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Bosch Rexroth IndraDrive Mi Project Planning Manual
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Bosch Rexroth IndraDrive Mi Project Planning Manual

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

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Summary of Contents for Bosch Rexroth IndraDrive Mi

  • Page 1 Electric Drives Linear Motion and and Controls Hydraulics Assembly Technologies Pneumatics Service Rexroth IndraDrive Mi R911320924 Edition 01 Drive Systems Project Planning Manual...
  • Page 2 Notes DOK-INDRV*-KCU+KSM****-PR01-EN-P 2007-04 First edition  Bosch Rexroth AG 2007 Copyright 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).

  • Page 3: Table Of Contents

    Contents Contents System Presentation Introduction ........................... 1-1 Rexroth IndraDrive Mi......................1-1 Features........................... 1-1 Drive System Rexroth IndraDrive Mi .................... 1-2 Components ..........................1-2 System Structure ........................1-3 Overview of Functions ......................1-5 Type Code ............................ 1-5 Introduction ..........................1-5 Distributed Servo Drive KSM....................1-6 Electronic Control System KCU....................
  • Page 4 Contents Rexroth IndraDrive Mi General Specification of the Components Certifications ..........................4-1 Transport and Storage........................4-2 Transporting the Devices......................4-2 Storing the Devices ......................... 4-2 Installation Conditions........................4-2 Ambient and Operating Conditions..................4-2 Type of Construction and Mounting Positions................. 4-4 Compatibility with Foreign Matters ..................
  • Page 5 Rexroth IndraDrive Mi Contents 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 Notes on Project Planning Notes on Mechanical Project Planning..................7-1 Mounting Clearance ........................ 7-1 Output Shaft..........................
  • Page 6 Contents Rexroth IndraDrive Mi 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 ...................

  • Page 7: System Presentation

    System Presentation System Presentation 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.

  • Page 8: Drive System Rexroth Indradrive Mi

    System Presentation Rexroth IndraDrive Mi In the following points, the system solution Rexroth IndraDrive Mi differs Differences to Rexroth IndraDrive and Rexroth IndraDyn 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.

  • Page 9: System Structure

    Rexroth IndraDrive Mi System Presentation The electronic control system KCU 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 •...
  • Page 10 System Presentation Rexroth IndraDrive Mi transformer (optional) fuses HMD, HMS inverter supply unit mains filter mains choke electronic control system distributed servo drive servo motor 24V supply mains contactor (for supply units without integrated mains contactor, e.g. HMV01.2R-W0120) terminal connector X3.2...

  • Page 11: Overview Of Functions

    Rexroth IndraDrive Mi System Presentation 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: •...

  • Page 12: Distributed Servo Drive Ksm

    System Presentation Rexroth IndraDrive Mi Distributed Servo Drive KSM Type Code Fig. 1-4: Type code KSM DOK-INDRV*-KCU+KSM****-PR01-EN-P...
  • Page 13 Abbrev. column 17 • Motor encoder Abbrev. column 19 20 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...
  • Page 14 System Presentation Rexroth IndraDrive Mi • Holding brake Abbrev. column 24 Distributed servo drives KSM can be optionally supplied with electrically released holding brakes. Option Holding brake without holding brake with holding brake For holding torque, see individual data sheets.

  • Page 15: Electronic Control System Kcu

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

  • Page 16: Guide To The Documentation

    1-10 System Presentation Rexroth IndraDrive Mi Guide to the Documentation Documentation Structure Chapter Title Contents System Presentation general information Important Directions for Use safety Safety Instructions General Specification of the Components Technical Data of the Components product description (for those doing project planning)
  • Page 17 1-11 Rexroth IndraDrive Mi System Presentation Firmware Title Kind of documentation Document typecode Rexroth IndraDrive Functional and Application DOK-INDRV*-SI*-**VRS**-FKxx-EN-P Integrated Safety Technology Description Rexroth IndraDrive Functional Description DOK-INDRV*-MP*-04VRS**-FKxx-EN-P Firmware for Drive Controllers or higher Rexroth IndraDrive Parameter Description DOK-INDRV*-GEN-**VRS**-PAxx-EN-P Firmware for Drive Controllers...
  • Page 18 1-12 System Presentation Rexroth IndraDrive Mi DOK-INDRV*-KCU+KSM****-PR01-EN-P...

  • Page 19: Important Directions For Use

    Rexroth IndraDrive Mi Important Directions for Use Important Directions for Use Appropriate Use Introduction Rexroth products represent state-of-the-art developments 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.

  • Page 20: Inappropriate Use

    Important Directions for Use Rexroth IndraDrive Mi 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...

  • Page 21: Safety Instructions For Electric Drives And Controls

    Follow these safety instructions at all times. • Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. • Read the operating, maintenance and safety instructions in your language before starting up the machine.
  • Page 22 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Mi • The devices have been designed for installation in industrial machinery. • The ambient conditions given in the product documentation must be observed. • Only use safety-relevant applications that are clearly and explicitly approved in the Project Planning Manual.

  • Page 23: Explanation Of Warning Symbols And Degrees Of Hazard Seriousness

    Rexroth IndraDrive Mi Safety Instructions for Electric Drives and Controls Explanation of Warning Symbols and Degrees of Hazard Seriousness The safety instructions describe the following degrees of hazard seriousness. The degree of hazard seriousness informs about the consequences resulting from non-compliance with the safety instructions:...
  • Page 24 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Mi Hot surfaces on device housing! Danger of injury! Danger of burns! CAUTION Risk of injury by improper handling! Risk of bodily injury by bruising, shearing, cutting, hitting or improper handling of pressurized...

  • Page 25: Instructions With Regard To Specific Dangers

    Rexroth IndraDrive Mi Safety Instructions for Electric Drives and Controls Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts Note: This section only concerns devices and drive components with voltages of more than 50 volts. Contact with parts conducting voltages above 50 volts can cause personal danger and electric shock.
  • Page 26 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Mi ⇒ With electrical drive and filter components, observe the following: Wait 30 minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch.

  • Page 27: Protection Against Electric Shock By Protective Extra-Low Voltage (Pelv)

    Rexroth IndraDrive Mi Safety Instructions for Electric Drives and Controls Protection Against Electric Shock by Protective Extra-Low Voltage (PELV) All connections and terminals with voltages between 5 and 50 volts at Rexroth products are protective extra-low voltage systems which are provided with touch guard according to the product standards.
  • Page 28 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Mi Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! ⇒ For the above reasons, ensure personal safety by means of qualified and tested higher-level monitoring DANGER devices or measures integrated in the installation.

  • Page 29: Protection Against Magnetic And Electromagnetic Fields During Operation And Mounting

    Rexroth IndraDrive Mi Safety Instructions for Electric Drives and Controls ⇒ Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: maintenance and repair work cleaning of equipment - long periods of discontinued equipment use ⇒...

  • Page 30: Protection Against Contact With Hot Parts

    3-10 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Mi Protection Against Contact with Hot Parts Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of burns! ⇒ Do not touch surfaces of device housings and...

  • Page 31: Protection During Handling And Mounting

    3-11 Rexroth IndraDrive Mi Safety Instructions for Electric Drives and Controls Protection During Handling and Mounting In unfavorable conditions, handling and assembling certain parts and components in an improper way can cause injuries. Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting! ⇒...

  • Page 32: Protection Against Pressurized Systems

    3-12 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Mi Protection Against Pressurized Systems According to the information given in the Project Planning Manuals, motors cooled with liquid and compressed air, as well as drive controllers, can be partially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids, and cooling lubricating agents.

  • Page 33: General Specification Of The Components

    Rexroth IndraDrive Mi General Specification of the Components General Specification of the Components Certifications Declaration of Conformity For the components, there are declarations of conformity available which confirm that the components have been designed according to the valid EN standards and EC directives. If required, our sales representative can provide you with the declarations of conformity.

  • Page 34: Transport And Storage

    General Specification of the Components Rexroth IndraDrive Mi Transport and Storage Transporting the Devices Description Symbol Unit Value temperature range °C -25 … 70 a_tran relative humidity 5 … 95 absolute humidity 1 … 60 climatic category (IEC721) moisture condensation...
  • Page 35 Rexroth IndraDrive Mi General Specification of the Components Description Symbol Unit Value KCU Value KSM degree of protection (IEC529) IP20 IP65 allowed mounting position IM V1, IM V3, IM B5 allowed ambient temperature range °C 0 … 40 a_work 0 … 55 allowed ambient temperature range during °C...

  • Page 36: Type Of Construction And Mounting Positions

    (e.g. lubricants in machine tools) which may interact with our controls and drives, it cannot be completely ruled out that any reactions with the materials used by Bosch Rexroth might occur. For this reason, before using the respective material a compatibility test has to be carried out for new lubricants, cleaning agents etc.

  • Page 37: Capacity Utilization

    Rexroth IndraDrive Mi General Specification of the Components It is permitted to provide the housing with additional varnish with a maximum coat thickness of 40 µm. Before varnishing, verify the adhesion and resistance of the new varnish. Capacity Utilization Where installation conditions differ, the following performance data are...
  • Page 38 General Specification of the Components Rexroth IndraDrive Mi As the installation altitude increases, the capacity utilization of the Capacity Utilization vs. Installation Altitude components is reduced according to the figure below. capacity utilization factor maximum installation altitude for operation with nominal data...

  • Page 39: Technical Data Of The Components

    Rexroth IndraDrive Mi Technical Data of the Components Technical Data of the Components Explanation of Terms and Definitions Data sheet KSM - Distributed servo drive with holding brake (optional) Description Symbol Unit Definition listing according to UL standard (UL) standard according to which UL listing takes place...
  • Page 40 Technical Data of the Components Rexroth IndraDrive Mi Description Symbol Unit Definition R.m.s. value of the induced motor voltage at motor constant voltage at 20 °C V/min temperature 20 °C and 1000 revolutions per minute. EMK_1000 Unit (V/1000min rotor inertia...
  • Page 41 Rexroth IndraDrive Mi Technical Data of the Components The motor data and characteristics are determined under the following Motor Data conditions: • ambient temperature 40 °C • insulated structure (aluminum flange) • Amplifier temperature P-0-0384 = 100 °C (∆T = 60 K);...
  • Page 42 EN 60034-1; 1998) and max. cycle duration 1 min. Rexroth IndraDrive Mi, controlled infeed DC 750 V Rexroth IndraDrive Mi, uncontrolled infeed 3 × AC 400 V. The voltage drop on the supply line has not been taken into account.

  • Page 43: Distributed Servo Drive Ksm

    Rexroth IndraDrive Mi Technical Data of the Components Distributed Servo Drive KSM KSM Data Sheet Data sheet KSM - Distributed servo drive with holding brake (optional) KSM01. KSM01. KSM01. KSM01. KSM01. KSM01. Description Symbol Unit 041C-42 061C-35 061C-61 071C-24 071C-35...
  • Page 44 Technical Data of the Components Rexroth IndraDrive Mi KSM01. KSM01. KSM01. KSM01. KSM01. KSM01. Description Symbol Unit 041C-42 061C-35 061C-61 071C-24 071C-35 076C-35 maximum speed 5500 4300 6000 3400 4700 insulation class according to DIN EN 60034–1 Data optional holding brake...

  • Page 45: Ksm Characteristics

    Rexroth IndraDrive Mi Technical Data of the Components KSM Characteristics KSM01.2B-041C-42 S1, S3 characteristics apply to a PWM frequency of 4 kHz IndraDrive, controlled infeed (1) 3x AC 400V) IndraDrive, uncontrolled infeed (2) 3x AC 480V) (3) 3x AC (2)(3)(4) M 440V) (4) 3x AC 400V) Fig.
  • Page 46 Technical Data of the Components Rexroth IndraDrive Mi KSM01.2B-061C-61 S1, S3 characteristics apply to a PWM frequency of 4 kHz IndraDrive, controlled infeed (1) 3x AC 400V) IndraDrive, uncontrolled infeed (2) 3x AC 480V) (3) 3x AC (2)(3)(4) M 440V) (4) 3x AC 400V) Fig.
  • Page 47 Rexroth IndraDrive Mi Technical Data of the Components KSM01.2B-071C-35 S1, S3 characteristics apply to a PWM frequency of 4 kHz IndraDrive, controlled infeed (1) 3x AC 400V) IndraDrive, uncontrolled infeed (2) 3x AC 480V) (3) 3x AC (2)(3)(4) M 440V) (4) 3x AC 400V) Fig.

  • Page 48: Dimensions And Technical Design

    5-10 Technical Data of the Components Rexroth IndraDrive Mi Dimensions and Technical Design Dimensions 78.8 149.1 78.55 16.25 KSM01.2B-041 KSM01.2B-061 86.8 157.1 81.05 16.25 102.3 74.5 172.6 83.55 16.25 KSM01.2B-071 102.3 74.5 172.6 83.55 16.25 KSM01.2B-076 dimension R: brackets open Fig.
  • Page 49 5-11 Rexroth IndraDrive Mi Technical Data of the Components According to DIN 42955, ed. 12.81(IEC 60072-1) Concentricity, Run-Out and Alignment Encoder Concentricity tolerance Run-out and alignment tolerance S1, M1 S2, M2 Fig. 5-14: Tolerance for concentricity, run-out and alignment, depending on...

  • Page 50: Bearings And Shaft Load

    5-12 Technical Data of the Components Rexroth IndraDrive Mi Bearings and Shaft Load For additional information on • allowed radial and axial forces • shaft load • bearings see chapter "Notes on Project Planning" Radial Force F radial Fig. 5-16: KSM01.2B-041: allowed radial force (shaft and bearings load)
  • Page 51 5-13 Rexroth IndraDrive Mi Technical Data of the Components Fig. 5-18: KSM01.2B-071: allowed radial force (shaft and bearings load) Fig. 5-19: KSM01.2B-076: allowed radial force (shaft and bearings load) Axial Force F axial Type Maximum allowed axial force in [N] KSM01.2B-041...

  • Page 52: Electronic Control System Kcu

    5-14 Technical Data of the Components Rexroth IndraDrive Mi Electronic Control System KCU Brief Description and Applications The electronic control system fulfills the following functions: • transmission of power supply of KSM • conversion from SERCOS (fiber optic cable) to RS422 •...
  • Page 53 5-15 Rexroth IndraDrive Mi Technical Data of the Components plus dissipation of braking resistor (HMV, HCS) and control section (HMx, HCS) according to DIN EN ISO 11205; comparative value at distance 1 m, out of cabinet; HCS types with order code -L***: load-dependent...
  • Page 54 5-16 Technical Data of the Components Rexroth IndraDrive Mi Mechanical System and Mounting Dimensions Fig. 5-23: Dimensions DOK-INDRV*-KCU+KSM****-PR01-EN-P...

  • Page 55: Hybrid Cables Rkh

    5-17 Rexroth IndraDrive Mi Technical Data of the Components Hybrid Cables RKH Technical Data Description Unit Ready-made hybrid cables RKH cable brief description [5x2,5mm² + 5x0,34mm²+(2x2x0,34mm²)C]StC temperature range during storage °C -30 °C to +60 °C ambient temperature during operation °C...
  • Page 56 5-18 Technical Data of the Components Rexroth IndraDrive Mi The cables coming from the electronic control system KCU must be Ready-Made Hybrid Cables plugged in the connection point X3.2 of KSM. KSM X3.1 KSM X3.1 KSM X3.2 KSM X3.2 (A-side)

  • Page 57: Interconnection Diagrams For Ready-Made Hybrid Cables

    5-19 Rexroth IndraDrive Mi Technical Data of the Components Interconnection Diagrams for Ready-Made Hybrid Cables Connector pin assignment hybrid cable (between supply unit and first Hybrid Cables (Between KCU KSM) and First KSM) Applies to RKH0301 RKH0401 plug-in connector KCU...
  • Page 58 5-20 Technical Data of the Components Rexroth IndraDrive Mi Both ends have been differently marked (R-End / L-End). Hybrid Cables (Between two KSMs) Applies to RKH0001 RKH0002 RKH0100 RKH0200 RKH0101 RKH0201 plug-in connector KSM non-assembled cable plug-in connector KSM RHS0001/C03...
  • Page 59 5-21 Rexroth IndraDrive Mi Technical Data of the Components At the last KSM, the terminal connector is plugged in the unassigned Terminal Connector connection (X3.1 or X3.2). It has two functions: • It closes the SERCOS ring and • it contains the pull-up resistor for power enable Bb_V for the supply unit (power off when a connector is removed).
  • Page 60 5-22 Technical Data of the Components Rexroth IndraDrive Mi DOK-INDRV*-KCU+KSM****-PR01-EN-P...

  • Page 61: Connection Points

    Rexroth IndraDrive Mi Connection Points Connection Points Connection Points of System Equipment Grounding Conductor connection point of equipment grounding conductor at supply unit with connection to equipment grounding system joint bars connect equipment grounding conductors of neighboring devices hybrid cables connect equipment grounding conductors of KSMs with one another and with equipment grounding conductor of KCU Fig.

  • Page 62: Ground Connection

    Connection Points Rexroth IndraDrive Mi Ground Connection Damage to the devices by voltage arcing! ⇒ For applications which can produce high static charging (e.g. printing, packaging), the impedance from the connection point of the machine to the drive CAUTION system must not be more than 8 ohm (e.g.

  • Page 63: Connection Points Of Kcu

    Rexroth IndraDrive Mi Connection Points Connection Points of KCU Positions of the Connection Points Fig. 6-2: Electronic control system KCU (left: front, right: bottom) Element Significance Notes connection point equipment grounding for connection to the equipment grounding system conductor joint bar equipment grounding conductor...

  • Page 64: X1, Module Bus

    Connection Points Rexroth IndraDrive Mi Element Significance Notes 24 V, control voltage connection for connection to supply unit via contact bars (part of basic accessory HAS01) L+, L- DC bus connection for connection to supply unit via contact bars (part of basic accessory HAS01)

  • Page 65: X20 Tx, X21 Rx (Sercos Interface)

    Rexroth IndraDrive Mi Connection Points X20 TX, X21 RX (SERCOS interface) Risk of damage! ⇒ The maximum tightening torque of the union nut at the coupling elements of the fiber optic cables is 0.6 Nm. CAUTION Description Fig. 6-4: SERCOS interface...

  • Page 66: X50, E-Stop Input

    Connection Points Rexroth IndraDrive Mi X50, E-Stop Input Complies with EN61131-2 View Connection Signal name Function 24V output for E-Stop input E_Stop digital input for E-Stop, isolated; active with input voltage "L" 0V output for E-Stop input condition as supplied:...

  • Page 67: X52, Status Messages

    Rexroth IndraDrive Mi Connection Points X52, Status Messages Distributed servo drives KSM have no module bus connection. Connection to the overall system takes place via the electronic control system KCU. View Connection Signal name Function ______ E-Stop Bb_V _____ internal signals between...

  • Page 68: X54, Dc Bus, Equipment Grounding Conductor Output Ksm

    Connection Points Rexroth IndraDrive Mi X54, DC Bus, Equipment Grounding Conductor Output KSM View Connection Function DC bus; negative pole equipment grounding conductor DC bus; positive pole Spring terminal (connector at hybrid cable) Unit Min. Max. connection cable stranded wire n.s.

  • Page 69: Dc Bus Connection L+, L

    Rexroth IndraDrive Mi Connection Points DC Bus Connection L+, L- Lethal electric shock caused by live parts with more than 50 V! ⇒ Wait at least 30 minutes after switching off power to allow discharging. To shorten the waiting time until...
  • Page 70 6-10 Connection Points Rexroth IndraDrive Mi Fig. 6-12: Connection by contact bars If in special cases it is not possible to use the contact bars provided to Notes on Installation establish the connection, the connection must be established using the shortest possible (2 ×...

  • Page 71: Control Voltage Supply +24V, 0V

    6-11 Rexroth IndraDrive Mi Connection Points Control Voltage Supply +24V, 0V View Identification Function power supply +24V connection to neighboring devices with contact bars from the HAS01.1 accessory reference potential for power supply connection to neighboring devices with contact bars from the HAS01.1 accessory...

  • Page 72: Connection Accessory

    6-12 Connection Points Rexroth IndraDrive Mi Connection Accessory Strain Relief and Shield Connection The accessory HAS02.1-015-NNN-NN is used to • provide the hybrid cable with a strain relief • connect the shield of the hybrid cable to the electronic control system...

  • Page 73: Connection Points Of Ksm

    6-13 Rexroth IndraDrive Mi Connection Points Connection Points of KSM Positions of the Connection Points SERCOS address selector switch (10×) SERCOS address selector switch (1×) serial interface (RS232) X3.1, X3.2 hybrid cable MultiMediaCard X37, X38 digital inputs/outputs Fig. 6-15: Connection points of KSM...

  • Page 74: X2 Serial Interface, Service Input "Release Brake

    6-14 Connection Points Rexroth IndraDrive Mi X2 Serial Interface, Service Input "Release Brake" View Connection Signal name Function reference potential Receive Data Transmit Data Request To Send n. c. reserved, not connected n. c. reserved, not connected input "release brake": connect X2.1 to X2.2 to release brake...

  • Page 75: X3.1, X3.2 Connection Point Hybrid Cable

    6-15 Rexroth IndraDrive Mi Connection Points X3.1, X3.2 Connection Point Hybrid Cable View Connection Signal name Function equipment grounding conductor power supply, DC 750 V, 25 A 42V supply, max. 5 A Bb_A _____ Warn control signals (24 V) Bb_V...

  • Page 76: X7 Connection Point Multimediacard (Mmc)

    6-16 Connection Points Rexroth IndraDrive Mi X7 Connection Point MultiMediaCard (MMC) Fig. 6-18: X7 A MultiMediaCard (MMC; product name: PFM02) is contained in the scope of supply of the distributed servo drive KSM. Description X7 is used for reading and storing data (firmware, drive parameters, operating data) from or on the MultiMediaCard.

  • Page 77: X37, X38 Digital Inputs/Outputs

    6-17 Rexroth IndraDrive Mi Connection Points X37, X38 Digital Inputs/Outputs View Connection Signal name Function external supply X37.1 19…30 V, max. 1 A, connected to X38.1 X37.2 I/O_3 dig. I/O, configurable reference potential; X37.3 external supply, connected to X38.3 dig. I/O, configurable, X37.4...
  • Page 78 6-18 Connection Points Rexroth IndraDrive Mi Data: Inputs Data Unit Min. Typ. Max. allowed input voltage input current input resistance kΩ non-linear, varies depending on input voltage sampling frequency depending on firmware control delay µs 100 + 1 cycle time of...
  • Page 79 6-19 Rexroth IndraDrive Mi Connection Points Data: Outputs Data Unit Min. Typ. Max. output voltage ON - 0,5 output voltage OFF output current OFF 0,05 allowed output current per output allowed output current total 1000 or per group update interval...

  • Page 80: Ground Connection

    6-20 Connection Points Rexroth IndraDrive Mi Ground Connection View Connection Signal name Function Connection point for low-impedance additional connection to earth-circuit connectors, ground for example, in the case of interference connection in the drive system. Thread M4 (for ring cable lug)

  • Page 81: Notes On Project Planning

    Note: Modifications to the keys may be made only by the user himself and on his own responsibility. Bosch Rexroth does not provide any warranty for modified keys or motor shafts. DOK-INDRV*-KCU+KSM****-PR01-EN-P...
  • Page 82 Notes on Project Planning Rexroth IndraDrive Mi Output Shaft With Shaft Sealing Ring The motors have been designed with radial shaft sealing rings according to DIN 3760 – design A. radial shaft sealing ring Fig. 7-2: Radial shaft sealing ring Wear Radial shaft sealing rings are rubbing seals.

  • Page 83: Bearings And Shaft Load

    Rexroth IndraDrive Mi Notes on Project Planning Bearings and Shaft Load During operation, both radial and axial forces act upon the motor shaft and the motor bearings. The construction of the machine, the selected motor type and the attachment of driving elements on the shaft side must be adapted to one another to ensure that the load limits specified are not exceeded.
  • Page 84 Notes on Project Planning Rexroth IndraDrive Mi • • average speed phase 1 average speed phase 2 processing speed processing speed run-up time run-up time processing time processing time braking time braking time standstill time standstill time Fig. 7-4: Average speed A complete processing cycle can consist of several phases with different speeds.

  • Page 85: Holding Brakes

    The holding brake must not be used to stop the turning motor during normal operation! The brake must not be used for safety-relevant purposes either. Note: For Rexroth IndraDrive Mi, optional holding brakes are available. The supplied brake has been adapted to the corresponding motor! DOK-INDRV*-KCU+KSM****-PR01-EN-P...
  • Page 86 Notes on Project Planning Rexroth IndraDrive Mi Safety Requirements In normal operation, use the brake only when at a standstill and when performing the drive-integrated brake check. The holding brake is required for holding the axis when the machine is in a de-energized state.
  • Page 87 Rexroth IndraDrive Mi Notes on Project Planning Electrically Releasing Holding The electrically releasing holding brake is used to hold the axes at a Brake standstill and when the drive enable signal is off. When the supply voltage fails and the drive enable signal has been switched off, the electrically releasing holding brake will automatically apply.

  • Page 88: Mechanical Attachment Of Driving Elements

    Note: If redundant attachment cannot be avoided, it is absolutely necessary that you consult Bosch Rexroth. Gear Attachment The machine construction and the attachment elements used must be carefully adapted to the motor type so that the load limits of shaft and bearing are not exceeded.
  • Page 89 Rexroth IndraDrive Mi Notes on Project Planning S1 60K motor S1 gear Fig. 7-7: Reduction of characteristic S1 with gear attachment Note: The torques indicated in the motor characteristics have to be reduced by approx. 10–20% when gears are attached.

  • Page 90: Notes On Electrical Project Planning

    Maximum Number of Axes per System Combination The maximum allowed number of axes in a system combination of several Rexroth IndraDrive Mi at a supply unit is limited by the following variables: • signal exchange between KCU and KSM with max. 20 axes •...

  • Page 91: 24V Control Voltage

    7-11 Rexroth IndraDrive Mi Notes on Project Planning When accelerating, the voltage drop causes the corner speed to be reduced. The figure shows exemplary curves of reduction to 80% and 90% of the data sheet corner speeds. The maximum speed is proportional to the DC bus voltage available at the motor.
  • Page 92 7-12 Notes on Project Planning Rexroth IndraDrive Mi Maximum Cable Length vs. Number of Axes The maximum cable length of a string of drives depends on the number of servo drives and brakes: l total [m] total cable length in meters...

  • Page 93: Power Supply

    Supply Units following devices used supply units Rexroth IndraDrive Mi drive system: • Rexroth IndraDrive M supply units (HMV) • Rexroth IndraDrive C converters (HCS) Note: For the allowed combinations regarding power supply, see Project Planning Manual "Rexroth IndraDrive, Drive System".

  • Page 94: Address Selector Switch

    7-14 Notes on Project Planning Rexroth IndraDrive Mi Note: The 24V supply has to make available the inrush current generated when each electronic control system KCU is switched on. The inrush current depends on the power consumption P (see calculation above): N3 (KCU) ≤...

  • Page 95: Motor Blower

    Rexroth IndraDrive Mi Notes on Project Planning Motor Blower Blowers are not available for Rexroth IndraDrive Mi. Motor Current Limitation The current limitation makes sure that neither controller nor motor are damaged by overload, as long as the motor temperature remains below 100 °C.

  • Page 96: Motor Temperature

    7-16 Notes on Project Planning Rexroth IndraDrive Mi Schematic Diagram for Behavior With Overload overload ratio turning shaft n > ~60 min turning shaft n < ~60 min Fig. 7-14: Current limitation for example KSM01.2B-041C-42 Motor Temperature As the electronic system is thermally connected to the motor housing, the amplifier temperature is the most important variable for the load.

  • Page 97: Identification

    Rexroth IndraDrive Mi Identification Identification Scope of Supply Standard Optional PFM02 memory card module (MultiMediaCard) Fig. 8-1: Scope of supply KSM Standard Optional connection accessories for strain relief and shield connection HAS02.1-015 basic accessory HAS01.1-050 mounting accessory HAS03 further information on accessory HAS: see Project Planning Manual "Rexroth IndraDrive, Drive System"...
  • Page 98 Identification Rexroth IndraDrive Mi Design brand production week; example 07W16: year 2007, week 16 type designation IndraDrive Mi rated power rated voltage country of manufacture manufacturer's factory control voltage control power insulation system thermal class cooling mode mass of KSM incl. optional holding brake degree of protection max.

  • Page 99: Type Plate Kcu

    Rexroth IndraDrive Mi Identification Type Plate KCU Arrangement type plate Fig. 8-5: Type plate arrangement Design device type part number serial number bar code country of manufacture production week; example 07W16: year 2007, week 16 hardware index Fig. 8-6: Type plate...
  • Page 100 Identification Rexroth IndraDrive Mi DOK-INDRV*-KCU+KSM****-PR01-EN-P...

  • Page 101: Mounting And Installation

    System Overview Available Connections The electrical connections of all sizes of Rexroth IndraDrive Mi motors have been standardized. The motors are provided with • two power connections (hybrid connectors for power, control voltage,...
  • Page 102 Rexroth connection cables, this ensures easy, quick and error-safe mounting and commissioning. Note: The connection diagram applies to all KSMs! Overview of cables and connectors for Rexroth IndraDrive Mi: hybrid cable terminal connector at last motor X3.2 connection point of hybrid cable at first distributed servo drive Fig.

  • Page 103: Connection Diagram Kcu

    Rexroth IndraDrive Mi Mounting and Installation Connection Diagram KCU Fig. 9-2: Connection diagram KCU DOK-INDRV*-KCU+KSM****-PR01-EN-P...

  • Page 104: Mounting

    Mounting and Installation Rexroth IndraDrive Mi Mounting Practical Tips General Information Observe the following aspects for installation and mounting: • The motors have been equipped with two power connectors X3.1 and X3.2 which allow looping through the motor cable. Both connection points are basically equivalent.

  • Page 105: Mechanical Interfaces

    Rexroth IndraDrive Mi Mounting and Installation 8. Check whether the motor holding brake attains the holding torque If the Optional Holding Brake is Used specified in the data sheet. If the brake does not attain the specified torque, first proceed as described in chapter "Commissioning, Operation, Diagnoses, Service and Maintenance"...

  • Page 106: Electrical Connection

    Mounting and Installation Rexroth IndraDrive Mi Electrical Connection Danger to life due to electric voltage! Handling within the range of live parts is extremely dangerous. Therefore: ⇒ Any work required on the electric system may be DANGER carried out only by skilled electricians. It is absolutely necessary to use power tools.

  • Page 107: Notes

    Rexroth IndraDrive Mi Mounting and Installation Notes The motor cable is a hybrid cable in which the communication line has been integrated, too. Only the original Rexroth cable can ensure the function. It is supplied as ready-made cable. The outgoing direction of the...
  • Page 108 Mounting and Installation Rexroth IndraDrive Mi Example with supply unit HMV: transformer HMD, HMS inverters supply unit mains filter mains choke electronic control system distributed servo drive servo motor 24V supply mains contactor terminal connector X3.2 hybrid cable connection Fig. 9-4:...
  • Page 109 Rexroth IndraDrive Mi Mounting and Installation Parallel Strings of Drives Note: At the first motor, always plug the hybrid cable in connection point X3.2. Always terminate the unassigned connection at the last motor with a terminal connector. supply unit electronic control system terminal connector X3.2...

  • Page 110: Handling Of The Devices

    9-10 Mounting and Installation Rexroth IndraDrive Mi Handling of the Devices Damage or injuries and invalidation of the warranty due to improper handling! ⇒ Avoid mechanical stressing, throwing, tipping or dropping of the products. CAUTION ⇒ Use only suitable tackles.
  • Page 111 9-11 Rexroth IndraDrive Mi Mounting and Installation Fig. 9-8: Lifting and transporting motors by means of lifting sling belts DOK-INDRV*-KCU+KSM****-PR01-EN-P...
  • Page 112 9-12 Mounting and Installation Rexroth IndraDrive Mi DOK-INDRV*-KCU+KSM****-PR01-EN-P...

  • Page 113: Commissioning, Operation, Diagnoses, Service And Maintenance

    10-1 Rexroth IndraDrive Mi Commissioning, Operation, Diagnoses, Service and Maintenance Commissioning, Operation, Diagnoses, Service and Maintenance 10.1 Notes on Commissioning High electrical voltage! Danger to life, electric shock and severe bodily injury! ⇒ Read and observe the detailed safety instructions contained in this documentation in chapter "Safety...

  • Page 114: 10.3 Diagnostic Functions

    10-2 Commissioning, Operation, Diagnoses, Service and Maintenance Rexroth IndraDrive Mi 10.3 Diagnostic Functions Distributed Servo Drive KSM Fig. 10-1: LED H14 At the back of KSM, there is a tricolor LED which displays the drive status. Color Display Significance Measures...

  • Page 115: Electronic Control System Kcu

    10-3 Rexroth IndraDrive Mi Commissioning, Operation, Diagnoses, Service and Maintenance Electronic Control System KCU Fig. 10-3: LEDs at device Color Display Significance Measures H52.1 continuous light E-Stop active (/E_Stop) activate E-Stop, if necessary (see connection point X50) E-Stop not activated deactivate E-Stop, if necessary H52.2...

  • Page 116: Diagnostic Messages Via Parameters

    See also Functional Description of firmware chapter "Handling, Diagnostic and Service Functions / Oscilloscope Function" Analog Outputs Note: Rexroth IndraDrive Mi has no analog outputs! Patch Function The distributed servo drive KSM has a function which allows reading or writing controller-internal memory cells.

  • Page 117: 10.4 Service Functions/Troubleshooting

    10-5 Rexroth IndraDrive Mi Commissioning, Operation, Diagnoses, Service and Maintenance Monitoring Function For extended diagnostic possibilities, the distributed servo drive has a monitoring function. See also Functional Description of firmware chapter "Handling, Diagnostic and Service Functions / Extended Diagnostic Possibilities / Monitoring Function"...

  • Page 118: Replacing Ksm

    10-6 Commissioning, Operation, Diagnoses, Service and Maintenance Rexroth IndraDrive Mi Burns caused by hot surfaces with temperatures of more than 100 °C! ⇒ Before beginning to work, let the motors cool down. The thermal time constant specified in the Technical...

  • Page 119: Service Function "Release Holding Brake

    10-7 Rexroth IndraDrive Mi Commissioning, Operation, Diagnoses, Service and Maintenance Service Function "Release Holding Brake" Via the interface X2 at KSM, you can "release" the integrated holding brake. Lethal injury caused by errors when controlling motors and working at moving parts! ⇒...

  • Page 120: Mmc

    10-8 Commissioning, Operation, Diagnoses, Service and Maintenance Rexroth IndraDrive Mi After you have unscrewed the cover, you can remove the MMC (MultiMediaCard) from the MMC slot X7. The MMC contains firmware and parameters which allows easily programming drive during commissioning.
  • Page 121 10-9 Rexroth IndraDrive Mi Commissioning, Operation, Diagnoses, Service and Maintenance Danger of injury due to moving elements! ⇒ Do not carry out any maintenance measures at running machines. ⇒ During maintenance work, secure the installation WARNING against restart and unauthorized use.

  • Page 122: Maintenance Of The Electronic System Of The Drive

    10-10 Commissioning, Operation, Diagnoses, Service and Maintenance Rexroth IndraDrive Mi 3. If the holding torque specified in the data sheets is attained, the holding brake is ready for operation. If the holding torque specified in the data sheets is not attained, carry out the abrasion procedure as described in step 4.

  • Page 123: Disposal And Environmental Protection

    11-1 Rexroth IndraDrive Mi Disposal and Environmental Protection Disposal and Environmental Protection 11.1 Disposal Products Our products can be returned to us free of charge for disposal. It is a precondition, however, that the products are free of oil, grease or other dirt.

  • Page 124: Recycling

    11-2 Disposal and Environmental Protection Rexroth IndraDrive Mi Recycling Due to their high content of metal, most of the product components can be recycled. In order to recycle the metal in the best possible way, the products must be disassembled into individual modules.

  • Page 125: Appendix

    12-1 Rexroth IndraDrive Mi Appendix Appendix 12.1 Discharging of DC Bus Capacitors In the drive system Rexroth IndraDrive, capacitors are used in the DC bus as energy stores. In the drive controllers and particularly in the supply units, such capacitors have already been integrated.

  • Page 126: 12.2 Discharging Device

    12-2 Appendix Rexroth IndraDrive Mi 12.2 Discharging Device Lethal electric shock caused by live parts with more than 50 V! ⇒ Before touching live parts, check in any case whether the voltage between the DC bus terminals WARNING L+ and L- has fallen below 50 V!

  • Page 127: Service And Support

    13-1 Rexroth IndraDrive Mi Service and Support Service and Support 13.1 Helpdesk Our service helpdesk at our headquarters in Lohr, Germany, will assist you with all kinds of enquiries. Phone +49 (0) 9352 40 50 60 Call Entry Center Mo–Fr 7.00–18.00 Uhr...
  • Page 128 13-2 Service and Support Rexroth IndraDrive Mi DOK-INDRV*-KCU+KSM****-PR01-EN-P...

  • Page 129: Index

    CE label 4-1 Certifications 4-1 Characteristics KSM 5-7 Cleaning 10-9 Commissioning 10-1 Compatibility With foreign matters 4-4 Components General specification 4-1 Rexroth IndraDrive Mi 1-2 Conditions Ambient 4-2 Installation 4-2 Operation 4-2 Storage 4-2 Transport 4-2 Connection Accessory 6-12 DOK-INDRV*-KCU+KSM****-PR01-EN-P...
  • Page 130 14-2 Index Rexroth IndraDrive Mi Connection diagram drive system 9-7 Connection diagram KCU 9-3 Connection points KCU 6-3 Connection points KSM 6-13 Control voltage supply 6-11 DC bus 6-9 Electrical 9-6 Equipment grounding conductor 6-1 Ground 6-2 Hybrid cable 6-15...
  • Page 131 14-3 Rexroth IndraDrive Mi Index F4 6-3 F5 6-3 Failure of bearing 7-4 Firmware 1-9 Functions 10-4 Update 10-7 Foreign matters Compatibility 4-4 Fuse F4 6-3 F5 6-3 Gear attachment 7-8 Grease Service life 7-4 Ground connection 6-2 Additional, KSM 6-20 H14 10-2 H52.1…H54 10-3...
  • Page 132 14-4 Index Rexroth IndraDrive Mi Interfaces Electrical 9-7 Internet 13-1 Isolated inputs/outputs 6-17 KCU 1-1 Applications 5-14 Brief description 5-14 Connection diagram 9-3 Connection points 6-3 Dimensional drawing 5-16 Dimensions 5-16 LED H52.1…H54 10-3 Notes on project planning 7-13 Scope of supply 8-1...
  • Page 133 14-5 Rexroth IndraDrive Mi Index Required steps to follow 9-4 Mounting clearance 7-1 Mounting depth 6-10 Mounting positions 4-4 Mounting the flange 9-5 MultiMediaCard 6-16, 10-8 Notes on operation 10-1 Number of axes Maximum 7-10 ON time 5-3 Operating conditions 4-2...
  • Page 134 14-6 Index Rexroth IndraDrive Mi S4, S5 SERCOS address selector switch 7-14 S6 6-5 Safety instructions for electric drives 3-1 Safety option 1-8 Scope of supply KCU 8-1 KSM 8-1 Sealing ring 7-2 SERCOS Address selector switch 7-14 Interface 6-5...
  • Page 135 14-7 Rexroth IndraDrive Mi Index Types of installation 4-4 UL listing 4-1 5-14 Appropriate use 2-1 Varnish 4-4 Winding 1-7 X1 6-4 X2 6-14 X20 TX 6-5 X21 RX 6-5 X3.1, X3.2 6-15 X37, X38 6-17 X50 6-6 X51 6-6...
  • Page 136 14-8 Index Rexroth IndraDrive Mi DOK-INDRV*-KCU+KSM****-PR01-EN-P...
  • Page 138 Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Phone +49 (0)93 52-40-50 60 +49 (0)93 52-40-49 41 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany R911320924 DOK- INDRV*KCU+KSM****-PR01-EN-P...

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