Rexroth IndraDrive Mi Drive Systems€¦ · • Rexroth IndraDrive converter HCS02.1 or HCS03.1...

Rexroth IndraDrive MiDrive Systems

R911320924Edition 01

Project Planning Manual

Electric Drivesand Controls Pneumatics Service

Linear Motion and Assembly TechnologiesHydraulics

About this Documentation

DOK-INDRV*-KCU+KSM****-PR01-EN-P

Rexroth IndraDrive MiDrive Systems

Project Planning Manual


120-2400-B324-01/EN

This documentation describes …• how to design the control cabinet• how to install the drive system

Description Release Date NotesDOK-INDRV*-KCU+KSM****-PR01-EN-P 2007-04 First edition

Bosch Rexroth AG 2007Copying this document, giving it to others and the use or communicationof the contents thereof without express authority, are forbidden. Offendersare liable for the payment of damages. All rights are reserved in the eventof 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. Nostatements concerning a certain condition or suitability for a certainapplication can be derived from our information. The given informationdoes not release the user from the obligation of own judgement andverification. It must be remembered that our products are subject to anatural process of wear and aging.

Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. MainTelephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85http://www.boschrexroth.de/Dept. BRC/EDY1 (MW/RR/US/BB) and BRC/EDM2 (JW)

This document has been printed on chlorine-free bleached paper.

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Rexroth IndraDrive Mi Contents I


Contents

1 System Presentation 1-11.1 Introduction ................................................................................................................................... 1-1

Rexroth IndraDrive Mi.............................................................................................................. 1-1Features................................................................................................................................... 1-1

1.2 Drive System Rexroth IndraDrive Mi ............................................................................................ 1-2Components ............................................................................................................................ 1-2System Structure ..................................................................................................................... 1-3Overview of Functions ............................................................................................................. 1-5

1.3 Type Code .................................................................................................................................... 1-5Introduction .............................................................................................................................. 1-5Distributed Servo Drive KSM................................................................................................... 1-6Electronic Control System KCU............................................................................................... 1-9Firmware.................................................................................................................................. 1-9

1.4 Guide to the Documentation ....................................................................................................... 1-10Documentation Structure....................................................................................................... 1-10Documentations - Overview .................................................................................................. 1-10

2 Important Directions for Use 2-12.1 Appropriate Use............................................................................................................................ 2-1

Introduction .............................................................................................................................. 2-1Areas of Use and Application .................................................................................................. 2-1

2.2 Inappropriate Use ......................................................................................................................... 2-2

3 Safety Instructions for Electric Drives and Controls 3-13.1 General Information ...................................................................................................................... 3-1

Using the Safety Instructions and Passing Them on to Others............................................... 3-1Instructions for Use.................................................................................................................. 3-1Explanation of Warning Symbols and Degrees of Hazard Seriousness ................................. 3-3Hazards by Improper Use........................................................................................................ 3-3

3.2 Instructions with Regard to Specific Dangers............................................................................... 3-5Protection Against Contact with Electrical Parts ..................................................................... 3-5Protection Against Electric Shock by Protective Extra-Low Voltage (PELV) .......................... 3-7Protection Against Dangerous Movements ............................................................................. 3-7Protection Against Magnetic and Electromagnetic Fields During Operation andMounting .................................................................................................................................. 3-9Protection Against Contact with Hot Parts ............................................................................ 3-10Protection During Handling and Mounting............................................................................. 3-11Battery Safety ........................................................................................................................ 3-11Protection Against Pressurized Systems .............................................................................. 3-12

II Contents Rexroth IndraDrive Mi


4 General Specification of the Components 4-14.1 Certifications ................................................................................................................................. 4-14.2 Transport and Storage.................................................................................................................. 4-2

Transporting the Devices......................................................................................................... 4-2Storing the Devices ................................................................................................................. 4-2

4.3 Installation Conditions................................................................................................................... 4-2Ambient and Operating Conditions.......................................................................................... 4-2Type of Construction and Mounting Positions......................................................................... 4-4Compatibility with Foreign Matters .......................................................................................... 4-4Prime Coat and Housing Varnish ............................................................................................ 4-4

4.4 Capacity Utilization ....................................................................................................................... 4-5

5 Technical Data of the Components 5-15.1 Explanation of Terms and Definitions........................................................................................... 5-15.2 Distributed Servo Drive KSM........................................................................................................ 5-5

KSM Data Sheet ...................................................................................................................... 5-5KSM Characteristics ................................................................................................................ 5-7Dimensions and Technical Design ........................................................................................ 5-10Bearings and Shaft Load ....................................................................................................... 5-12

5.3 Electronic Control System KCU.................................................................................................. 5-14Brief Description and Applications......................................................................................... 5-14Technical Data....................................................................................................................... 5-14

5.4 Hybrid Cables RKH..................................................................................................................... 5-17Technical Data....................................................................................................................... 5-17Selecting Ready-Made Cables .............................................................................................. 5-17Interconnection Diagrams for Ready-Made Hybrid Cables................................................... 5-19

6 Connection Points 6-16.1 Connection Points of System ....................................................................................................... 6-1

Equipment Grounding Conductor ............................................................................................ 6-1Ground Connection ................................................................................................................. 6-2

6.2 Connection Points of KCU............................................................................................................ 6-3Positions of the Connection Points.......................................................................................... 6-3X1, Module Bus ....................................................................................................................... 6-4X20 TX, X21 RX (SERCOS interface)..................................................................................... 6-5X50, E-Stop Input .................................................................................................................... 6-6X51, Master Communication SERCOS................................................................................... 6-6X52, Status Messages............................................................................................................. 6-7X53, Control Voltage Output.................................................................................................... 6-7X54, DC Bus, Equipment Grounding Conductor Output KSM ................................................ 6-8DC Bus Connection L+, L-....................................................................................................... 6-9Control Voltage Supply +24V, 0V.......................................................................................... 6-11Connection Accessory........................................................................................................... 6-12

6.3 Connection Points of KSM.......................................................................................................... 6-13Positions of the Connection Points........................................................................................ 6-13X2 Serial Interface, Service Input "Release Brake"............................................................... 6-14

Rexroth IndraDrive Mi Contents III


X3.1, X3.2 Connection Point Hybrid Cable ........................................................................... 6-15X7 Connection Point MultiMediaCard (MMC) ....................................................................... 6-16X37, X38 Digital Inputs/Outputs ............................................................................................ 6-17Ground Connection ............................................................................................................... 6-20

7 Notes on Project Planning 7-17.1 Notes on Mechanical Project Planning......................................................................................... 7-1

Mounting Clearance ................................................................................................................ 7-1Output Shaft............................................................................................................................. 7-1Bearings and Shaft Load ......................................................................................................... 7-3Holding Brakes ........................................................................................................................ 7-5Mechanical Attachment of Driving Elements........................................................................... 7-8

7.2 Notes on Electrical Project Planning .......................................................................................... 7-10Allowed Cable Lengths.......................................................................................................... 7-10Maximum Number of Axes per System Combination............................................................ 7-1024V Control Voltage .............................................................................................................. 7-11Power Supply......................................................................................................................... 7-13Electronic Control System KCU............................................................................................. 7-13Address Selector Switch........................................................................................................ 7-14Motor Blower.......................................................................................................................... 7-15Motor Current Limitation ........................................................................................................ 7-15Motor Temperature................................................................................................................ 7-16Switching Frequency ............................................................................................................. 7-16

8 Identification 8-18.1 Scope of Supply............................................................................................................................ 8-1

KSM ......................................................................................................................................... 8-1KCU ......................................................................................................................................... 8-1

8.2 Identifying and Checking the Delivered Components .................................................................. 8-1Type Plate KSM....................................................................................................................... 8-1Type Plate KCU....................................................................................................................... 8-3

9 Mounting and Installation 9-19.1 Introduction ................................................................................................................................... 9-1

Important Notes ....................................................................................................................... 9-1System Overview..................................................................................................................... 9-1Connection Diagram KCU ....................................................................................................... 9-3

9.2 Mounting ....................................................................................................................................... 9-4Practical Tips ........................................................................................................................... 9-4Required Steps to Follow ........................................................................................................ 9-4Mechanical Interfaces.............................................................................................................. 9-5

9.3 Electrical Connection .................................................................................................................... 9-6Notes ....................................................................................................................................... 9-7Electrical Interfaces ................................................................................................................. 9-7

9.4 Handling of the Devices.............................................................................................................. 9-10

IV Contents Rexroth IndraDrive Mi


10 Commissioning, Operation, Diagnoses, Service and Maintenance 10-110.1 Notes on Commissioning............................................................................................................ 10-1

Preparing ............................................................................................................................... 10-1Carrying Out .......................................................................................................................... 10-1

10.2 Notes on Operation..................................................................................................................... 10-110.3 Diagnostic Functions .................................................................................................................. 10-2

Distributed Servo Drive KSM................................................................................................. 10-2Electronic Control System KCU............................................................................................. 10-3Diagnostic Messages via Parameters ................................................................................... 10-4Firmware Functions ............................................................................................................... 10-4

10.4 Service Functions/Troubleshooting ............................................................................................ 10-5Deactivating and Dismounting the Drive ............................................................................... 10-5Replacing KSM...................................................................................................................... 10-6Service Function "Release Holding Brake" ........................................................................... 10-7Saving Parameters ................................................................................................................ 10-7Firmware Update ................................................................................................................... 10-7MMC ...................................................................................................................................... 10-8

10.5 Maintenance ............................................................................................................................... 10-8Maintenance of the Motor Component .................................................................................. 10-8Maintenance of the Electronic System of the Drive............................................................. 10-10

11 Disposal and Environmental Protection 11-111.1 Disposal ...................................................................................................................................... 11-1

Products................................................................................................................................. 11-1Packaging Materials .............................................................................................................. 11-1

11.2 Environmental Protection............................................................................................................ 11-1No Release of Hazardous Substances ................................................................................. 11-1Materials Contained in the Products ..................................................................................... 11-1Recycling ............................................................................................................................... 11-2

12 Appendix 12-112.1 Discharging of DC Bus Capacitors ............................................................................................. 12-112.2 Discharging Device..................................................................................................................... 12-2

13 Service and Support 13-113.1 Helpdesk..................................................................................................................................... 13-113.2 Service Hotline............................................................................................................................ 13-113.3 Internet........................................................................................................................................ 13-113.4 Helpful Information...................................................................................................................... 13-1

14 Index 14-1

Rexroth IndraDrive Mi System Presentation 1-1


1 System Presentation

1.1 Introduction

Rexroth IndraDrive MiRexroth IndraDrive Mi is an innovative system solution within the RexrothIndraDrive platform, consisting of synchronous servo motors (on the basisof Rexroth IndraDyn S) with integrated inverters and control sections.

Features

Fig. 1-1: Rexroth IndraDrive Mi - features

1-2 System Presentation Rexroth IndraDrive Mi


In the following points, the system solution Rexroth IndraDrive Mi differsfrom 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

ComponentsThe drive system Rexroth IndraDrive Mi consists of the followingcomponents:

1 distributed servo drive KSM1a: basic motor1b: 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 RexrothIndraDrive and Rexroth IndraDyn

Distributed Servo Drive KSM

Ready-Made Hybrid Cable



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

LinesSee chapter "Type Code"• distributed servo drive KSM• electronic control system KCU

System StructureThe 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 involvedcomponents (with HMV as supply unit).

Electronic Control System KCU



DST transformer (optional)F fusesHMD, HMS inverterHMV supply unitHNF mains filterHNL mains chokeKCU electronic control systemKSM distributed servo driveMSK servo motor24V 24V supply1 mains contactor (for supply units without integrated mains

contactor, e.g. HMV01.2R-W0120)2 terminal connectorX3.2 connection of hybrid cable

Fig. 1-3: System structure



Overview of Functions

Firmware Functions (Functional Packages)

Note: For details on the available firmware functions, see chapter"Functional Packages" of the Functional Description forfirmware MPB04VRS or higher.

Hardware-related functional restrictions as compared to drive controllerswith CSB and CSH control sections:• no safety technology• no analog inputs or outputs• no digital and analog I/O extensions

1.3 Type Code

IntroductionThe 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 intoaccount:• 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 typecodes. Our sales representative will help you with the currentstatus of available versions.

Notes on Product Selection



Distributed Servo Drive KSM

Type Code

Fig. 1-4: Type code KSM



Explanation of the Type CodeThe type code has the following basic structure:• ProductKSM Rexroth-specific designation of the motor line

• SizeThe motor size defines important mechanical motor dimensions. Inaddition, the rotor inertia is distinguished in column 11.Abbrev. column 12 : 1 rotor inertia reduced

6 rotor inertia normal• LengthWithin one line, increasing motor length is graded by code letters inalphabetic order.

• WindingThe two-digit sequence of numerals, multiplied by 100, makes the ratedspeed applying to the corresponding winding variant.

• Cooling modeN: natural convection

• Motor encoderRexroth IndraDrive Mi motors have been equipped with an integratedencoder system. To control the motor speed or position the motor, thedrive controller needs the current motor position.

Option Encoder typeS1 Optical encoder single-turn,

position detection absolute over 1 motor revolution with a resolutionof 128 x 213 pieces of information per revolution

M1 Optical encoder multi-turn,position detection absolute over 4096 motor revolutions with aresolution of 128 x 213 pieces of information per revolution

Fig. 1-5: Motor encoder

• Connection systemConnection for hybrid cable RKH

• ShaftTo connect the machine elements to be driven to the motor shafts, thereare the following options.

Option Design DetailG plain shaft

P shaft with keyway 1)with centering hole on the end face withthread "DS" according to DIN 332, part2, edition 05.83

1) keyway according to DIN 6885, sheet 1, edition 08.68 (for details seedimensional 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 22

Abbrev. column 23



• Holding brakeDistributed servo drives KSM can be optionally supplied with electricallyreleased holding brakes.

Option Holding brake0 without holding brake

2 with holding brake For holding torque, see individual datasheets.

Fig. 1-7: KSM holding brakes

Note: The holding brake is not suited for personal protection or asservice brake! Observe the installation and safety instructionsfor the motor holding brakes!

• Master communicationSE: SERCOS (RS422)

• Safety option (X41)NN: none

• Connecting voltageD7: DC 750 V

• Other designNN: none

• FirmwareFW: Firmware must be ordered as separate subposition

• Standard referenceThe item "Standard reference" refers to standards cited in the type code(e.g. DIN, EN, ISO …) or reference INN... factory standards. The typecode lists the edition valid at the point of time the type code is issued.

Abbrev. column 24








Electronic Control System KCU

Type Code

Fig. 1-8: Type code KCU

FirmwareOperating a Rexroth IndraDrive Mi drive system requires the standardfirmware MPB04-V20 or higher.Type code: see Functional Description of firmware



1.4 Guide to the Documentation

Documentation Structure

Chapter Title Contents

1 System Presentation general information

2 Important Directions for Use

3 Safety Instructionssafety

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 andMaintenance

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 IndraDriveDrive System

Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P

Rexroth IndraDriveDrive ControllersControl Sections Cxx

Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P

Rexroth IndraDriveSupply Units and Power Sections

Project Planning Manual DOK-INDRV*-HMV-S-D+HCS-PR01-EN-P

Rexroth IndraDriveAdditional 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-P1) In the document typecodes, "xx" is a wild card for the current edition

of the documentation (example: "PR01" is the first edition of aProject Planning Manual)

Fig. 1-10: Documentations - overview



Firmware

Title Kind of documentation Document typecode1)

Rexroth IndraDriveIntegrated Safety Technology

Functional and ApplicationDescription

DOK-INDRV*-SI*-**VRS**-FKxx-EN-P

Rexroth IndraDriveFirmware for Drive Controllers

Functional Description DOK-INDRV*-MP*-04VRS**-FKxx-EN-Por higher


Parameter Description DOK-INDRV*-GEN-**VRS**-PAxx-EN-P


Troubleshooting Guide DOK-INDRV*-GEN-**VRS**-WAxx-EN-P

1) In the document typecodes, "xx" is a wild card for the current editionof the documentation (example: "FK01" is the first edition of aFunctional Description)

Fig. 1-11: Documentations - overview

Rexroth IndraDrive Mi Important Directions for Use 2-1


2 Important Directions for Use

2.1 Appropriate Use

IntroductionRexroth products represent state-of-the-art developments andmanufacturing. They are tested prior to delivery to ensure operating safetyand reliability.The products may only be used in the manner that is defined asappropriate. If they are used in an inappropriate manner, then situationscan develop that may lead to property damage or injury to personnel.

Note: Rexroth as manufacturer is not liable for any damagesresulting from inappropriate use. In such cases, the guaranteeand the right to payment of damages resulting frominappropriate use are forfeited. The user alone carries allresponsibility of the risks.

Before using Rexroth products, make sure that all the pre-requisites foran 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 familiarwith appropriate use.

• If the products take the form of hardware, then they must remain intheir original state, in other words, no structural changes are permitted.It is not permitted to decompile software products or alter sourcecodes.

• 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 ApplicationDrive controllers made by Rexroth are designed to control electricalmotors and monitor their operation.Control and monitoring of the motors may require additional sensors andactors.

Note: The drive controllers may only be used with the accessoriesand parts specified in this document. If a component has notbeen specifically named, then it may neither be mounted norconnected. The same applies to cables and lines.Operation is only permitted in the specified configurations andcombinations of components using the software and firmwareas 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 anapplication.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 withdifferent drive power and different interfaces.

2-2 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 andinstallation conditions described in this documentation, in the specifiedposition of normal use and under the ambient conditions as described(temperature, degree of protection, humidity, EMC, etc.).

2.2 Inappropriate UseUsing the drive controllers outside of the operating conditions described inthis documentation and outside of the indicated technical data andspecifications 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, operationunder water, under extreme temperature fluctuations or extremely highmaximum temperatures.

• Furthermore, the drive controllers must not be used in applicationswhich have not been expressly authorized by Rexroth. Please carefullyfollow the specifications outlined in the general Safety Instructions!

Rexroth IndraDrive Mi Safety Instructions for Electric Drives and Controls 3-1


3 Safety Instructions for Electric Drives and Controls

3.1 General Information

Using the Safety Instructions and Passing Them on to OthersDo not attempt to install or commission this device without first reading alldocumentation provided with the product. Read and understand thesesafety instructions and all user documentation prior to working with thedevice. If you do not have the user documentation for the device, contactthe responsible Bosch Rexroth sales representative. Ask for thesedocuments to be sent immediately to the person or persons responsiblefor the safe operation of the device.If the device is resold, rented and/or passed on to others in any otherform, then these safety instructions must be delivered with the device.

WARNING

Improper use of these devices, failure to followthe safety instructions in this document ortampering with the product, including disablingof safety devices, may result in materialdamage, bodily harm, electric shock or evendeath!

Instructions for UseRead these instructions before the initial startup of the equipment in orderto eliminate the risk of bodily harm or material damage. Follow thesesafety 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. If you find that you cannotcompletely understand the documentation for your product, please askyour supplier to clarify.

• Proper and correct transport, storage, assembly and installation aswell as care in operation and maintenance are prerequisites foroptimal and safe operation of this device.

• Only assign trained and qualified persons to work with electricalinstallations:• Only persons who are trained and qualified for the use and

operation of the device may work on this device or within itsproximity. The persons are qualified if they have sufficientknowledge of the assembly, installation and operation of theequipment as well as an understanding of all warnings andprecautionary measures noted in these instructions.

• Furthermore, they must be trained, instructed and qualified toswitch electrical circuits and devices on and off in accordance withtechnical safety regulations, to ground them and to mark themaccording to the requirements of safe work practices. They musthave adequate safety equipment and be trained in first aid.

• Only use spare parts and accessories approved by the manufacturer.• Follow all safety regulations and requirements for the specific

application as practiced in the country of use.

3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Mi


• The devices have been designed for installation in industrialmachinery.

• The ambient conditions given in the product documentation must beobserved.

• Only use safety-relevant applications that are clearly and explicitlyapproved in the Project Planning Manual. If this is not the case, theyare excluded.Safety-relevant are all such applications which can cause danger topersons and material damage.

• The information given in the documentation of the product with regardto the use of the delivered components contains only examples ofapplications and suggestions.The machine and installation manufacturer must• make sure that the delivered components are suited for his

individual application and check the information given in thisdocumentation with regard to the use of the components,

• make sure that his application complies with the applicable safetyregulations and standards and carry out the required measures,modifications and complements.

• Startup of the delivered components is only permitted once it is surethat the machine or installation in which they are installed complieswith the national regulations, safety specifications and standards of theapplication.

• Operation is only permitted if the national EMC regulations for theapplication are met.

• The instructions for installation in accordance with EMC requirementscan be found in the documentation "EMC in Drive and ControlSystems".

• The machine or installation manufacturer is responsible forcompliance with the limiting values as prescribed in the nationalregulations.

• Technical data, connections and operational conditions are specified inthe product documentation and must be followed at all times.



Explanation of Warning Symbols and Degrees of Hazard SeriousnessThe safety instructions describe the following degrees of hazardseriousness. The degree of hazard seriousness informs about theconsequences resulting from non-compliance with the safety instructions:

Warning symbol with signalword

Degree of hazard seriousness accordingto ANSI Z 535

DANGER

Death or severe bodily harm will occur.

WARNING

Death or severe bodily harm may occur.

CAUTION

Bodily harm or material damage may occur.

Fig. 3-1: Degrees of hazard seriousness (according to ANSI Z 535)

Hazards by Improper Use

DANGER

High electric voltage and high working current!Risk of death or severe bodily injury by electricshock!

DANGER

Dangerous movements! Danger to life, severebodily injury or material damage byunintentional motor movements!

WARNING

High electric voltage by incorrect connection!Risk of death or bodily injury by electric shock!

WARNING

Health hazard for persons with heartpacemakers, metal implants and hearing aids inproximity to electrical equipment!



CAUTION

Hot surfaces on device housing! Danger ofinjury! Danger of burns!

CAUTION

Risk of injury by improper handling! Risk ofbodily injury by bruising, shearing, cutting,hitting or improper handling of pressurizedlines!

CAUTION

Risk of injury by improper handling of batteries!



3.2 Instructions with Regard to Specific Dangers

Protection Against Contact with Electrical Parts

Note: This section only concerns devices and drive components withvoltages of more than 50 volts.

Contact with parts conducting voltages above 50 volts can cause personaldanger and electric shock. When operating electrical equipment, it isunavoidable that some parts of the devices conduct dangerous voltage.

DANGER

High electrical voltage! Danger to life, electricshock and severe bodily injury!⇒ Only those trained and qualified to work with or on

electrical equipment are permitted to operate,maintain and repair this equipment.

⇒ Follow general construction and safety regulationswhen working on electrical power installations.

⇒ Before switching on the device, the equipmentgrounding conductor must have been non-detachably connected to all electrical equipment inaccordance with the connection diagram.

⇒ Do not operate electrical equipment at any time,even for brief measurements or tests, if theequipment grounding conductor is not permanentlyconnected to the mounting points of the componentsprovided for this purpose.

⇒ Before working with electrical parts with voltagepotentials higher than 50 V, the device must bedisconnected from the mains voltage or powersupply unit. Provide a safeguard to preventreconnection.



⇒ With electrical drive and filter components, observethe following:Wait 30 minutes after switching off power to allowcapacitors to discharge before beginning to work.Measure the voltage on the capacitors beforebeginning to work to make sure that the equipment issafe to touch.

⇒ Never touch the electrical connection points of acomponent while power is turned on.

⇒ Install the covers and guards provided with theequipment properly before switching the device on.Before switching the equipment on, cover andsafeguard live parts safely to prevent contact withthose parts.

⇒ A residual-current-operated circuit-breaker or r.c.d.cannot be used for electric drives! Indirect contactmust be prevented by other means, for example, byan overcurrent protective device according to therelevant standards.

⇒ Secure built-in devices from direct touching ofelectrical parts by providing an external housing, forexample a control cabinet.

European countries: according to EN 50178/ 1998,section 5.3.2.3.USA: See National Electrical Code (NEC), NationalElectrical Manufacturers' Association (NEMA), as well aslocal engineering regulations. The operator must observeall the above regulations at any time.

With electrical drive and filter components, observe the following:

DANGER

High housing voltage and high leakage current!Risk of death or bodily injury by electric shock!⇒ Before switching on, the housings of all electrical

equipment and motors must be connected orgrounded with the equipment grounding conductor tothe grounding points. This is also applicable beforeshort tests.

⇒ The equipment grounding conductor of the electricalequipment and the units must be non-detachablyand permanently connected to the power supply unitat all times. The leakage current is greater than3.5 mA.

⇒ Over the total length, use copper wire of a crosssection of a minimum of 10 mm2 for this equipmentgrounding connection!

⇒ Before start-up, also in trial runs, always attach theequipment grounding conductor or connect with theground wire. Otherwise, high voltages may occur atthe housing causing electric shock.



Protection Against Electric Shock by Protective Extra-Low Voltage(PELV)

All connections and terminals with voltages between 5 and 50 volts atRexroth products are protective extra-low voltage systems which areprovided with touch guard according to the product standards.

WARNING

High electric voltage by incorrect connection!Risk of death or bodily injury by electric shock!⇒ To all connections and terminals with voltages

between 0 and 50 volts, only devices, electricalcomponents, and conductors may be connectedwhich are equipped with a PELV (Protective Extra-Low Voltage) system.

⇒ Connect only voltages and circuits which are safelyisolated from dangerous voltages. Safe isolation isachieved for example by isolating transformers, safeoptocouplers or battery operation without mainsconnection.

Protection Against Dangerous MovementsDangerous movements can be caused by faulty control of connectedmotors. Some common examples are:• improper or wrong wiring of cable connections• incorrect operation of the equipment components• wrong input of parameters before operation• malfunction of sensors, encoders and monitoring devices• defective components• software or firmware errorsDangerous movements can occur immediately after equipment isswitched on or even after an unspecified time of trouble-free operation.The monitoring in the drive components will normally be sufficient to avoidfaulty operation in the connected drives. Regarding personal safety,especially the danger of bodily harm and material damage, this alonecannot be relied upon to ensure complete safety. Until the integratedmonitoring functions become effective, it must be assumed in any casethat faulty drive movements will occur. The extent of faulty drivemovements depends upon the type of control and the state of operation.



DANGER

Dangerous movements! Danger to life, risk ofinjury, severe bodily harm or material damage!⇒ For the above reasons, ensure personal safety by

means of qualified and tested higher-level monitoringdevices or measures integrated in the installation.They have to be provided for by the user accordingto the specific conditions within the installation and ahazard and fault analysis. The safety regulationsapplicable for the installation have to be taken intoconsideration. Unintended machine motion or othermalfunction is possible if safety devices are disabled,bypassed or not activated.

To avoid accidents, bodily harm and/or materialdamage:

⇒ Keep free and clear of the machine’s range ofmotion and moving parts. Possible measures toprevent people from accidentally entering themachine’s range of motion:- use safety fences- use safety guards- use protective coverings- install light curtains or light barriers

⇒ Fences and coverings must be strong enough toresist maximum possible momentum.

⇒ Mount the emergency stop switch in the immediatereach of the operator. Verify that the emergency stopworks before startup. Don’t operate the device if theemergency stop is not working.

⇒ Isolate the drive power connection by means of anemergency stop circuit or use a safety relatedstarting lockout to prevent unintentional start.

⇒ Make sure that the drives are brought to a safestandstill before accessing or entering the dangerzone.

⇒ Additionally secure vertical axes against falling ordropping after switching off the motor power by, forexample:- mechanically securing the vertical axes,- adding an external braking/ arrester/ clamping

mechanism or- ensuring sufficient equilibration of the vertical

axes.The standard equipment motor brake or an externalbrake controlled directly by the drive controller arenot sufficient to guarantee personal safety!



⇒ Disconnect electrical power to the equipment using amaster switch and secure the switch againstreconnection for:- maintenance and repair work- cleaning of equipment- long periods of discontinued equipment use

⇒ Prevent the operation of high-frequency, remotecontrol and radio equipment near electronics circuitsand supply leads. If the use of such devices cannotbe avoided, verify the system and the installation forpossible malfunctions in all possible positions ofnormal use before initial startup. If necessary,perform a special electromagnetic compatibility(EMC) test on the installation.

Protection Against Magnetic and Electromagnetic Fields DuringOperation and Mounting

Magnetic and electromagnetic fields generated by current-carryingconductors and permanent magnets in motors represent a seriouspersonal danger to those with heart pacemakers, metal implants andhearing aids.

WARNING

Health hazard for persons with heartpacemakers, metal implants and hearing aids inproximity to electrical equipment!⇒ Persons with heart pacemakers and metal implants

are not permitted to enter following areas:- Areas in which electrical equipment and parts are

mounted, being operated or commissioned.- Areas in which parts of motors with permanent

magnets are being stored, repaired or mounted.⇒ If it is necessary for somebody with a pacemaker to

enter such an area, a doctor must be consulted priorto doing so. The interference immunity of present orfuture implanted heart pacemakers differs greatly, sothat no general rules can be given.

⇒ Those with metal implants or metal pieces, as wellas with hearing aids must consult a doctor beforethey enter the areas described above. Otherwisehealth hazards may occur.



Protection Against Contact with Hot Parts

CAUTION

Hot surfaces at motor housings, on drivecontrollers or chokes! Danger of injury! Dangerof burns!⇒ Do not touch surfaces of device housings and

chokes in the proximity of heat sources! Danger ofburns!

⇒ Do not touch housing surfaces of motors! Danger ofburns!

⇒ According to operating conditions, temperatures canbe higher than 60 °C, 140 °F during or afteroperation.

⇒ Before accessing motors after having switched themoff, let them cool down for a sufficiently long time.Cooling down can require up to 140 minutes!Roughly estimated, the time required for coolingdown is five times the thermal time constantspecified in the Technical Data.

⇒ After switching drive controllers or chokes off, wait15 minutes to allow them to cool down beforetouching them.

⇒ Wear safety gloves or do not work at hot surfaces.⇒ For certain applications, the manufacturer of the end

product, machine or installation, according to therespective safety regulations, has to take measuresto avoid injuries caused by burns in the endapplication. These measures can be, for example:warnings, guards (shielding or barrier), technicaldocumentation.



Protection During Handling and MountingIn unfavorable conditions, handling and assembling certain parts andcomponents in an improper way can cause injuries.

CAUTION

Risk of injury by improper handling! Bodilyinjury by bruising, shearing, cutting, hitting!⇒ Observe the general construction and safety

regulations on handling and assembly.⇒ Use suitable devices for assembly and transport.⇒ Avoid jamming and bruising by appropriate

measures.⇒ Always use suitable tools. Use special tools if

specified.⇒ Use lifting equipment and tools in the correct

manner.⇒ If necessary, use suitable protective equipment (for

example safety goggles, safety shoes, safetygloves).

⇒ Do not stand under hanging loads.⇒ Immediately clean up any spilled liquids because of

the danger of skidding.

Battery SafetyBatteries consist of active chemicals enclosed in a solid housing.Therefore, improper handling can cause injury or damages.

CAUTION

Risk of injury by improper handling!⇒ Do not attempt to reactivate low batteries by heating

or other methods (risk of explosion andcauterization).

⇒ Do not recharge the batteries as this may causeleakage or explosion.

⇒ Do not throw batteries into open flames.⇒ Do not dismantle batteries.⇒ Do not damage electrical parts installed in the

devices.

Note: Environmental protection and disposal! The batteries installedin the product are considered dangerous goods during land,air, and sea transport (risk of explosion) in the sense of thelegal regulations. Dispose of used batteries separately fromother waste. Observe the local regulations in the country ofassembly.



Protection Against Pressurized SystemsAccording 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 ascompressed air, hydraulics oil, cooling liquids, and cooling lubricatingagents. In these cases, improper handling of external supply systems,supply lines, or connections can cause injuries or damages.

CAUTION

Risk of injury by improper handling of pressurizedlines!⇒ Do not attempt to disconnect, open, or cut

pressurized lines (risk of explosion).⇒ Observe the respective manufacturer's operating

instructions.⇒ Before dismounting lines, relieve pressure and

empty medium.⇒ Use suitable protective equipment (for example

safety goggles, safety shoes, safety gloves).⇒ Immediately clean up any spilled liquids from the

floor.

Note: Environmental protection and disposal! The agents used tooperate the product might not be economically friendly.Dispose of ecologically harmful agents separately from otherwaste. Observe the local regulations in the country ofassembly.

Rexroth IndraDrive Mi General Specification of the Components 4-1


4 General Specification of the Components

4.1 CertificationsFor the components, there are declarations of conformity available whichconfirm that the components have been designed according to the validEN standards and EC directives. If required, our sales representative canprovide you with the declarations of conformity.

Designation StandardCE conformity regarding Low-Voltage Directive EN61800-5-1

CE conformity regarding EMC product standard EN61800-3

listing according to UL standard (UL) UL 508 C (in preparation)

Fig. 4-1: Applied standards

Note: Before making a high-voltage test for the installation in whichthe components are used, disconnect all connections to thedevices or disconnect the plug-in connections to protect theelectronic components.

Fig. 4-2: CE label

in preparation

Declaration of Conformity

CE Label

C-UL-US Listing

4-2 General Specification of the Components Rexroth IndraDrive Mi


4.2 Transport and Storage

Transporting the Devices

Description Symbol Unit Valuetemperature range Ta_tran °C -25 … 70

relative humidity % 5 … 95

absolute humidity g/m3 1 … 60

climatic category (IEC721) 2K3

moisture condensation1) n

icing2) n1) 2) n: not allowed

Fig. 4-3: Ambient and operating conditions – transport

Storing the DevicesDescription Symbol Unit Valuetemperature range Ta_store °C -25 … 55



climatic category 1K3 (IEC721)

moisture condensation1) n

icing2) n1) 2) n: not allowed

Fig. 4-4: Ambient and operating conditions – storage

4.3 Installation Conditions

Ambient and Operating ConditionsThe following devices have been designed for control cabinet mounting:• drive controllers HCS• supply units HMV• electronic control system KCU• corresponding additional components

Note: The user must check that the ambient conditions, in particularthe control cabinet temperature, are complied with bycalculating the heat levels in the control cabinet and makingthe corresponding measurements.In the Technical Data of the individual components, the powerdissipation is indicated as an important input value forcalculating the heat levels.



Description Symbol Unit Value KCU Value KSMdegree of protection (IEC529) IP20 IP65

allowed mounting position G1 IM V1, IM V3, IM B5

allowed ambient temperature range Ta_work °C 0 … 40

allowed ambient temperature range duringoperation with reduced nominal data 1) Ta_work_red °C

0 … 55

see fig. "Capacity utilization at higher ambienttemperature" in chapter "Capacity Utilization"

derating at Ta_work < Ta < Ta_work_red 2) fTa %/K 1,33

nominal data up to installation altitude hnenn m 1000

maximum installation altitude without additionalovervoltage limiter hmax_ohne m

2000

maximum installation altitude3) hmax m

4000

see fig. "Capacity utilization at higherinstallation altitude" in chapter "CapacityUtilization"

reduced power data above installation altitude atTa < Ta_work_red 4)

hred m1000



climatic category (IEC721) 3K4

allowed pollution degree (EN50178) 2 3 (connector pluggedin)

allowed dust, steam EN50178 tab. A.2 according to degreeof protection

vibration sine: amplitude (peak-peak) at 10 … 57Hz5) mm

0,15 ±15 % -

vibration sine: acceleration at 57...150 Hz6) g 1 ±15 % -

vibration noise (random) frequency (IEC 68-2-36) Hz

20 … 150 -

vibration noise (random) spectral accelerationdensity, amplitude (IEC 68-2-36) g

2/Hz 0,005 ±3 dB -

vibration noise (random) rms value of totalacceleration (IEC 68-2-36) g

1 -

shock test out of operation (11 ms) 7) g 10 -

shock test half sine: out of operation (6 ms) 7) g - 15

vibration sine: acceleration at 10 … 2000 Hz 6),axial g

- 1

vibration sine: acceleration at 10 … 2000 Hz 6),radial g

- 1

1) observe derating2) data to be derated: PDC_cont; M0_603) In the installation, install overvoltage limiter for transient

overvoltages to limit the voltage to 1 kV between the outerconductors and to 2.5 kV between conductor-ground

4) see following characteristic; observe derating5) according to EN 60068-2-366) according to EN 60068-2-67) according to EN 60068-2-27

Fig. 4-5: Ambient and operating conditions



Type of Construction and Mounting PositionsDistributed servo drives KSM can be supplied in type of construction B05.The allowed types of installation according to EN 60034-7:1993 arecontained in the following table.

Allowed types of installationType ofconstr. ofmotor Designation Drawing Installation

IM B5 flange mounting ondrive side of flange

IM V1flange mounting ondrive side of flange,drive side bottomB05

IM V3flange mounting ondrive side of flange,drive side top

Fig. 4-6: Mounting positions

DANGER

Penetration of fluids! If motors are attachedaccording to IM V3, fluid present at the outputshaft over a prolonged time may enter into andcause damage to the motors!⇒ For that reason, ensure that fluid cannot be present

at the output shaft.

Compatibility with Foreign MattersAll Rexroth controls and drives are developed and tested according to thestate-of-the-art technology.As it is impossible to follow the continuing development of all materials(e.g. lubricants in machine tools) which may interact with our controls anddrives, it cannot be completely ruled out that any reactions with thematerials used by Bosch Rexroth might occur.For this reason, before using the respective material a compatibility testhas to be carried out for new lubricants, cleaning agents etc. and ourhousings/our housing materials.

Prime Coat and Housing VarnishThe housing varnish of the motors consists of black (RAL9005) 2K epoxyresin coating on the basis of epoxy polyamide resin in water.

Chemically resistant to In restricted formresistant to

Nonresistant to

• diluted acids/lyes

• water, sea water,waste water

• common mineral oils

• organic solvents

• hydraulic oil

• concentratedacids/lyes

Fig. 4-7: Varnish resistance



It is permitted to provide the housing with additional varnish with amaximum coat thickness of 40 µm. Before varnishing, verify the adhesionand resistance of the new varnish.

4.4 Capacity UtilizationWhere installation conditions differ, the following performance data arereduced in accordance with the diagrams:Motor:• power• continuous torque at standstill• S1 continuous torques• short-time service torque MKB

If differing ambient temperatures and higher installation altitudes occursimultaneously, both capacity utilization factors must be multiplied. Theinstallation altitude must only be taken into account once, deviatingambient temperatures must be taken into account separately for motorand drive controller.

Note: Use outside of the indicated installation conditions is notallowed, even if the performance data are additionallyreduced.

As the ambient temperature increases, the capacity utilization of thecomponents is reduced according to the figure below.

fTa capacity utilization factorTa work ambient temperature range for operation with nominal dataTa work red ambient temperature range for operation with reduced nominal data

Fig. 4-8: Capacity utilization at higher ambient temperature

Capacity Utilization vs. AmbientTemperature



As the installation altitude increases, the capacity utilization of thecomponents is reduced according to the figure below.

f capacity utilization factorhnenn maximum installation altitude for operation with nominal datahmax_ohne maximum installation altitude for operation with reduced nominal

data without using an overvoltage limiterhmax maximum installation altitude for operation with reduced nominal

data when using an overvoltage limiterFig. 4-9: Capacity utilization at higher installation altitude

Capacity Utilization vs.Installation Altitude

Rexroth IndraDrive Mi Technical Data of the Components 5-1


5 Technical Data of the Components

5.1 Explanation of Terms and DefinitionsData sheet KSM - Distributed servo drive with holding brake(optional)

Description Symbol Unit Definitionlisting according to UL standard (UL) standard according to which UL listing takes place

listing according to CSA standard (UL) standard according to which CSA listing takes place

UL files (UL) UL file number under which the components arelisted

short circuit current rating, SCCR,symmetrical amperes (UL) 1) ISCCR A rms

current which may flow at the point of infeed in thecase of error (short circuit)

ambient temperature during operation Tum °C ambient temperature during operation

degree of protection according to EN 60529

mass 2) mmot kg specified value plus optional holding brake

average sound pressure level (accuracyclass 2) at PDC_cont 3)

LP dB (A)according to DIN EN ISO 11205; comparative valueat distance 1 m, out of cabinet

minimum distance on the top of the device 4) dtop mm distance required to allow heat dissipation

minimum distance on the bottom of thedevice 5 dbot mm distance required to allow heat dissipation

horizontal spacing on the device 6) dhor mm distance required to allow heat dissipation

power dissipation at continuous current andcontinuous DC bus power respectively (UL)7)

PDiss_cont W occurring power dissipation at continuous power

Control voltage supply

rated control voltage input (UL) 8) UN3 V supply voltage of control electronics

rated power consumption control voltageinput at UN3 (UL) 9)

PN3 Wpower with which the power supply unit is loaded for24V supply

Data power section

rated power (t > 10 min) PLN_nenn Wpower consumption at the point of maximum power;mechanical power and power dissipation

rated input voltage, power (UL) 10) ULN_nenn V DCvoltage with which the component is supplied at thepower input

capacitance in DC bus CDC mF capacitance in DC bus

allowed switching frequencies 11) fs kHz allowed switching frequencies

Data motor stage

continuous torque at standstill 60 K M0_60 NmContinuous torque that can be delivered at the motoroutput shaft at speed n ≥ 0.01 Hz and 4 kHz ofswitching frequency.

maximum torque Mmax NmMaximum torque that can be delivered for approx.400 ms at maximum current Imax (manufacturingtolerances + 5% / -20%).

maximum current Imax(eff) AMaximum, temporarily allowed phase current (r.m.s.value) in the motor winding without damaging effecton the permanent-magnet circuit of the motor.

torque constant at 20 °C 12) KM_N Nm/ARatio of torque to current in the motor winding (r.m.s.value) at motor temperature 20 °C. Unit (Nm/A).

5-2 Technical Data of the Components Rexroth IndraDrive Mi


Description Symbol Unit Definition

constant voltage at 20 °C 13) KEMK_1000 V/min-1R.m.s. value of the induced motor voltage at motortemperature 20 °C and 1000 revolutions per minute.Unit (V/1000min-1).

rotor inertia 14) Jrot kg*m2 inertia of rotor without optional holding brake

thermal time constant Tth min

Time of the temperature rise to 63% of the endtemperature of the motor housing with the motorloaded with the allowed S1 continuous torque. Thethermal time constant is determined by the size ofthe motors and the method of cooling used.

(1): course of the motor housing temperature overtimeΘmax: highest temperature (motor housing)Tth: thermal time constant

maximum speed nmax min-1Maximum allowed speed of the motor. Limitingfactors can have mechanical (centrifugal forces,bearing stress) or electrical (DC bus voltage) causes.

insulation class according to DIN EN 60034–1 insulation class

Data optional holding brake

holding torque M4 Nm transmittable holding torque

rated voltage UN V input voltage of the holding brake

rated current IN A current consumption of the holding brake

clamping delay t1 ms ON delay when clamping

release delay t2 ms release delay

mass brake mBr kg add mass of holding brake to mass of motor

inertia brake Jrot kg*m2 add inertia of holding brake to rotor inertia1) Suitable for use on a circuit capable of delivering not more than this

SCCR value, 600 V AC or less. The drive series shall be used withlisted AC input line fuses or listed circuit breakers specified in thisdocumentation.

2) value plus holding brake3) according to DIN EN ISO 11205; comparative value at distance 1 m,

out of cabinet; HCS types with order code -L***: load-dependent4) 5) 6) see fig. "Air intake and air outlet at drive controller"7) HMV, HCS: plus dissipation of braking resistor, control section; KSM:

rated power consumption control voltage input8) observe supply voltage for motor holding brakes9) HMx: plus holding brake and control section; KCU: dependent on

number of axes; KSM: plus holding brake (UN x IN)10) HMS, HMD, HLB, HLC, KCU: DC bus L+, L-; HMV, HCS: mains input

L1, L2, L311) also depending on firmware and control section; see parameter

description "P-0-0001, Switching frequency of the power outputstage"; see "P-0-4058, Amplifier type data"

12) 13) manufacturing tolerance ±5%14) Specified without brake. If necessary, add the inertia of the brake.

Fig. 5-1: Data sheet KSM01.2B-041, KSM01.2B-061, KSM01.2B-071,KSM01.2B-076



The motor data and characteristics are determined under the followingconditions:• ambient temperature 40 °C• insulated structure (aluminum flange)• Amplifier temperature P-0-0384 = 100 °C (∆T = 60 K); this

temperature is slightly higher than the temperature of the motorhousing.

• switching frequency 4 kHz (at 8 kHz reduced continuous torque andpeak torque)

• motors with radial shaft sealing ring

Distributed servo drives KSM are documented according to the testcriteria and measuring methods of EN 60034-1. The specifiedcharacteristics correspond to operating modes S1 or S3.

P loadPV electric lossesΘ temperatureΘmax highest temperature (motor housing)t timeTC cycle duration∆tP operating time with constant load∆tV idle time

Fig. 5-2: Operating modes according to EN 60034-1: 1998

Operating mode S3 (intermittent duty) is supplemented by specification ofthe ON time ED %. The ON time is calculated as follows:

%100Tt

EDC

P ⋅=∆

ED relative ON time in %TC cycle duration∆tP operating time with constant load

Fig. 5-3: Relative ON time

The values specified in the documentation have been determined on thebasis of the following parameters:cycle duration: 1 minON time ED: 25%

Motor Data

Operating Modes

ON Time



Power consumption at the point of maximum power (PML); mechanicalpower and power dissipation

Mcont continuous torqueMS1 S1 torquen speedPcont continuous powerPML point of maximum power

Fig. 5-4: Power consumption

Electric peak power (worst-case value for dimensioning the supply unit)

S1 continuous operation characteristic of the motor (according to EN60034-1; 1998), natural convection

S3 intermittent duty characteristic with 25% ED of the motor (accordingto EN 60034-1; 1998) and max. cycle duration 1 min.

1 Mmax Rexroth IndraDrive Mi, controlled infeed DC 750 V2 Mmax Rexroth IndraDrive Mi, uncontrolled infeed 3 × AC 400 V. The

voltage drop on the supply line has not been taken intoaccount. With a high degree of voltage drop on long motorlines, we have inflected peak torque characteristics 1 and 2 atlower speeds. See chapter "Allowed Cable Lengths"

Fig. 5-5: Sample characteristic

DC Continuous PowerPDC

DC Peak PowerPDC_max

Sample Characteristic



5.2 Distributed Servo Drive KSM

KSM Data SheetData sheet KSM - Distributed servo drive with holding brake(optional)

Description Symbol UnitKSM01.

2B-041C-42

KSM01.2B-

061C-35

KSM01.2B-

061C-61

KSM01.2B-

071C-24

KSM01.2B-

071C-35

KSM01.2B-

076C-35listing according to UL standard(UL) tbd

listing according to CSA standard(UL) tbd

UL files (UL) tbd

short circuit current rating, SCCR,symmetrical amperes (UL) 1) ISCCR A rms 42000

ambient temperature duringoperation Tum °C 0...40

degree of protection IP 65

mass 2) mmot kg 5,5 9,5 14,0 14,5

average sound pressure level(accuracy class 2) at PDC_cont 3)

LP dB (A) < 75

minimum distance on the top ofthe device 4) dtop mm 100

minimum distance on the bottomof the device 5 dbot mm 100

horizontal spacing on the device 6) dhor mm 100

power dissipation at continuouscurrent and continuous DC buspower respectively (UL) 7)

PDiss_cont W 70 140 175 165


rated control voltage input (UL) 8) UN3 V 30...42

rated power consumption controlvoltage input at UN3 (UL) 9)

PN3 W 15,5

Data power section

rated power (t > 10 min) PLN_nenn W 495,0 930,0 800,0 1360,0 1325,0 1240,0

rated input voltage, power (UL) 10) ULN_nenn V DC 540...750

capacitance in DC bus CDC mF 0,012 0,024

allowed switching frequencies 11) fs kHz 4; 8

Data motor stage

continuous torque at standstill60 K M0_60 Nm 2,2 6,0 5,5 10,5 10,0 8,7

maximum torque Mmax Nm 9,4 25,0 18,0 35,0 28,0 29,0

maximum current Imax(eff) A 6,8 14,9 17,7

torque constant at 20 °C 12) KM_N Nm/A 1,60 2,03 1,16 2,52 1,85

constant voltage at 20 °C 13) KEMK_1000 V/min-1 98,2 125,0 71,5 155,0 114,0 113,8

rotor inertia 14) Jrot kg*m2 0,00017 0,00087 0,00173 0,00430

thermal time constant Tth min 13 18 15 25



Description Symbol UnitKSM01.

2B-041C-42

KSM01.2B-

061C-35

KSM01.2B-

061C-61

KSM01.2B-

071C-24

KSM01.2B-

071C-35

KSM01.2B-

076C-35maximum speed nmax min-1 5500 4300 6000 3400 4700

insulation class according toDIN EN 60034–1 155

Data optional holding brake

holding torque M4 Nm 4,0 10,0 16,0

rated voltage UN V 24 ± 10%

rated current IN A 0,50 0,75 1,00

clamping delay t1 ms 25 30

release delay t2 ms 35 40 50

mass brake mBr kg 0,5 0,8 1,1

inertia brake Jrot kg*m2 0,00002 0,00006 0,000161) Suitable for use on a circuit capable of delivering not more than this


2) value plus holding brake3) according to DIN EN ISO 11205; comparative value at distance 1 m,

out of cabinet; HCS types with order code -L***: load-dependent4) 5) 6) see fig. "Air intake and air outlet at drive controller"7) HMV, HCS: plus dissipation of braking resistor, control section; KSM:

rated power consumption control voltage input8) observe supply voltage for motor holding brakes9) HMx: plus holding brake and control section; KCU: dependent on

number of axes; KSM: plus holding brake (UN x IN)10) HMS, HMD, HLB, HLC, KCU: DC bus L+, L-; HMV, HCS: mains input

L1, L2, L311) also depending on firmware and control section; see parameter

description "P-0-0001, Switching frequency of the power outputstage"; see "P-0-4058, Amplifier type data"

12) 13) manufacturing tolerance ±5%14) Specified without brake. If necessary, add the inertia of the brake.

Fig. 5-6: Data sheet KSM01.2B-041, KSM01.2B-061, KSM01.2B-071,KSM01.2B-076



KSM Characteristics

S1, S3 characteristics apply to a PWM frequency of 4 kHz(1) Mmax IndraDrive, controlled infeed (1) 3x AC 400V)(2)(3)(4) Mmax IndraDrive, uncontrolled infeed (2) 3x AC 480V) (3) 3x AC

440V) (4) 3x AC 400V)Fig. 5-7: Characteristics KSM01.2B-041C-42



KSM01.2B-041C-42

KSM01.2B-061C-35







KSM01.2B-061C-61

KSM01.2B-071C-24







KSM01.2B-071C-35

KSM01.2B-076C-35



Dimensions and Technical Design

Dimensions

Typ A B C D E F G H K L M N P R SKSM01.2B-041 82 252 30 8 14 50 78.8 51 149.1 78.55 140 95 6.6 16.25 87

KSM01.2B-061 115 271 40 9.5 19 95 86.8 59 157.1 81.05 140 130 9 16.25 87

KSM01.2B-071 140 307 58 14 32 130 102.3 74.5 172.6 83.55 140 165 11 16.25 87

KSM01.2B-076 140 290 50 14 24 110 102.3 74.5 172.6 83.55 140 165 11 16.25 87dimension R: brackets open

Fig. 5-13: Dimensions KSM01.2B-041…076

Technical DesignType of construction of motor B5 according to EN 60034-7 (additionalinformation see 4-4 Type of Construction and Mounting Positions)

Black, RAL 9005

A, according to EN 60034-14: 2004

Type of Construction of Motor

Housing Varnish

Balance Value Level(Balance Quality)



According to DIN 42955, ed. 12.81(IEC 60072-1)

Encoder Concentricity tolerance Run-out and alignmenttolerance

S1, M1 N --- N ---

S2, M2 --- R --- R

Fig. 5-14: Tolerance for concentricity, run-out and alignment, depending onencoder option

According to DIN 42948, ed. 11.65

Motors with keyway have been balanced with the complete key. Themachine element to be driven must be balanced without a key.Shaft end cylindrical, acc. to DIN 748 part 3, ed. 07.75 (IEC 60072-1)Centering hole, according to DIN 332 part 2, ed. 05.83

Type

Corresponding key,according to DIN 6885-A(is not part of the scopeof supply of the motors)

Centering hole, accordingto DIN 332 part 2, ed. 05.83

KSM01.2B-041 5 × 5 × 20 DS M5

KSM01.2B-061 6 × 6 × 32 DS M6

KSM01.2B-071 10 × 8 × 45 DS M10

KSM01.2B-076 8 × 7 × 40 DS M8

Fig. 5-15: Key and centering hole

Concentricity, Run-Out andAlignment

Flange

Output Shaft, Shaft End andCentering Hole



Bearings and Shaft LoadFor additional information on• allowed radial and axial forces• shaft load• bearings

see chapter "Notes on Project Planning"

Fig. 5-16: KSM01.2B-041: allowed radial force (shaft and bearings load)


Radial Force Fradial





Type Maximum allowed axial force in [N]KSM01.2B-041 20

KSM01.2B-061 20

KSM01.2B-071 40

KSM01.2B-076 40

Fig. 5-20: Allowed axial force

Axial Force Faxial



5.3 Electronic Control System KCU

Brief Description and ApplicationsThe electronic control system fulfills the following functions:• transmission of power supply of KSM• conversion from SERCOS (fiber optic cable) to RS422• exchange of status signals between motors and supply unit• supply of KSM with control voltage

Technical DataDescription Symbol Unit KCU01.2N-SE-SE*-025-NN-Sweight m kg 3,80

degree of protection according to IEC529 IP20

minimum distance on the top of the device 1) dtop mm 80

minimum distance on the bottom of the device 2 dbot mm 110

temperature rise with minimum distances dbot; dtop; PBD ∆T K < 60

cooling type 3) f

volumetric capacity of forced cooling 4) V m3/h approx. 0.3

power dissipation at continuous current and continuous DC buspower respectively (UL) 5) PDiss_cont watt 90

insulation resistance at DC 500 V Ris Mohm > 50

average sound pressure level (accuracy class 2) at PDC_cont 6) LP dB (A) < 70


rated control voltage input (UL) 7) UN3 V 24 ±20%

maximum ripple content 8) w % -

rated power consumption control voltage input at UN3 = DC 24 V(UL) 9) PN3 W 675

inrush current at 24V supply IEIN3 A 8,00…(PN3/UN3)

pulse width of IEIN3 tEIN3Lade ms < 1000

input capacitance CN3 mF 5,00

maximum allowed voltage for 1 ms 10) UN3_max V 33,00

Power supply

rated input voltage, power (UL) 11) ULN_nenn V 540 ... 750

rated input current (UL) 12) IL_cont A 25,0

rated power (t > 10 min) at fs = 4 kHz; output frequency fout >fout_still; ULN_nenn; control factor a0 > 0,8; without mains choke 13)

PDC_cont kW 14,0 ... 18,8

maximum allowed DC bus power at ULN_nenn; without mains choke14) PDC_max kW 42,0 ... 53,3

capacitance in DC bus CDC mF < 0,001

capacitance against housing CY nF 2 × 470

maximum discharge time from UR_DC_On to DC 50 V 15) tentl_ZK sec. < 1

short circuit current rating, SCCR, symmetrical amperes (UL) 16) ISCCR A rms 420001) 2) see fig. "Air intake and air outlet at drive controller"3) n: natural convection; f: forced cooling4) HLR: see following note regarding cooling



5) plus dissipation of braking resistor (HMV, HCS) and control section(HMx, HCS)

6) according to DIN EN ISO 11205; comparative value at distance 1 m,out of cabinet; HCS types with order code -L***: load-dependent

7) observe supply voltage for motor holding brakes8) absolute voltage values must be within UN39) HMx: plus holding brake and control section; KCU: dependent on

number of axes; KSM: plus holding brake (UN x IN)10) see following note regarding overvoltage11) HMS, HMD, HLB, HLC, KCU: DC bus L+, L-; HMV, HCS: mains input

L1, L2, L312) at PDC_cont13) observe factors fTa; fP_DC; HMV: without fs; without fout; KCU:

independent of fs; fout; mains choke14) observe factors fTa; fP_DC15) without other device on DC bus16) Suitable for use on a circuit capable of delivering not more than this


Fig. 5-21: KCU – technical data

CAUTION

Property damage due to temperatures higherthan 105 °C!⇒ Comply with indicated minimum distances!

A air intakeB air outletC mounting surface in control cabinetdtop distance topdbot distance bottom

Fig. 5-22: Air intake and air outlet at drive controller



Mechanical System and MountingDimensions

Fig. 5-23: Dimensions



5.4 Hybrid Cables RKH

Technical Data

Description Unit Ready-made hybrid cables RKHcable brief description [5x2,5mm² + 5x0,34mm²+(2x2x0,34mm²)C]StC

temperature range during storage °C -30 °C to +60 °C

ambient temperature during operationand with permanent installation

°C -30 °C to +40 °C

ambient temperature during operationand with flexible installation

°C -20 °C to +40 °C

material of cable jacket PUR

approvals UL/CSA

silicone, halogens not containing any silicones or halogens

oil resistance according to DIN EN 60 811-2-1 and HD 22.10 appendix A, DIN282 part 10

burning behavior according t

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