Bosch rexroth IndraDrive Mi KLC03 Manuals

Manuals and User Guides for Bosch rexroth IndraDrive Mi KLC03. We have 1 Bosch rexroth IndraDrive Mi KLC03 manual available for free PDF download: Project Planning Manual

Bosch rexroth IndraDrive Mi KLC03 Project Planning Manual

Bosch rexroth IndraDrive Mi KLC03 Project Planning Manual (422 pages)

Drive Systems

Brand: Bosch | Category: DC Drives | Size: 25.35 MB

Table of Contents

Table of Contents
3
1 System Presentation

15
- Introduction
  15
- Indradrive MI
  15
- Features
  16
- Indradrive MI Drive System
  21
- Components
  21
- Series
  22
- Firmware
  23
- System Structure
  23
- Overview of Functions
  26
  - Firmware Functions (Functional Packages)
    26
- Type Code
  27
- Introduction
  27
- KSM02 Motor-Integrated Servo Drive
  28
  - KSM02 Type Code
    28
- KMS02 Near Motor Servo Drive
  31
  - KMS02 Type Code
    31
- KMS03 Near Motor Servo Drive
  33
  - KMS03 Type Code
    33
- KCU02 Drive Connection Box
  34
  - KCU02.2 Type Code
    34
- KMV03 Supply Unit
  35
  - KMV03 Type Code
    35
- KNK03 Mains Filter
  36
  - KNK03 Type Code
    36
- KLC03 DC Bus Capacitor Unit
  37
  - KLC03 Type Code
    37
- Firmware
  37
- About this Documentation
  38
- Editions
  38
- Documentations
  41
  - Drive Systems, System Components
    41
  - Motors
    42
  - Cables
    42
  - Firmware
    42
- Your Comments
  45
2 Important Directions for Use

47
- Intended Use
  47
- Introduction
  47
- Areas of Use and Application
  47
- Unintended Use
  48
3 Safety Instructions for Electric Drives and Controls

49
4 General Data and Specifications

59
5 Technical Data of the Components

75
6 Connection Points

155
- System Connection Points
  155
- Connection Point of Equipment Grounding Conductor
  155
  - Cabinet-Bound Drive Systems
    155
  - Cabinet Free Drive Systems
    156
- Ground Connection
  157
- KCU02 Connection Points
  158
- Positions of the Connection Points
  158
- X1, Module Bus
  159
- X29.1, X29.2, Multi-Ethernet
  160
- X49, L3 - Safe Torque off
  162
  - Data
    162
  - Pin Assignment, Function
    162
- X50, E-Stop Input
  163
- X52, Status Messages
  164
- X53, Control Voltage Output
  165
- X54, DC Bus, Equipment Grounding Conductor Output KSM02/KMS02
  166
- DC Bus Connection L+, L
  167
- Control Voltage Supply +24V, 0V
  170
- KSM02 Connection Points
  172
- Positions of the Connection Points
  172
- X37, X38, Digital Inputs/Outputs
  173
- X103.1, X103.2, Hybrid Cable Connection Point
  177
- X107, Programming Module
  179
- X108, X109, Communication Output Coupling
  181
- X118, X119, External Communication
  184
- X141, Safety Technology and Service Input "Release Brake
  187
- Second Connection Point of Equipment Grounding Conductor
  192
- KMS02 Connection Points
  194
- Positions of the Connection Points
  194
- X37, X38, Digital Inputs/Outputs
  195
- X103.1, X103.2, Hybrid Cable Connection Point
  195
- X104, Motor Encoder Connection
  196
- X107, Programming Module
  196
- X108, X109, Communication Output Coupling
  196
- X118, X119, External Communication
  196
- X141, Safety Technology
  196
- X156, Motor Connection
  197
- X156, Motor/Motor Encoder Connection (Single-Cable Connection)
  198
- Second Equipment Grounding Conductor Connection Point
  199
- KMS03 Connection Points
  200
- Positions of the Connection Points
  200
- Motor Cable and Encoder Cable Connection
  201
  - Condition as Supplied
    201
  - Connection Cover: Mounting Options
    202
  - Two-Piece Connection Cover
    202
  - Connecting the Cables
    203
- XD3, Motor Connection
  205
- XG3, Motor Temperature Monitoring and Motor Holding Brake
  206
- XG4, Digital Motor Encoder Connection
  209
- XG8, Analog Motor Encoder Connection
  210
- X37, X38, Digital Inputs/Outputs
  211
- X103.1, X103.2, Hybrid Cable Connection Point
  211
- X107, Programming Module
  211
- X108, X109, Communication Output Coupling
  211
- X118, X119, External Communication
  211
- X141, Safety Technology
  211
- Second Equipment Grounding Conductor Connection Point
  211
- KMV03 Connection Points
  212
- Positions of the Connection Points
  212
- X37, X38, Digital Inputs/Outputs
  213
- X103.1, X103.2, Hybrid Cable Connection Point
  213
- X118, X119, External Communication
  213
- X141, Safety Technology (KMV03)
  214
- Second Equipment Grounding Conductor Connection Point
  214
- XD1, Mains Voltage
  215
- XD10, Control Voltage
  216
- XD13, Fan Power Supply
  216
- XG3, Mains Choke Temperature Contact
  217
- XG14, Mains Voltage Synchronization
  218
- XG34, Mains Contactor Control and Feedback Contacts (KNK03)
  219
- Connection Cover: Mounting Options
  220
- Two-Piece Connection Cover
  220
- KNK03 Connection Points
  221
- Positions of the Connection Points
  221
- Second Equipment Grounding Conductor Connection Point
  221
- XD1, Mains Voltage
  222
- XD1.2, Supply Unit
  223
- XD13, Fan Power Supply
  223
- XG14, Mains Voltage Synchronization
  224
- XG3, Mains Choke Temperature Contact
  225
- XG34, Mains Contactor Control and Feedback Contacts
  226
- Connection Cover: Mounting Options
  227
- Two-Piece Connection Cover
  227
- KLC03 Connection Points
  228
- Positions of the Connection Points
  228
- Second Equipment Grounding Conductor Connection Point
  228
- XD13, Fan Power Supply
  228
- X54.1, X54.2; DC Bus
  229
- Connection Cover: Mounting Options
  230
- Two-Piece Connection Cover
  230
7 Notes on Project Planning

231
- Combining the Individual Components
  231
- Power Supply
  231
- Sizing Mains Filters
  231
- Power Supply by HMV01, HMV02, HCS01, HCS02 or HCS03
  231
  - Supply Units
    231
- Power Supply by HCS01
  232
- Power Supply by KMV03 and KNK03
  232
  - KMV03 Supply Unit, KNK03 Mains Filter
    232
- Control Voltage Power Requirement 42 V
  233
- KCU02 Drive Connection Box
  234
  - General Information
    234
  - Control Voltage Supply
    234
  - Power Supply to KSM/KMS (KCU)
    236
- KLC03 DC Bus Capacitor Unit
  240
  - Application Notes
    240
- Hybrid Cable Length
  241
- Zone Setup
  251
  - Safety Zones
    251
  - E-Stop Function
    254
- Motor Fan for KSM02
  256
- Evaluating Motor Encoders at KMS
  256
- Length of Motor Cables and Encoder Cables at KMS
  257
- Operation with Standard Motors
  257
- Notes on Electrical Project Planning
  259
- Address Selector Switch
  259
- IP Configuration
  260
- Current Limitation
  260
- Motor Temperature
  261
- Switching Frequency
  262
- Notes on Mechanical Project Planning
  262
- Mounting Clearance
  262
- Output Shaft
  262
  - Plain Shaft
    262
  - Output Shaft with Key
    262
  - Output Shaft with Shaft Sealing Ring
    263
- Bearings and Shaft Load
  264
  - General Information
    264
  - Radial Load, Axial Load
    265
  - Bearing Service Life
    266
- Holding Brakes
  267
  - Brake Control and Supply
    267
  - Safety Requirements
    267
  - Sizing Holding Brakes
    268
- Mechanically Attaching Driving Elements
  269
  - General Information
    269
  - Redundant Bearings
    269
  - Gearbox Attachment
    270
  - Coupling Attachment
    270
  - Bevel Gear Pinions or Skew Bevel Driving Pinions
    270
8 Identification

273
- Scope of Supply
  273
- Kcu02
  273
- Ksm02/Kms02
  273
- Kms03
  274
- Kmv03
  274
- Knk03
  274
- Klc03
  274
- Identifying and Checking the Delivered Components
  275
- KSM Type Plate
  275
  - Arrangement
    275
  - Design
    276
  - System Type Plate
    276
- KMS02 Type Plate
  277
  - Arrangement
    277
  - Design
    278
  - System Type Plate
    278
- KMS03 Type Plate
  279
  - Arrangement
    279
  - Design
    280
  - System Type Plate
    280
- KMV03 Type Plate
  281
  - Arrangement
    281
  - Design
    282
  - System Type Plate
    282
- KNK03 Type Plate
  283
  - Arrangement
    283
  - Design
    284
- KLC03 Type Plate
  285
  - Arrangement
    285
  - Design
    286
- System Type Plate (Module of Configured Variants)
  287
- Plates at KCU02
  288
  - Arrangement
    288
  - Type Plate Design
    288
  - Design of UL Performance Data Plate
    289
9 Mounting and Installation

291
- Introduction
  291
- Important Notes
  291
  - Safety
    291
  - Qualified Technical Staff
    291
  - Handling the Devices
    291
- System Overview
  292
  - Available Connection Points
    292
- Cold Plate
  293
- Ksm
  294
- Required Steps to Follow
  294
  - Preparations for Mounting
    294
  - Mounting KSM
    294
- Mechanical Interfaces
  295
  - Flange Mounting
    295
- Practical Tips
  295
- Kms
  296
- Required Steps to Follow
  296
  - Preparations for Mounting
    296
  - Mounting KMS
    296
- Kcu02
  297
- Mounting Depths
  297
- Touch Guard
  297
- KCU02 Connection Diagram
  299
- Knk03, Kmv03, Klc03
  300
- Arranging the Devices
  300
- Mounting
  300
- Electrical Connection
  300
- General Information
  300
- Notes
  301
- Electrical Interfaces
  302
  - Overall Connection Diagram
    302
  - HMV01 Used as Supply Unit
    303
  - HCS02 Used as Supply Unit
    304
  - HCS03 Used as Supply Unit
    305
  - HMV02 Used as Supply Unit
    306
  - HCS01.1E-W0054 Used as Supply Unit
    307
  - KMV03 Used as Supply Unit
    308
  - Parallel Drive Lines
    310
  - Fan Connection
    311
10 Accessories

313
- Overview
  313
- HAS01, Basic Accessory
  315
- HAS02, Shield Connection
  316
- HAS03, Control Cabinet Adapter
  317
- HAS05.1-018, Dummy Plate for KMS03 Encoder Connection
  318
- HAS05.1-019, KNK03 Mains Voltage
  319
- HAS05.1-020, KMV03 Control Voltage
  320
- HAS05.1-021, Hybrid Joint
  321
- Has05.1-021-Nnn-Nn
  321
- Has05.1-021-Ncn-Nn
  322
- HAS05.1-023, HCS01 Adapter
  324
- HAS05.1-024, Passive 42 V Supply Unit
  330
- View
  330
- Purpose
  330
- Properties
  331
- Dimensions
  332
- Connection
  333
  - X37
    333
  - X103.1, X103.2, Hybrid Cable Connection Point
    333
- HAS10, Mechanical Mounting Parts
  334
- Type Code
  334
- Use
  335
- Scope of Supply
  336
- RKB0021, Multi-Ethernet Cable
  339
- RKB0013, Multi-Ethernet Cable
  340
- RKB0033, Cable for Safety Technology
  341
- RKB0043, Communication Cable
  342
- RKB0044, Communication Cable
  343
- RKB0054, Fan Cable
  344
- RKS0010, Interface Cable
  345
- RBS0023, Connector for Safety Zone Node
  346
- RLS0725, KMS03 Motor Power Cable Connector
  347
- RGS0725, KMS03 Encoder Cable Connector
  348
- RHS0725, KMS03 Hybrid Motor Cable Connector
  349
- RH2-030DB, KMS02 - MS2N Hybrid Motor Cable
  350
- Metallic Flange for Circular Connectors
  351
- Netswitch Sercos III
  352
11 Commissioning, Operation, Diagnostics and Maintenance

353
- Notes on Commissioning
  353
- General Information
  353
- Preparation
  353
- Procedure
  353
- Notes on Operation
  353
- Diagnostic Functions
  355
- KMV Diagnostic Display
  355
  - Led H14
    355
- KCU02 Diagnostic Display
  357
- KSM/KMS Diagnostic Display
  359
  - Led H14
    359
    
    LED at Device
    359
    
    Diagnostic Display with Mpx-17/18
    359
    
    Diagnostic Display with Mpx-2X
    360
  - Led H25 H26
    361
    
    Use
    361
    
    LED H25, Displays
    362
    
    LED H26, Displays
    363
- Diagnostic Messages Via Parameters
  368
- Firmware Functions
  368
  - Easy Startup Mode
    368
  - Analog Outputs
    369
  - Oscilloscope Function
    369
  - Patch Function
    369
  - Monitoring Function
    369
  - Logbook Function
    369
- Service Functions/Troubleshooting
  370
- General Information
  370
- Replacing Fuses F4 and F5
  371
- Deactivating and Dismounting the Drive
  372
  - Deactivation
    372
  - Dismounting
    372
- Replacing the Component
  373
- Release Holding Brake" Service Function
  373
- Saving Parameters
  374
- Firmware Update
  374
- Replacing the Programming Module
  374
- Maintenance
  375
- Maintenance of the Motor Component
  375
  - General Information
    375
  - Cleaning
    375
  - Bearings
    375
  - Connection Cables
    375
  - Holding Brake - Commissioning and Maintenance Instructions
    376
- Maintenance of the Electronic System of the Drive
  377
12 Environmental Protection and Disposal

379
- Environmental Protection
  379
- Disposal
  379
13 Service and Support

381
14 Appendix

383
- Digital Inputs
  383
- Digital Inputs Type a (Standard)
  383
- Digital Inputs (Safety Technology L Options)
  383
- Digital Inputs (Safety Technology S Options)
  384
- Digital Outputs
  385
- Digital Outputs (Safety Technology L Options)
  385
- Digital Outputs (Safety Technology S Options)
  386
- Two-Piece Connection Cover
  388
- Sizing Mains Filters (Drive System)
  389
  - Index
    409

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