REXROTH Fe Series User manual

The Drive & Control Company
Rexroth Frequency Converter
Fe Series
Edition 11
Instruction Manual
R912001311

Rexroth Frequency Converter Fe
Instruction Manual
DOK-RCON01-FE*********-IB11-EN-P
RS-98646d080ba8386b0a6846a001a2e53b-5-en-US-5
Edition Release Date Notes
DOK-RCON01-FE*********-IB01-EN-P 2007-08 First Edition, applicable
to 0.75 to 7.5 kW
DOK-RCON01-FE*********-IB02-EN-P 2008-05 Applicable to 0.75 to 37
kW
DOK-RCON01-FE*********-IB03-EN-P 2008-06 Applicable to 0.75 to
110 kW
DOK-RCON01-FE*********-IB04-EN-P 2009-10 With CE, UL certification
DOK-RCON01-FE*********-IB05-EN-P 2010-03 Changed company infor‐
mation
DOK-RCON01-FE*********-IB06-EN-P 2010-08 Applicable to 0.75 to
160 kW
DOK-RCON01-FE*********-IB07-EN-P 2012-05 Improved layout and
added filter information
DOK-RCON01-FE*********-IB08-EN-P 2013-01 Changed "switch" to
"jumper"
DOK-RCON01-FE*********-IB09-EN-P 2013-11 Added new function
DOK-RCON01-FE*********-IB10-EN-P 2014-11 Added new function
DOK-RCON01-FE*********-IB11-EN-P 2014-12 Firmware upgrade
Reference For documentations available in other type or language, please consult your
local sales partner or check www.boschrexroth.com/fe.
Copyright © Bosch Rexroth (Xi'an) Electric Drives and Controls Co., Ltd. 2014
This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth (Xi'an) Electric Drives
and Controls Co., Ltd. It may not be reproduced or given to third parties with‐
out 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-RCON01-FE*********-IB11-EN-P
Rexroth Frequency Converter Fe

English Do not attempt to install or put these products into operation until you have
completely read, understood and observed the documents supplied with the
product.
If no documents in your language were supplied, please consult your Bosch
Rexroth sales partner.
Deutsch Nehmen Sie die Produkte erst dann in Betrieb, nachdem Sie die mit dem
Produkt gelieferten Unterlagen und Sicherheitshinweise vollständig
durchgelesen, verstanden und beachtet haben.
Sollten Ihnen keine Unterlagen in Ihrer Landessprache vorliegen, wenden
Sie sich an Ihren zuständigen Bosch Rexroth Vertriebspartner.
Français Ne mettez les produits en service qu'après avoir lu complètement et après
avoir compris et respecté les documents et les consignes de sécurité fournis
avec le produit.
Si vous ne disposez pas de la documentation dans votre langue, merci de
consulter votre partenaire Bosch Rexroth.
Italiano Mettere in funzione i prodotti solo dopo aver letto, compreso e osservato per
intero la documentazione e le indicazioni di sicurezza fornite con il prodotto.
Se non dovesse essere presente la documentazione nella vostra lingua, siete
pregati di rivolgervi al rivenditore Bosch Rexroth competente.
Español Los productos no se pueden poner en servicio hasta después de haber leído
por completo, comprendido y tenido en cuenta la documentación y las
advertencias de seguridad que se incluyen en la entrega.
Si no dispusiera de documentación en el idioma de su país, diríjase a su
distribuidor competente de Bosch Rexroth.
Português (Brasil) Utilize apenas os produtos depois de ter lido, compreendido e tomado em
consideração a documentação e as instruções de segurança fornecidas
juntamente com o produto.
Se não tiver disponível a documentação na sua língua dirija-se ao seu
parceiro de venda responsável da Bosch Rexroth.
Nederlands Stel de producten pas in bedrijf nadat u de met het product geleverde
documenten en de veiligheidsinformatie volledig gelezen, begrepen en in
acht genomen heeft.
Mocht u niet beschikken over documenten in uw landstaal, kunt u contact
opnemen met uw plaatselijke Bosch Rexroth distributiepartner.
Svenska Använd inte produkterna innan du har läst och förstått den dokumentation
och de säkerhetsanvisningar som medföljer produkten, och följ alla
anvisningar.
Kontakta din Bosch Rexroth återförsäljare om dokumentationen inte
medföljer på ditt språk.
Suomi Ota tuote käyttöön vasta sen jälkeen, kun olet lukenut läpi tuotteen mukana
toimitetut asiakirjat ja turvallisuusohjeet, ymmärtänyt ne ja ottanut ne
huomioon.
Jos asiakirjoja ei ole saatavana omalla äidinkielelläsi, ota yhteys
asianomaiseen Bosch Rexroth myyntiedustajaan.
Český Před uvedením výrobků do provozu si přečtěte kompletní dokumentaci a
bezpečnostní pokyny dodávané s výrobkem, pochopte je a dodržujte.
Nemáte-li k dispozici podklady ve svém jazyce, obraťte se na příslušného
obchodního partnera Bosch Rexroth.
DOK-RCON01-FE*********-IB11-EN-P
Rexroth Frequency Converter Fe
Bosch Rexroth AG I/227

Magyar Üzembe helyezés előtt olvassa el, értelmezze, és vegye figyelembe a
csomagban található dokumentumban foglaltakat és a biztonsági
útmutatásokat.
Amennyiben a csomagban nem talál az Ön nyelvén írt dokumentumokat,
vegye fel a kapcsolatot az illetékes Bosch Rexroth-képviselővel.
Polski Produkty wolno uruchamiać dopiero po przeczytaniu wszystkich dokumentów
dostarczonych wraz z produktem oraz wskazówek dotyczących
bezpieczeństwa i ich pełnym zrozumieniu. Wszystkich wskazówek tam
zawartych należy przestrzegać.
Jeżeli brak jest dokumentów w Państwa języku, proszę się skontaktować z
lokalnym partnerem handlowym Bosch Rexroth.
Πо русски Вводить изделие в эксплуатацию разрешается только после того, как Вы
полностью прочли, поняли и учли информацию, содержащуюся в
поставленных вместе с изделием документах, а также указания по
технике безопасности.
Если Вы не получили документацию на соответствующем национальном
языке, обращайтесь к полномочному представителю фирмы Bosch
Rexroth.
Română Punerea în funcţiune a produselor trebuie efectuată după citirea, înţelegerea
şi respectarea documentelor şi instrucţiunilor de siguranţă, care sunt livrate
împreună cu produsele.
În cazul în care documentele nu sunt în limba dumneavoastră maternă,
contactaţi furnizorul dumneavoastră competent pentru Bosch Rexroth.
Türkçe Ürünleri beraberinde teslim edilen evrakları ve güvenlik talimatlarını tamamen
okuduktan, anladıktan ve dikkate aldıktan sonrak i‚leme koyun.
Şayet size ulusal dilinizde evraklar teslim edilmemiş ise, sizinle ilgili olan
Bosch Rexroth dağıtım ortağınla irtibata geçin.
中文 请在完全通读、理解和遵守随同产品提供的资料和安全提示后才使用这些产
品。
若产品资料还未翻译成您本国语言，请联系 Bosch Rexroth 相应的销售伙伴。
日本語 本製品をお使いになる前に、必ず同封の文書および安全注意事項を全部お読
みになり理解した上で指示に従って本製品を使用していただきますようお願
いいたします。
同封の文書がお客様の言語で書かれていない場合は、どうぞ Bosch Rexroth
製品の販売契約店までお問い合わせください。
한국어 먼저 회사의 제품을 받으신 다음 제품과 함께 배송된 안내서 및 안전에 관한
지침서를 충분히 숙지하여 이를 준수하여 주십시오.
귀하의 모국어로 된 안내서가 배송되지 않았다면 Bosch Rexroth 대리점에 알
려주시기 바랍니다.
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Table of Contents
Page
1 Introduction.................................................................................................................... 7
1.1 About this Documentation....................................................................................................................... 7
1.2 Definition................................................................................................................................................. 8
1.3 Type Coding........................................................................................................................................... 9
1.3.1 Type Coding of Fe............................................................................................................................... 9
1.3.2 Type Coding of Fe Function Modules................................................................................................ 10
1.3.3 Type Coding of Fe Accessories......................................................................................................... 11
1.4 Delivery and Storage............................................................................................................................ 14
1.4.1 Brief Introduction............................................................................................................................... 14
1.4.2 The Scope of Supply......................................................................................................................... 14
1.4.3 Transport of the Components............................................................................................................ 15
1.4.4 Storage of the Components............................................................................................................... 15
1.5 Fe Description....................................................................................................................................... 16
1.5.1 Certification........................................................................................................................................ 16
1.5.2 Properties of the Basic Device Fe..................................................................................................... 19
1.5.3 Functions........................................................................................................................................... 20
1.5.4 Interfaces........................................................................................................................................... 20
1.5.5 Cooling Types.................................................................................................................................... 20
1.6 Version Matching Table........................................................................................................................ 21
2 Safety Instructions for Electric Drives and Controls..................................................... 23
2.1 Definitions of Terms.............................................................................................................................. 23
2.2 Explanation of signal words and the Safety alert symbol..................................................................... 24
2.3 General Information.............................................................................................................................. 24
2.3.1 Using the Safety Instructions and Passing Them on to Others......................................................... 24
2.3.2 Requirements for Safe Use............................................................................................................... 25
2.3.3 Hazards by Improper Use.................................................................................................................. 26
2.4 Instructions with Regard to Specific Dangers....................................................................................... 26
2.4.1 Protection against Contact with Electrical Parts and Housings......................................................... 26
2.4.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 27
2.4.3 Protection against Dangerous Movements........................................................................................ 28
2.4.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 29
2.4.5 Protection against contact with hot parts........................................................................................... 29
2.4.6 Protection during handling and mounting.......................................................................................... 30
3 Important Directions for Use........................................................................................ 31
3.1 Appropriate Use.................................................................................................................................... 31
3.2 Inappropriate Use................................................................................................................................. 31
4 Fe Mounting................................................................................................................. 33
4.1 Mounting............................................................................................................................................... 33
4.2 Fe Dimensions and Figure.................................................................................................................... 35
4.2.1 Fe Dimensions................................................................................................................................... 35
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Table of Contents

Page
4.2.2 Fe Figure........................................................................................................................................... 36
5 Installation.................................................................................................................... 39
5.1 Fe Opening Instruction......................................................................................................................... 39
5.2 Drive System Wiring............................................................................................................................. 46
5.2.1 Block Diagram................................................................................................................................... 46
5.2.2 Main Circuit Wiring............................................................................................................................ 47
5.2.3 Control Circuit Wiring......................................................................................................................... 50
5.2.4 Cable and Fuse Dimensions............................................................................................................. 50
5.3 Wiring Terminals Description................................................................................................................ 56
5.3.1 Main Circuit Terminals....................................................................................................................... 56
5.3.2 Control Circuit Terminals................................................................................................................... 58
5.3.3 Jumper Wiring................................................................................................................................... 61
5.3.4 NPN / PNP Mode Selection............................................................................................................... 61
6 Commissioning............................................................................................................ 63
6.1 Operating Panel.................................................................................................................................... 63
6.1.1 Overview............................................................................................................................................ 63
6.1.2 3-Level Menu Structure..................................................................................................................... 64
6.1.3 Operation Mode Description.............................................................................................................. 65
6.1.4 Example of Operating Panel Operation............................................................................................. 67
6.2 Commission Process............................................................................................................................ 69
6.2.1 Check and Preparation before Commissioning................................................................................. 69
6.2.2 Notes on Commissioning................................................................................................................... 69
6.2.3 Fe Basic Parameter Fast Setting....................................................................................................... 70
6.2.4 Commissioning of Fe with Potentiometer.......................................................................................... 71
6.3 Restore Parameters to Factory Defaults.............................................................................................. 71
6.4 Solutions for Simple Faults during Commissioning.............................................................................. 72
7 Parameter Settings...................................................................................................... 73
7.1 Description of Attribute Symbols in Parameter Tables......................................................................... 73
7.2 Parameters List..................................................................................................................................... 74
7.2.1 Category b: Basic Parameters........................................................................................................... 74
7.2.2 Category E: Extended Parameters.................................................................................................... 79
7.2.3 Category P: Programmable Control Parameters............................................................................... 85
7.2.4 Category H: Advanced Parameters................................................................................................... 87
7.3 Notes on Function Groups.................................................................................................................... 91
7.3.1 Category b: Basic Parameters........................................................................................................... 91
7.3.2 Category E: Extended Parameters.................................................................................................. 114
7.3.3 Category P: Programmable Control Parameters............................................................................. 134
7.3.4 Category H: Advanced Parameters................................................................................................. 140
7.3.5 Category d: Monitoring Parameters................................................................................................. 151
8 Error Indication........................................................................................................... 153
8.1 Error Types ........................................................................................................................................ 153
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Page
8.2 List of Error Protection Actions .......................................................................................................... 155
9 Technical Data........................................................................................................... 157
9.1 Fe General Technical Data................................................................................................................. 157
9.2 Derating of Electrical Data.................................................................................................................. 159
9.2.1 Derating and Ambient Temperature................................................................................................ 159
9.2.2 Derating and Mains Voltage............................................................................................................ 160
9.2.3 Derating and Output Current........................................................................................................... 161
9.3 Electrical Data (400 V Series)............................................................................................................. 162
9.4 Electromagnetic Compatibility (EMC)................................................................................................. 163
9.4.1 EMC Requirements......................................................................................................................... 163
9.4.2 Ensuring the EMC Requirements.................................................................................................... 167
9.4.3 EMC Measures for Design and Installation..................................................................................... 168
10 Accessories................................................................................................................ 177
10.1 EMC Filter........................................................................................................................................... 177
10.1.1 The Function of EMC Filter.............................................................................................................. 177
10.1.2 EMC Filter Type............................................................................................................................... 177
10.1.3 Technical Data................................................................................................................................. 178
10.2 Brake Components............................................................................................................................. 184
10.2.1 Brake Chopper................................................................................................................................ 184
10.2.2 Brake Resistor................................................................................................................................. 189
10.3 Communication Interface.................................................................................................................... 197
10.3.1 PROFIBUS Adapter......................................................................................................................... 197
10.3.2 RS232 / RS485 Adapter.................................................................................................................. 197
10.3.3 Cable for PROFIBUS Adapter......................................................................................................... 197
10.3.4 Cable between Frequency Converter and RS232 / RS485 Adapter............................................... 197
10.4 Accessories for Control Cabinet Mounting......................................................................................... 197
10.4.1 Operating Panel for Control Cabinet Mounting................................................................................ 197
10.4.2 Operating Panel Cable for Control Cabinet Mounting..................................................................... 199
10.4.3 Operating Panel with Potentiometer for Converters above 11K0.................................................... 199
10.5 Engineering Software......................................................................................................................... 199
11 Additional Information................................................................................................ 201
11.1 Running Setting Diagram.................................................................................................................... 201
11.2 Process Control.................................................................................................................................. 202
11.2.1 Process Control Illustration.............................................................................................................. 202
11.2.2 Simple Applications of Process Control........................................................................................... 202
11.3 Discharging of Capacitors................................................................................................................... 204
11.3.1 Discharging of DC Bus Capacitors.................................................................................................. 204
11.3.2 Discharging Device.......................................................................................................................... 204
12 Communication Protocols.......................................................................................... 207
12.1 Brief Introduction................................................................................................................................. 207
12.2 ModBus Protocol................................................................................................................................ 207
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Table of Contents

Page
12.2.1 Protocol Description........................................................................................................................ 207
12.2.2 Interface........................................................................................................................................... 208
12.2.3 Protocol Functions........................................................................................................................... 209
12.2.4 Communication Mapping Register Address Distribution................................................................. 213
12.2.5 ModBus Communication Example.................................................................................................. 216
12.2.6 Communication Networking............................................................................................................. 217
13 Service and support................................................................................................... 219
14 Environmental protection and disposal ..................................................................... 221
14.1 Environmental protection.................................................................................................................... 221
14.2 Disposal.............................................................................................................................................. 221
Index.......................................................................................................................... 223
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Table of Contents

1 Introduction
1.1 About this Documentation
Personal injury and property damage caused
by incorrect project planning for applications,
machines and installations!
WARNING
Do not attempt to install or put these products into operation until you have
completely read, understood and observed the documents supplied with the
product.
If no documents in your language were supplied, please consult your
Bosch Rexroth sales partner.
Chapters and contents
Chapter Title Description
1 Introduction Overview
2Safety Instructions for Electric Drives and
Controls Safety cautions
3 Important Directions for Use
4 Fe Mounting Product information
(project specific)
5 Installation
6 Commissioning
Actual applications
(for operators and repairers)
7 Parameter Settings
8 Error Indication
9 Technical Data
10 Accessories
11 Additional Information
12 Communication Protocols
13 Service and Support Service information
14 Environmental Protection and Disposal Environmental information
– Index Index information
Tab. 1-1: Chapters and contents
Feedback Your experience is important for us to improve products and this manual. We
will be pleased to receive your feedback on any mistake or request for varia‐
tion.
Please send your feedback via email to:
[email protected]
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Introduction

1.2 Definition
Rexroth Frequency Converter Fe drive system is composed of individual
parts (components) for application in different circumstances.
● Fe: Rexroth Frequency Converter Fe
● FECC: Fe operating panel
● FSWA: Engineering software
● FEAA: Interface adapter
● FRKB: Interface adapter cable
● FRKS: Operating panel cable
● FELR: Brake resistor
● FELB: External brake chopper
● FENF: EMC filter
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Introduction

1.3 Type Coding
1.3.1 Type Coding of Fe
Fig. 1-1: Type coding of Fe
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Introduction

1.3.2 Type Coding of Fe Function Modules
Operating panel type coding
Fig. 1-2: Operating panel type coding
Engineering software type coding
Fig. 1-3: Engineering software type coding
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Introduction

1.3.3 Type Coding of Fe Accessories
Interface adapter type coding
Fig. 1-4: Interface adapter type coding
Interface adapter cable type coding
Fig. 1-5: Interface adapter cable type coding
Operating panel cable type coding
Fig. 1-6: Operating panel cable type coding
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Introduction

Brake resistor type coding
Fig. 1-7: Brake resistor type coding
Brake chopper type coding
Fig. 1-8: Brake chopper type coding
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Introduction

EMC filter type coding
Fig. 1-9: EMC filter type coding
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Introduction

1.4 Delivery and Storage
1.4.1 Brief Introduction
Check the unit for transport damages, e.g. deformation or loose parts, imme‐
diately after receipt/unpacking. In case of damage, contact the forwarder at
once and arrange for a thorough review of the situation.
This is also applicable if the packaging is undamaged.
1.4.2 The Scope of Supply
Standard supply
● Frequency Converter Fe, protection class of IP 20
(Control cabinet mounting)
● Internal brake chopper (0K75...15K0)
● Operating panel
● Safety Instructions
● Instruction Manual (UL)
● Instruction Manual (Quick Start)
Optional accessories
● Instruction Manual
● Operating panel for control cabinet mounting
● Operating panel with potentiometer (11K0...160K)
● PROFIBUS adapter
● RS232/485 adapter
● Engineering software
● EMC filter (EN 61800-3 Environment 2)
● Motor filter (dV/dt filter)
● Mains choke
● Brake resistor
● External brake chopper (18K5...160K)
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Introduction

1.4.3 Transport of the Components
Ambient and operating conditions - Transport
Description Symbol Unit Value
Temperature range Ta_store ℃ -25…70
Relative humidity – % 5…95
Absolute humidity – g/m31…60
Climate category (IEC 721) – – 2K3
Moisture condensation – – not allowed
Icing – – not allowed
Tab. 1-2: Transport conditions
1.4.4 Storage of the Components
Damage to the components caused by long
storage periods!
CAUTION
Frequency converters contain electrolytic capacitors which may deteriorate
during storage.
When storing frequency converters for a long period of time, operate them
once a year for at least 1 hour with power on:
● Fe with mains voltage ULN
● FELB with DC bus voltage UDC
Ambient and operating conditions - Storage
Description Symbol Unit Value
Temperature range Ta_store ℃ -25…55
Relative humidity – % 5…95
Absolute humidity – g/m31…29
Climate category (IEC 721) – – 1K3
Moisture condensation – – not allowed
Icing – – not allowed
Tab. 1-3: Storage conditions
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Introduction

1.5 Fe Description
1.5.1 Certification
CE certification
Declaration of conformity For Fe, there are declarations of conformity which confirm that the frequency
converters comply with the applicable EN standards and EC Directives. If re‐
quired, you may ask our sales representative for the declarations of conformi‐
ty.
EU directives Standard
Low-Voltage Directive 2006/95/EC EN 61800-5-1
(IEC 61800-5-1: 2007)
EMC Directive 2004/108/EC EN 61800-3
(IEC 61800-3: 2004)
Tab. 1-4: EU directives and standards
CE label
Fig. 1-10: CE label
High-voltage test According to standard EN 61800-5-1, all Fe components are tested with high
voltage.
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Introduction

UL certification
The frequency converters are listed by UL "Underwriters Laboratories Inc.®".
You can find the evidence of certification on the Internet under http://
www.ul.com under “Certifications” by entering the file number or the “Compa‐
ny Name: Rexroth”.
UL listing
Fig. 1-11: UL listing
UL standard UL 508C
Company name BOSCH REXROTH (XIAN) ELECTRIC DRIVES and CONTROLS CO., LTD.
Category name Power Conversion Equipment
File number E328841
UL ratings For using the components in the scope of UL, take the UL ratings of the indi‐
vidual component into account.
Make sure that the indicated short circuit rating SCCR is not exceeded
(0K75...90K0: 5,000 Arms; 110K...160K: 42,000 Arms), e.g. by appropriate
fuses in the power supply lines.
UL wiring material In the scope of UL, use copper 60 ℃ or above only.
For 45K0...160K frequency converters, use copper 75 ℃ or above only.
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Introduction

RCM
Frequency converters Fe comply with the relevant ACMA standards made
under the Radiocommunications Act 1992 and the Telecommunications Act
1997.These standards are referenced in notices made under section 182 of
the Radiocommunications Act and 407 of the Telecommunications Act.
RCM label
Fig. 1-12: RCM label
RCM standard EN 61800-3:2004, Adjustable speed electrical power drive systems - Part3:
EMC requirements and specific test methods
ACMA supplier code E1066
CAN, ABN or ARBN ABN / IRDN 89003258384
Category Fe complies with the applicable requirements detailed in EN 61800-3:2004
(Category 3 limits) and is not intended to be used directly on a low-voltage
public network which supplies domestic premises. Radio frequency interfer‐
ence is expected if used on such a network, in which supplementary mitiga‐
tion measures are required.
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Introduction