bevel driving pinions......................................................................... 233
8 Identification............................................................................................................... 235
8.1 Scope of supply.................................................................................................................................. 235
8.1.1 KCU02............................................................................................................................................. 235
8.1.2 KSM02/KMS02................................................................................................................................ 235
8.1.3 KMS03............................................................................................................................................. 236
8.1.4 KMV03............................................................................................................................................. 236
8.1.5 KNK03............................................................................................................................................. 236
8.2 Identifying and checking the delivered components........................................................................... 237
8.2.1 KSM type plate................................................................................................................................ 237
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-PVI/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
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Arrangement................................................................................................................................. 237
Design.......................................................................................................................................... 238
8.2.2 KMS02 type plate............................................................................................................................ 239
Arrangement................................................................................................................................. 239
Design.......................................................................................................................................... 240
8.2.3 KMS03 type plate............................................................................................................................ 241
Arrangement................................................................................................................................. 241
Design.......................................................................................................................................... 242
8.2.4 KMV03 type plate............................................................................................................................ 243
Arrangement................................................................................................................................. 243
Design.......................................................................................................................................... 244
8.2.5 KNK03 type plate............................................................................................................................. 245
Arrangement................................................................................................................................. 245
Design.......................................................................................................................................... 246
8.2.6 Plates at KCU02.............................................................................................................................. 247
Arrangement................................................................................................................................. 247
Type plate design......................................................................................................................... 247
Design of UL performance data plate........................................................................................... 248
9 Mounting and installation........................................................................................... 249
9.1 Introduction......................................................................................................................................... 249
9.1.1 Important notes................................................................................................................................ 249
Safety........................................................................................................................................... 249
Qualified technical staff................................................................................................................ 249
Handling the devices.................................................................................................................... 249
9.1.2 System overview............................................................................................................................. 250
Available connection points.......................................................................................................... 250
9.1.3 Cold plate........................................................................................................................................ 251
9.2 KSM.................................................................................................................................................... 252
9.2.1 Required Steps to Follow................................................................................................................ 252
Preparations for Mounting............................................................................................................ 252
Mounting KSM.............................................................................................................................. 252
9.2.2 Mechanical Interfaces...................................................................................................................... 253
Flange Mounting........................................................................................................................... 253
9.2.3 Practical tips.................................................................................................................................... 253
9.3 KMS.................................................................................................................................................... 254
9.3.1 Required steps to follow.................................................................................................................. 254
Preparations for mounting............................................................................................................ 254
Mounting KMS.............................................................................................................................. 254
9.4 KCU02................................................................................................................................................ 255
9.4.1 Mounting depths.............................................................................................................................. 255
9.4.2 Touch Guard.................................................................................................................................... 255
9.4.3 KCU02 connection diagram............................................................................................................. 257
9.5 KNK03/KMV03.................................................................................................................................... 258
9.5.1 Arranging the devices...................................................................................................................... 258
9.5.2 Mounting.......................................................................................................................................... 258
DOK-INDRV*-KCU02+KSM02-PR03-EN-P Bosch Rexroth AG VII/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
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9.6 Electrical connection........................................................................................................................... 258
9.6.1 General information......................................................................................................................... 258
9.6.2 Notices............................................................................................................................................. 259
9.6.3 Electrical interfaces......................................................................................................................... 259
Overall connection diagram.......................................................................................................... 259
HMV01 used as supply unit.......................................................................................................... 261
HCS02 used as supply unit.......................................................................................................... 262
HCS03 used as supply unit.......................................................................................................... 263
HMV02 used as supply unit.......................................................................................................... 265
HCS01.1E-W0054 used as supply unit........................................................................................ 266
KMV03 used as supply unit.......................................................................................................... 268
Parallel drive lines........................................................................................................................ 270
10 Accessories................................................................................................................ 273
10.1 Overview............................................................................................................................................. 273
10.2 HAS01, basic accessory..................................................................................................................... 274
10.3 HAS02, shield connection .................................................................................................................. 275
10.4 HAS03, control cabinet adapter.......................................................................................................... 276
10.5 HAS05.1-018, dummy plate for KMS03 encoder connection............................................................. 277
10.6 HAS05.1-019, KNK03 mains voltage.................................................................................................. 278
10.7 HAS05.1-020, KMV03 control voltage................................................................................................ 279
10.8 HAS10, mechanical mounting parts................................................................................................... 280
10.8.1 Type code........................................................................................................................................ 280
10.8.2 Use.................................................................................................................................................. 280
10.8.3 Scope of supply............................................................................................................................... 281
10.9 RKB0011, Multi-Ethernet Cable.......................................................................................................... 284
10.10 RKB0013, Multi-Ethernet Cable.......................................................................................................... 285
10.11 RKB0033, cable for safety technology................................................................................................ 286
10.12 RKB0043, Communication Cable....................................................................................................... 287
10.13 RKB0044, Communication Cable....................................................................................................... 288
10.14 RKS0010, Interface Cable.................................................................................................................. 289
10.15 RBS0023, connector for safety zone node......................................................................................... 290
10.16 RLS0725, KMS03 motor power cable connector................................................................................ 291
10.17 RGS0725, KMS03 encoder cable connector...................................................................................... 292
10.18 RHS0725, KMS03 motor cable connector.......................................................................................... 293
10.19 netSWITCH sercos III......................................................................................................................... 294
11 Commissioning, operation, diagnostics and maintenance......................................... 295
11.1 Notes on commissioning..................................................................................................................... 295
11.1.1 General information......................................................................................................................... 295
11.1.2 Preparation...................................................................................................................................... 295
11.1.3 Procedure........................................................................................................................................ 295
11.2 Notes on operation............................................................................................................................. 295
11.3 Diagnostic functions............................................................................................................................ 297
11.3.1 KMV diagnostic display................................................................................................................... 297
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-PVIII/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
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LED H14....................................................................................................................................... 297
11.3.2 KCU02 Diagnostic Display.............................................................................................................. 299
11.3.3 KSM/KMS diagnostic display........................................................................................................... 301
H14 LED....................................................................................................................................... 301
H25 H26 LED............................................................................................................................... 303
Use............................................................................................................................................ 303
H25 LED, displays..................................................................................................................... 304
H26 LED, displays..................................................................................................................... 305
11.3.4 Diagnostic messages via parameters.............................................................................................. 308
11.3.5 Firmware functions.......................................................................................................................... 308
Easy startup mode........................................................................................................................ 308
Analog outputs.............................................................................................................................. 308
Oscilloscope function.................................................................................................................... 309
Patch function............................................................................................................................... 309
Monitoring function....................................................................................................................... 309
Logbook function.......................................................................................................................... 309
11.4 Service functions/troubleshooting....................................................................................................... 310
11.4.1 General information......................................................................................................................... 310
11.4.2 Replacing Fuses F4 and F5............................................................................................................ 311
11.4.3 Deactivating and Dismounting the Drive......................................................................................... 311
Deactivation.................................................................................................................................. 311
Dismounting.................................................................................................................................. 312
11.4.4 Replacing the component................................................................................................................ 312
11.4.5 "Release holding brake" service function........................................................................................ 313
11.4.6 Saving Parameters.......................................................................................................................... 314
11.4.7 Firmware Update............................................................................................................................. 314
11.4.8 Replacing the programming module................................................................................................ 314
11.5 Maintenance....................................................................................................................................... 315
11.5.1 Maintenance of the Motor Component............................................................................................ 315
General Information...................................................................................................................... 315
Cleaning ...................................................................................................................................... 315
Bearings....................................................................................................................................... 315
Connection Cables....................................................................................................................... 315
Holding Brake – Commissioning and Maintenance Instructions .................................................. 316
11.5.2 Maintenance of the Electronic System of the Drive......................................................................... 317
12 Environmental protection and disposal ..................................................................... 319
12.1 Environmental protection.................................................................................................................... 319
12.2 Disposal.............................................................................................................................................. 319
13 Service and support................................................................................................... 321
14 Appendix.................................................................................................................... 323
14.1 Digital inputs....................................................................................................................................... 323
14.1.1 Digital Inputs Type A (Standard)..................................................................................................... 323
DOK-INDRV*-KCU02+KSM02-PR03-EN-P Bosch Rexroth AG IX/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
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14.1.2 Digital inputs (safety technology L options)..................................................................................... 323
14.1.3 Digital inputs (safety technology S options)..................................................................................... 324
14.2 Digital outputs..................................................................................................................................... 325
14.2.1 Digital Outputs (Safety Technology L Options)............................................................................... 325
14.2.2 Digital outputs (safety technology S options).................................................................................. 326
Index.......................................................................................................................... 329
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-PX/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
Table of Contents
1 System presentation
1.1 Introduction
1.1.1 Rexroth IndraDrive Mi
Rexroth IndraDrive Mi is an innovative system solution within the Rexroth
IndraDrive platform with
●KSM02 motor-integrated servo drives
⇒ Synchronous servo motors (on the basis of Rexroth IndraDyn S) with
integrated inverters and control sections
●KMS02 and KMS03 near motor servo drives
⇒ Very compact inverters with control sections
●KCU02 drive connection box
⇒ Component used to connect the servo drives to HMV supply units or
HCS converters
●KMV03 supply unit
⇒ Component used to supply servo drives
●KNK03 mains filter (with integrated mains choke)
⇒ Mains connection component for KMV03 supply units
The KNK03 and KMV03 components allow a drive system to be designed
without a control cabinet.
The KCU02 component with the assigned supply unit (e.g., HMV or HCS) al‐
ways requires a control cabinet.
DOK-INDRV*-KCU02+KSM02-PR03-EN-P Bosch Rexroth AG 11/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
System presentation
1.1.2 Features
KSM02 motor-integrated servo drive
*Power is supplied to the drives via HMV or HCS (alternative
power supply: KMV); HMS, HMD: optional
Fig. 1-1: Rexroth IndraDrive Mi with KSM02 – Features
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-P12/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
System presentation
KMS02 near motor servo drive
*Power is supplied to the drives via HMV or HCS (alternative
power supply: KMV); HMS, HMD: optional
Fig. 1-2: Rexroth IndraDrive Mi with KMS02 – Features
DOK-INDRV*-KCU02+KSM02-PR03-EN-P Bosch Rexroth AG 13/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
System presentation
KNK03 mains filter, KMV03 supply unit, KMS03 near motor servo drive
Components Features
Cabinet free, distributed drive technology
KNK03, mains filter
● Degree of protection IP65
● Integrated mains choke
● Integrated mains contactor
● Thermal interface for cold plate mounting
KMV03, supply unit
● Degree of protection IP65
● Integrated brake chopper
● Multi-Ethernet communication
● Thermal interface for cold plate mounting
● KSM02 and KMS02 can also be supplied
KMS03, near motor servo drive
● Degree of protection IP65
● With heat sink (KMS03.1B-A)
● With thermal interface for cold plate mounting (KMS03.1B-B)
● MultiEncoder interface: Hiperface, Endat 2.1/2.2, SSI, Safety 4 Wire,
1 Vpp
● 4 digital inputs and outputs, two thereof can be used as fast probe inputs
● Multi-Ethernet communication
● External Multi-Ethernet communication (optional)
● MultiEthernet communication output coupling (optional)
● Safe Torque Off or Safe Motion safety technology (optional)
● Integrated Motion Logic in accordance with IEC 61131-3
RKH, hybrid cable
●
RKH0xxx
– DC bus connection
– Control voltage and signal exchange cable
– Communication cable
●
RKH0800
– Mains voltage
– Mains contactor
●
RKH0801
– Mains choke
– Mains voltage synchronization
● The hybrid cable is supplied in ready-made form with connectors.
The bulk cable (hybrid cable without connector) is named REH0800 (hy‐
brid cable incl. communication) or REH0803 (hybrid cable without com‐
munication; devices with external communication (ES option) use sepa‐
rate cables for communication).
Tab. 1-1: Rexroth IndraDrive Mi with KMS03 – Features
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-P14/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
System presentation
Maximum number of drives per drive line
Power supply Drive Maximum number
HMV, HCS KSM02, KMS02, KMS03 30 1)
KMV03 KSM02, KMS02, KMS03 30 1)
1) The maximum power dissipation of the control voltage supply
should not be exceeded. Observe power requirements of any
available motor holding brakes.
Tab. 1-2: Maximum number of drives per drive line
DOK-INDRV*-KCU02+KSM02-PR03-EN-P Bosch Rexroth AG 15/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
System presentation
1.2 Rexroth IndraDrive Mi drive system
1.2.1 Components
Cabinet-bound, distributed drive technology
Components: See chapter "KSM02 motor-integrated servo drive" on page 12
or chapter "KMS02 near motor servo drive" on page 13
KSM motor-integrated servo drive The KSM motor-integrated servo drive consists of 2 parts:
● Servo motor (on the basis of Rexroth IndraDyn S)
● Drive electronics, consisting of control section and power section
KMS near motor servo drive The KMS near motor servo drive consists of a control section and a power
section.
RKH hybrid cable The RKH hybrid cable replaces the following individual cables:
● DC bus connection
● Control voltage and signal exchange cable
● Communication cable
(Devices with external communication (ES option) use separate cables
for communication. For this case, hybrid cables without communication
lines are available.)
The hybrid cable is supplied in ready-made form with connectors.
The bulk cable (hybrid cable without connector) is named REH0800 (hybrid
cable incl. communication) or REH0803 (hybrid cable without communica‐
tion).
Drive Connection Box KCU02 The drive connection box KCU02
● supplies the motor-integrated servo drives KSM and the near motor ser‐
vo drives KMS
– with power (from the DC bus connection to an HMV supply unit or
HCS converter)
– with 42V control voltage
● with integrated fuses protects the hybrid cable RKH against electric
overload
● allows communication between the higher-level control unit and the mo‐
tor-integrated servo drives KSM and near motor servo drives KMS
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-P16/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
System presentation
Cabinet free, distributed drive technology
Components: See chapter "KNK03 mains filter, KMV03 supply unit, KMS03
near motor servo drive" on page 14.
KMV03 supply unit The KMV03 supply unit
● supplies the KSM motor-integrated servo drives and KMS near motor
servo drives
– with power
– with 42V control voltage
● allows the higher-level control unit to communicate with the KSM motor-
integrated servo drives and KMS near motor servo drives
KSM motor-integrated servo drive,
KMS near motor servo drive, RKH
hybrid cable
See chapter "Cabinet-bound, distributed drive technology" on page 16.
Series
See section "Type code"
●KCU02 drive connection box
●KSM02 motor-integrated servo drive
●KMS02 near motor servo drive
●KMS03 near motor servo drive
●KMV03 supply unit
●KNK03 mains filter
DOK-INDRV*-KCU02+KSM02-PR03-EN-P Bosch Rexroth AG 17/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
System presentation
1.2.2 Firmware
Firmware required to operate a Rexroth IndraDrive Mi drive system:
Product
Series
Features Supported as of firmware version
KSM02.1B 041C … 076C MPB-17V08
"Safe Motion" safety technology:
MPB-18V08
KMS02 B-A018-P-D7-ET-***-**-** MPB-17V10
"Safe Motion" safety technology:
MPB-18V08
KMS03 *-A036-P-D7-ET-***-**-**
*-B036-P-D7-ET-***-**-**
MPB-20VRS
KMV03 *-B0007-P-D7-ET-****-** PSB-20VRS
Tab. 1-3: Required firmware versions for KMS
1.2.3 System structure
The supply unit that is used significantly defines the system structure.
Possible supply units:
● Rexroth IndraDrive HMV01.1E/R or HMV02.1R supply unit
● Rexroth IndraDrive HCS02.1E or HCS03.1E converter (makes sense if
another axis is required)
● Rexroth IndraDrive HCS01.1E-W0054 converter
● Rexroth IndraDrive KMV03.1R supply unit
The figure below shows a Rexroth IndraDrive Mi drive system
containing KSM motor-integrated servo drives. This system struc‐
ture also applies to Rexroth IndraDrive Mi drive systems with
KMS near motor servo drives.
Bosch Rexroth AG DOK-INDRV*-KCU02+KSM02-PR03-EN-P18/337
Rexroth IndraDrive Mi Drive Systems with KCU02 KSM02, KMS02/03, KMV03, KNK03
System presentation
Other manuals for Rexroth IndraDrive Mi
3
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