Bosch Rexroth IndraDrive Mi Technical manual

Rexroth IndraDrive Mi
Drive Systems
R911320924
Edition 01
Project Planning Manual
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics

About this Documentation
DOK-INDRV*-KCU+KSM****-PR01-EN-P
Rexroth IndraDrive Mi
Drive Systems
Project Planning Manual
DOK-INDRV*-KCU+KSM****-PR01-EN-P
120-2400-B324-01/EN
This documentation describes …
•how to design the control cabinet
•how to install the drive system
Description Release Date Notes
DOK-INDRV*-KCU+KSM****-PR01-EN-P 2007-04 First edition
Bosch Rexroth AG 2007
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
The data specified above only serve to describe the product. No
statements concerning a certain condition or suitability for a certain
application can be derived from our information. The given information
does not release the user from the obligation of own judgement and
verification. It must be remembered that our products are subject to a
natural process of wear and aging.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.de/
Dept. BRC/EDY1 (MW/RR/US/BB) and BRC/EDM2 (JW)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revisions
Copyright
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Published by
Note

Rexroth IndraDrive Mi Contents I
DOK-INDRV*-KCU+KSM****-PR01-EN-P
Contents
1 System Presentation 1-1
1.1 Introduction................................................................................................................................... 1-1
Rexroth IndraDrive Mi.............................................................................................................. 1-1
Features................................................................................................................................... 1-1
1.2 Drive System Rexroth IndraDrive Mi ............................................................................................ 1-2
Components ............................................................................................................................ 1-2
System Structure..................................................................................................................... 1-3
Overview of Functions............................................................................................................. 1-5
1.3 Type Code .................................................................................................................................... 1-5
Introduction.............................................................................................................................. 1-5
Distributed Servo Drive KSM................................................................................................... 1-6
Electronic Control System KCU............................................................................................... 1-9
Firmware.................................................................................................................................. 1-9
1.4 Guide to the Documentation....................................................................................................... 1-10
Documentation Structure....................................................................................................... 1-10
Documentations - Overview .................................................................................................. 1-10
2 Important Directions for Use 2-1
2.1 Appropriate Use............................................................................................................................ 2-1
Introduction.............................................................................................................................. 2-1
Areas of Use and Application.................................................................................................. 2-1
2.2 Inappropriate Use ......................................................................................................................... 2-2
3 Safety Instructions for Electric Drives and Controls 3-1
3.1 General Information...................................................................................................................... 3-1
Using the Safety Instructions and Passing Them on to Others............................................... 3-1
Instructions for Use.................................................................................................................. 3-1
Explanation of Warning Symbols and Degrees of Hazard Seriousness................................. 3-3
Hazards by Improper Use........................................................................................................ 3-3
3.2 Instructions with Regard to Specific Dangers............................................................................... 3-5
Protection Against Contact with Electrical Parts ..................................................................... 3-5
Protection Against Electric Shock by Protective Extra-Low Voltage (PELV) .......................... 3-7
Protection Against Dangerous Movements............................................................................. 3-7
Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting.................................................................................................................................. 3-9
Protection Against Contact with Hot Parts ............................................................................ 3-10
Protection During Handling and Mounting............................................................................. 3-11
Battery Safety........................................................................................................................ 3-11
Protection Against Pressurized Systems .............................................................................. 3-12

II Contents Rexroth IndraDrive Mi
DOK-INDRV*-KCU+KSM****-PR01-EN-P
4 General Specification of the Components 4-1
4.1 Certifications................................................................................................................................. 4-1
4.2 Transport and Storage.................................................................................................................. 4-2
Transporting the Devices......................................................................................................... 4-2
Storing the Devices ................................................................................................................. 4-2
4.3 Installation Conditions................................................................................................................... 4-2
Ambient and Operating Conditions.......................................................................................... 4-2
Type of Construction and Mounting Positions......................................................................... 4-4
Compatibility with Foreign Matters .......................................................................................... 4-4
Prime Coat and Housing Varnish............................................................................................ 4-4
4.4 Capacity Utilization....................................................................................................................... 4-5
5 Technical Data of the Components 5-1
5.1 Explanation of Terms and Definitions........................................................................................... 5-1
5.2 Distributed Servo Drive KSM........................................................................................................ 5-5
KSM Data Sheet...................................................................................................................... 5-5
KSM Characteristics................................................................................................................ 5-7
Dimensions and Technical Design........................................................................................ 5-10
Bearings and Shaft Load....................................................................................................... 5-12
5.3 Electronic Control System KCU.................................................................................................. 5-14
Brief Description and Applications......................................................................................... 5-14
Technical Data....................................................................................................................... 5-14
5.4 Hybrid Cables RKH..................................................................................................................... 5-17
Technical Data....................................................................................................................... 5-17
Selecting Ready-Made Cables.............................................................................................. 5-17
Interconnection Diagrams for Ready-Made Hybrid Cables................................................... 5-19
6 Connection Points 6-1
6.1 Connection Points of System ....................................................................................................... 6-1
Equipment Grounding Conductor............................................................................................ 6-1
Ground Connection ................................................................................................................. 6-2
6.2 Connection Points of KCU............................................................................................................ 6-3
Positions of the Connection Points.......................................................................................... 6-3
X1, Module Bus ....................................................................................................................... 6-4
X20 TX, X21 RX (SERCOS interface)..................................................................................... 6-5
X50, E-Stop Input .................................................................................................................... 6-6
X51, Master Communication SERCOS................................................................................... 6-6
X52, Status Messages............................................................................................................. 6-7
X53, Control Voltage Output.................................................................................................... 6-7
X54, DC Bus, Equipment Grounding Conductor Output KSM................................................ 6-8
DC Bus Connection L+, L-....................................................................................................... 6-9
Control Voltage Supply +24V, 0V.......................................................................................... 6-11
Connection Accessory........................................................................................................... 6-12
6.3 Connection Points of KSM.......................................................................................................... 6-13
Positions of the Connection Points........................................................................................ 6-13
X2 Serial Interface, Service Input "Release Brake"............................................................... 6-14

Rexroth IndraDrive Mi Contents III
DOK-INDRV*-KCU+KSM****-PR01-EN-P
X3.1, X3.2 Connection Point Hybrid Cable ........................................................................... 6-15
X7 Connection Point MultiMediaCard (MMC) ....................................................................... 6-16
X37, X38 Digital Inputs/Outputs ............................................................................................ 6-17
Ground Connection ...............................................................................................................6-20
7 Notes on Project Planning 7-1
7.1 Notes on Mechanical Project Planning.........................................................................................7-1
Mounting Clearance ................................................................................................................ 7-1
Output Shaft............................................................................................................................. 7-1
Bearings and Shaft Load.........................................................................................................7-3
Holding Brakes ........................................................................................................................ 7-5
Mechanical Attachment of Driving Elements........................................................................... 7-8
7.2 Notes on Electrical Project Planning .......................................................................................... 7-10
Allowed Cable Lengths.......................................................................................................... 7-10
Maximum Number of Axes per System Combination............................................................ 7-10
24V Control Voltage .............................................................................................................. 7-11
Power Supply......................................................................................................................... 7-13
Electronic Control System KCU............................................................................................. 7-13
Address Selector Switch........................................................................................................ 7-14
Motor Blower.......................................................................................................................... 7-15
Motor Current Limitation........................................................................................................7-15
Motor Temperature................................................................................................................ 7-16
Switching Frequency.............................................................................................................7-16
8 Identification 8-1
8.1 Scope of Supply............................................................................................................................ 8-1
KSM......................................................................................................................................... 8-1
KCU......................................................................................................................................... 8-1
8.2 Identifying and Checking the Delivered Components .................................................................. 8-1
Type Plate KSM....................................................................................................................... 8-1
Type Plate KCU....................................................................................................................... 8-3
9 Mounting and Installation 9-1
9.1 Introduction................................................................................................................................... 9-1
Important Notes....................................................................................................................... 9-1
System Overview..................................................................................................................... 9-1
Connection Diagram KCU....................................................................................................... 9-3
9.2 Mounting....................................................................................................................................... 9-4
Practical Tips........................................................................................................................... 9-4
Required Steps to Follow ........................................................................................................9-4
Mechanical Interfaces.............................................................................................................. 9-5
9.3 Electrical Connection.................................................................................................................... 9-6
Notes ....................................................................................................................................... 9-7
Electrical Interfaces ................................................................................................................. 9-7
9.4 Handling of the Devices.............................................................................................................. 9-10

IV Contents Rexroth IndraDrive Mi
DOK-INDRV*-KCU+KSM****-PR01-EN-P
10 Commissioning, Operation, Diagnoses, Service and Maintenance 10-1
10.1 Notes on Commissioning............................................................................................................ 10-1
Preparing ............................................................................................................................... 10-1
Carrying Out .......................................................................................................................... 10-1
10.2 Notes on Operation..................................................................................................................... 10-1
10.3 Diagnostic Functions .................................................................................................................. 10-2
Distributed Servo Drive KSM................................................................................................. 10-2
Electronic Control System KCU............................................................................................. 10-3
Diagnostic Messages via Parameters................................................................................... 10-4
Firmware Functions............................................................................................................... 10-4
10.4 Service Functions/Troubleshooting............................................................................................ 10-5
Deactivating and Dismounting the Drive............................................................................... 10-5
Replacing KSM...................................................................................................................... 10-6
Service Function "Release Holding Brake"........................................................................... 10-7
Saving Parameters................................................................................................................ 10-7
Firmware Update................................................................................................................... 10-7
MMC...................................................................................................................................... 10-8
10.5 Maintenance ............................................................................................................................... 10-8
Maintenance of the Motor Component.................................................................................. 10-8
Maintenance of the Electronic System of the Drive............................................................. 10-10
11 Disposal and Environmental Protection 11-1
11.1 Disposal...................................................................................................................................... 11-1
Products................................................................................................................................. 11-1
Packaging Materials .............................................................................................................. 11-1
11.2 Environmental Protection............................................................................................................ 11-1
No Release of Hazardous Substances ................................................................................. 11-1
Materials Contained in the Products ..................................................................................... 11-1
Recycling............................................................................................................................... 11-2
12 Appendix 12-1
12.1 Discharging of DC Bus Capacitors............................................................................................. 12-1
12.2 Discharging Device..................................................................................................................... 12-2
13 Service and Support 13-1
13.1 Helpdesk..................................................................................................................................... 13-1
13.2 Service Hotline............................................................................................................................ 13-1
13.3 Internet........................................................................................................................................ 13-1
13.4 Helpful Information...................................................................................................................... 13-1
14 Index 14-1

Rexroth IndraDrive Mi System Presentation 1-1
DOK-INDRV*-KCU+KSM****-PR01-EN-P
1 System Presentation
1.1 Introduction
Rexroth IndraDrive Mi
Rexroth IndraDrive Mi is an innovative system solution within the Rexroth
IndraDrive platform, consisting of synchronous servo motors (on the basis
of Rexroth IndraDyn S) with integrated inverters and control sections.
Features
Fig. 1-1: Rexroth IndraDrive Mi - features

1-2 System Presentation Rexroth IndraDrive Mi
DOK-INDRV*-KCU+KSM****-PR01-EN-P
In the following points, the system solution Rexroth IndraDrive Mi differs
from a standard solution with Rexroth IndraDrive and Rexroth IndraDyn:
•limited performance levels and exclusively available on the basis of
Rexroth IndraDyn S, i.e. no linear and kit motors
•SERCOS interface as master communication
1.2 Drive System Rexroth IndraDrive Mi
Components
The drive system Rexroth IndraDrive Mi consists of the following
components:
1 distributed servo drive KSM
1a: basic motor
1b: electronic system of drive (power section and control section)
2 terminal connector (to close the SERCOS ring)
3 hybrid cable (for power and communication)
4 electronic control system KCU (power supply and signal conversion)
Fig. 1-2: Components
The distributed servo drive KSM consists of 2 parts:
•servo motor (on the basis of Rexroth IndraDyn S)
•electronic system of drive, consisting of control section and power
section
The ready-made hybrid cable replaces the following individual cables:
•motor power cable
•encoder cable
•control voltage and signal exchange cable
•SERCOS cable
The hybrid cable is supplied in ready-made form with connectors.
Differences to Rexroth
IndraDrive and Rexroth IndraDyn
Distributed Servo Drive KSM
Ready-Made Hybrid Cable

Rexroth IndraDrive Mi System Presentation 1-3
DOK-INDRV*-KCU+KSM****-PR01-EN-P
The electronic control system KCU
•supplies power to the distributed servo drives (from the DC bus
connection to an HMV supply unit or HCS converter)
•with integrated fuses protects the hybrid cable against electric
overload
•allows communication between the higher-level control unit and the
distributed servo drives
Lines
See chapter "Type Code"
•distributed servo drive KSM
•electronic control system KCU
System Structure
The supply unit which is used significantly defines the system structure.
Possible supply units:
•Rexroth IndraDrive supply unit HMV01.1E/R or HMV02.1R
•Rexroth IndraDrive converter HCS02.1 or HCS03.1 (makes sense if
another axis is required)
The figure below illustrates the system structure with all involved
components (with HMV as supply unit).
Electronic Control System KCU

1-4 System Presentation Rexroth IndraDrive Mi
DOK-INDRV*-KCU+KSM****-PR01-EN-P
DST transformer (optional)
F fuses
HMD, HMS inverter
HMV supply unit
HNF mains filter
HNL mains choke
KCU electronic control system
KSM distributed servo drive
MSK servo motor
24V 24V supply
1 mains contactor (for supply units without integrated mains
contactor, e.g. HMV01.2R-W0120)
2 terminal connector
X3.2 connection of hybrid cable
Fig. 1-3: System structure

Rexroth IndraDrive Mi System Presentation 1-5
DOK-INDRV*-KCU+KSM****-PR01-EN-P
Overview of Functions
Firmware Functions (Functional Packages)
Note: For details on the available firmware functions, see chapter
"Functional Packages" of the Functional Description for
firmware MPB04VRS or higher.
Hardware-related functional restrictions as compared to drive controllers
with CSB and CSH control sections:
•no safety technology
•no analog inputs or outputs
•no digital and analog I/O extensions
1.3 Type Code
Introduction
The type code is the basis of each purchase order of a Rexroth product.
It unequivocally describes all variants which can be supplied.
•distributed servo drive KSM
•electronic control system KCU
•firmware ≥MPB04V20
For product selection and purchase order, take the following aspects into
account:
•Detailed information and instructions in the chapters "Technical Data"
and "Notes on Project Planning"
•Before placing a purchase order, have our sales representative check
whether individual options are available
Note: The following figures illustrate the basic structure of the type
codes. Our sales representative will help you with the current
status of available versions.
Notes on Product Selection

1-6 System Presentation Rexroth IndraDrive Mi
DOK-INDRV*-KCU+KSM****-PR01-EN-P
Distributed Servo Drive KSM
Type Code
Fig. 1-4: Type code KSM

Rexroth IndraDrive Mi System Presentation 1-7
DOK-INDRV*-KCU+KSM****-PR01-EN-P
Explanation of the Type Code
The type code has the following basic structure:
•Product
KSM Rexroth-specific designation of the motor line
•Size
The motor size defines important mechanical motor dimensions. In
addition, the rotor inertia is distinguished in column 11.
Abbrev. column 12 : 1 rotor inertia reduced
6 rotor inertia normal
•Length
Within one line, increasing motor length is graded by code letters in
alphabetic order.
•Winding
The two-digit sequence of numerals, multiplied by 100, makes the rated
speed applying to the corresponding winding variant.
•Cooling mode
N: natural convection
•Motor encoder
Rexroth IndraDrive Mi motors have been equipped with an integrated
encoder system. To control the motor speed or position the motor, the
drive controller needs the current motor position.
Option Encoder type
S1 Optical encoder single-turn,
position detection absolute over 1 motor revolution with a resolution
of 128 x 213 pieces of information per revolution
M1 Optical encoder multi-turn,
position detection absolute over 4096 motor revolutions with a
resolution of 128 x 213 pieces of information per revolution
Fig. 1-5: Motor encoder
•Connection system
Connection for hybrid cable RKH
•Shaft
To connect the machine elements to be driven to the motor shafts, there
are the following options.
Option Design Detail
G plain shaft
P shaft with keyway 1)
with centering hole on the end face with
thread "DS" according to DIN 332, part
2, edition 05.83
1) keyway according to DIN 6885, sheet 1, edition 08.68 (for details see
dimensional drawing!)
Fig. 1-6: KSM output shafts
Note: Distributed servo drives KSM are balanced with entire key.
The corresponding key is not part of the scope of supply.
Abbrev. column 1 2 3 4 5 6 7 8
Abbrev. column 10 11 12
Abbrev. column 13
Abbrev. column 15 16
Abbrev. column 17
Abbrev. column 19 20
Abbrev. column 22
Abbrev. column 23

1-8 System Presentation Rexroth IndraDrive Mi
DOK-INDRV*-KCU+KSM****-PR01-EN-P
•Holding brake
Distributed servo drives KSM can be optionally supplied with electrically
released holding brakes.
Option Holding brake
0 without holding brake
2 with holding brake For holding torque, see individual data
sheets.
Fig. 1-7: KSM holding brakes
Note: The holding brake is not suited for personal protection or as
service brake! Observe the installation and safety instructions
for the motor holding brakes!
•Master communication
SE: SERCOS (RS422)
•Safety option (X41)
NN: none
•Connecting voltage
D7: DC 750 V
•Other design
NN: none
•Firmware
FW: Firmware must be ordered as separate subposition
•Standard reference
The item "Standard reference" refers to standards cited in the type code
(e.g. DIN, EN, ISO …) or reference INN... factory standards. The type
code lists the edition valid at the point of time the type code is issued.
Abbrev. column 24
Abbrev. column 26 27
Abbrev. column 29 30
Abbrev. column 32 33
Abbrev. column 35 36
Abbrev. column 38 39

Rexroth IndraDrive Mi System Presentation 1-9
DOK-INDRV*-KCU+KSM****-PR01-EN-P
Electronic Control System KCU
Type Code
Fig. 1-8: Type code KCU
Firmware
Operating a Rexroth IndraDrive Mi drive system requires the standard
firmware MPB04-V20 or higher.
Type code: see Functional Description of firmware

1-10 System Presentation Rexroth IndraDrive Mi
DOK-INDRV*-KCU+KSM****-PR01-EN-P
1.4 Guide to the Documentation
Documentation Structure
Chapter Title Contents
1 System Presentation general information
2 Important Directions for Use
3 Safety Instructions safety
4 General Specification of the Components
5 Technical Data of the Components
6 Connection Points
7 Notes on Project Planning
product description
(for those doing project planning)
8 Identification
9 Mounting and Installation
10 Commissioning, Operation, Diagnoses, Service and
Maintenance
11 Disposal and Environmental Protection
12 Appendix
13 Service and Support
practical application
(for operators and maintenance staff)
14 Index
Fig. 1-9: Documentation structure
Documentations - Overview
Hardware
Title Kind of documentation Document typecode1)
Rexroth IndraDrive
Drive System Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P
Rexroth IndraDrive
Drive Controllers
Control Sections Cxx
Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P
Rexroth IndraDrive
Supply Units and Power Sections Project Planning Manual DOK-INDRV*-HMV-S-D+HCS-PR01-EN-P
Rexroth IndraDrive
Additional Components Project Planning Manual DOK-INDRV*-ADDCOMP****-PRxx-EN-P
Rexroth Connection Cables Selection Data DOK-CONNEC-CABLE*STAND-AUxx-EN-P
Safety Instructions for Electrical Drives Safety Guidelines DOK-GENERAL-DRIVE******-SVSx-MS-P
1) In the document typecodes, "xx" is a wild card for the current edition
of the documentation (example: "PR01" is the first edition of a
Project Planning Manual)
Fig. 1-10: Documentations - overview

Rexroth IndraDrive Mi System Presentation 1-11
DOK-INDRV*-KCU+KSM****-PR01-EN-P
Firmware
Title Kind of documentation Document typecode1)
Rexroth IndraDrive
Integrated Safety Technology Functional and Application Description DOK-INDRV*-SI*-**VRS**-FKxx-EN-P
Rexroth IndraDrive
Firmware for Drive Controllers Functional Description DOK-INDRV*-MP*-04VRS**-FKxx-EN-P or higher
Rexroth IndraDrive
Firmware for Drive Controllers Parameter Description DOK-INDRV*-GEN-**VRS**-PAxx-EN-P
Rexroth IndraDrive
Firmware for Drive Controllers Troubleshooting Guide DOK-INDRV*-GEN-**VRS**-WAxx-EN-P
1) In the document typecodes, "xx" is a wild card for the current edition
of the documentation (example: "FK01" is the first edition of a
Functional Description)
Fig. 1-11: Documentations - overview

1-12 System Presentation Rexroth IndraDrive Mi
DOK-INDRV*-KCU+KSM****-PR01-EN-P

Rexroth IndraDrive Mi Important Directions for Use 2-1
DOK-INDRV*-KCU+KSM****-PR01-EN-P
2 Important Directions for Use
2.1 Appropriate Use
Introduction
Rexroth products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note: Rexroth as manufacturer is not liable for any damages
resulting from inappropriate use. In such cases, the guarantee
and the right to payment of damages resulting from
inappropriate use are forfeited. The user alone carries all
responsibility of the risks.
Before using Rexroth products, make sure that all the pre-requisites for
an appropriate use of the products are satisfied:
•Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
•If the products take the form of hardware, then they must remain in
their original state, in other words, no structural changes are permitted.
It is not permitted to decompile software products or alter source
codes.
•Do not mount damaged or faulty products or use them in operation.
•Make sure that the products have been installed in the manner
described in the relevant documentation.
Areas of Use and Application
Drive controllers made by Rexroth are designed to control electrical
motors and monitor their operation.
Control and monitoring of the motors may require additional sensors and
actors.
Note: The drive controllers may only be used with the accessories
and parts specified in this document. If a component has not
been specifically named, then it may neither be mounted nor
connected. The same applies to cables and lines.
Operation is only permitted in the specified configurations and
combinations of components using the software and firmware
as specified in the relevant Functional Descriptions.
Every drive controller has to be programmed before commissioning,
making it possible for the motor to execute the specific functions of an
application.
The drive controllers have been developed for use in single- and multi-
axis drive and control tasks.
To ensure application-specific use, the drive controllers are available with
different drive power and different interfaces.

2-2 Important Directions for Use Rexroth IndraDrive Mi
DOK-INDRV*-KCU+KSM****-PR01-EN-P
Typical applications of the drive controllers include:
•handling and mounting systems,
•packaging and food machines,
•printing and paper processing machines and
•machine tools.
The drive controllers may only be operated under the assembly and
installation conditions described in this documentation, in the specified
position of normal use and under the ambient conditions as described
(temperature, degree of protection, humidity, EMC, etc.).
2.2 Inappropriate Use
Using the drive controllers outside of the operating conditions described in
this documentation and outside of the indicated technical data and
specifications is defined as "inappropriate use".
Drive controllers may not be used, if ...
•... they are subject to operating conditions that do not meet the
specified ambient conditions. This includes, for example, operation
under water, under extreme temperature fluctuations or extremely high
maximum temperatures.
•Furthermore, the drive controllers must not be used in applications
which have not been expressly authorized by Rexroth. Please carefully
follow the specifications outlined in the general Safety Instructions!