Rexroth IndraDrive Supply Units Edition 01 Project ... Rexroth/Drives/Indradrive... · Project...

R911299229Edition 01

Rexroth IndraDriveSupply Units

Project Planning Manual

IndustrialHydraulics

Electric Drivesand Controls

Linear Motion andAssembly Technologies Pneumatics

ServiceAutomation

MobileHydraulics

About this Documentation Rexroth IndraDrive

DOK-INDRV*-HMV-*******-PR01-EN-P

Rexroth IndraDrive

Supply Units

Project Planning Manual


Document number 120-2400-B312-01/EN

Description ReleaseDate

Notes

DOK-INDRV*-HMV-*******-PR01-EN-P 01.2004 Project Planning Manual;first edition

2004 Bosch Rexroth AG

Copying 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 specified data is for product description purposes only and may notbe deemed to be guaranteed unless expressly confirmed in the contract.All rights are reserved with respect to the content of this documentationand the availability of the product.

Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main

Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85

http://www.boschrexroth.de/

Dept. EDC1/EDY1 (EH/US)

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

Title

Type of Documentation

Document Typecode

Internal File Reference

Record of Revisions

Copyright

Validity

Published by

Note

Rexroth IndraDrive Contents I


Contents

1 Introduction 1-1

1.1 About this Documentation............................................................................................................. 1-1

Purpose of Documentation ...................................................................................................... 1-1

1.2 Introducing the Devices................................................................................................................. 1-1

Features and Fields of Application .......................................................................................... 1-1

Main Features .......................................................................................................................... 1-1

Basic Structure......................................................................................................................... 1-2

Drive System............................................................................................................................ 1-3

Tests and Certifications ........................................................................................................... 1-4

2 Important Directions for Use 2-1

2.1 Appropriate Use ............................................................................................................................ 2-1

Introduction .............................................................................................................................. 2-1

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

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

3 Safety Instructions for Electric Drives and Controls 3-1

3.1 Introduction ................................................................................................................................... 3-1

3.2 Explanations.................................................................................................................................. 3-1

3.3 Hazards by Improper Use ............................................................................................................. 3-2

3.4 General Information ...................................................................................................................... 3-3

3.5 Protection Against Contact with Electrical Parts........................................................................... 3-5

3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) ......................................... 3-6

3.7 Protection Against Dangerous Movements .................................................................................. 3-7

3.8 Protection Against Magnetic and Electromagnetic Fields During Operation andMounting ....................................................................................................................................... 3-9

3.9 Protection Against Contact with Hot Parts .................................................................................. 3-10

3.10 Protection During Handling and Mounting .................................................................................. 3-10

3.11 Battery Safety.............................................................................................................................. 3-11

3.12 Protection Against Pressurized Systems.................................................................................... 3-11

4 Identifying and Checking the Delivered Components 4-1

4.1 Delivery of Components................................................................................................................ 4-1

Packaging ................................................................................................................................ 4-1

Accompanying Documents ...................................................................................................... 4-1

4.2 Scope of Delivery .......................................................................................................................... 4-1

Overview .................................................................................................................................. 4-1

Checking the Delivered Components ...................................................................................... 4-1

4.3 Component Designation................................................................................................................ 4-2

II Contents Rexroth IndraDrive


Type Plates on the Unit............................................................................................................ 4-2

4.4 Device Types ................................................................................................................................ 4-3

Type Code................................................................................................................................ 4-3

5 Transport and Storage 5-1

5.1 Transporting the Devices .............................................................................................................. 5-1

Conditions ................................................................................................................................ 5-1

5.2 Storing the Devices ....................................................................................................................... 5-1

Conditions ................................................................................................................................ 5-1

In Case of Long Storage Periods............................................................................................. 5-1

6 Mechanical Mounting 6-1

6.1 Mounting Conditions ..................................................................................................................... 6-1

Ambient and Operating Conditions.......................................................................................... 6-1

Duty Capacity........................................................................................................................... 6-3

6.2 Mechanical Technical Data........................................................................................................... 6-4

Dimensions .............................................................................................................................. 6-4

Installation Orientation ............................................................................................................. 6-5

Arrangement of Components in the Control Cabinet............................................................... 6-5

6.3 Cooling and Cooling Units ............................................................................................................ 6-7

Power Dissipation .................................................................................................................... 6-7

Mounting Cooling Units............................................................................................................ 6-8

7 Electrical Installation 7-1

7.1 General Information ...................................................................................................................... 7-1

7.2 Interference Elimination and EMC ................................................................................................ 7-2

Interference Elimination ........................................................................................................... 7-2

10 Rules for EMC-Correct Installation of Drives...................................................................... 7-3

Optimal EMC Installation ......................................................................................................... 7-5

7.3 Electrical Data ............................................................................................................................... 7-7

HMV01.1E-W0030, -W0075, -W0120...................................................................................... 7-7

HMV01.1R-W0018, -W0045, -W0065 ..................................................................................... 7-8

Control Voltage ........................................................................................................................ 7-9

7.4 Complete Connection Diagram................................................................................................... 7-10

7.5 Connecting Cables and Rails...................................................................................................... 7-11

Connections (Power Section) ................................................................................................ 7-11

Control Voltage (+24 V, 0 V).................................................................................................. 7-15

DC Bus (L+, L-) ...................................................................................................................... 7-17

PE Connection of Power Supply............................................................................................ 7-19

PE Connection, Power Supply Unit and Neighboring Device................................................ 7-20

X1, Bus Module...................................................................................................................... 7-21

X2, RS232.............................................................................................................................. 7-22

X3, Mains Connection............................................................................................................ 7-23

X31, Connection for Messages.............................................................................................. 7-25

X32, Mains Contactor Control, DC Bus Short Circuit, Braking Resistor Threshold............... 7-27

X33, Acknowledge Messages of Internal Mains Contactor ................................................... 7-29

Rexroth IndraDrive Contents III


X14, Mains Voltage Synchronization ..................................................................................... 7-30

7.6 Touch Guard ............................................................................................................................... 7-31

Cutouts................................................................................................................................... 7-31

Mounting ................................................................................................................................ 7-32

8 Determination of Appropriate Power Supply Units 8-1

8.1 Introduction ................................................................................................................................... 8-1

8.2 DC Bus Continuous Power ........................................................................................................... 8-1

8.3 DC Bus Peak Power ..................................................................................................................... 8-4

8.4 Regenerated Energy..................................................................................................................... 8-5

8.5 Continuous Regenerated Power................................................................................................... 8-6

8.6 Peak Regenerated Power............................................................................................................. 8-7

8.7 Connected Load of the Supply Unit .............................................................................................. 8-8

9 Control Mains Contactor 9-1

9.1 Control Possibilities....................................................................................................................... 9-1

Shutdowns with Faulty Drive Electronics................................................................................. 9-1

Braking with Emergency Stop or Power Failure ...................................................................... 9-1

9.2 Controlling the Supply Unit with Emergency Stop Relays ............................................................ 9-1

With DC Bus Dynamic Brake................................................................................................... 9-1

Without DC Bus Dynamic Brake.............................................................................................. 9-4

9.3 Control via NC Controller .............................................................................................................. 9-6

10 Troubleshooting 10-1

10.1 General........................................................................................................................................ 10-1

10.2 Fault Diagnostics and Resetting Faults ...................................................................................... 10-1

10.3 Checking and Repairing the Unit ................................................................................................ 10-2

10.4 Replacing the Unit....................................................................................................................... 10-3

10.5 Diagnostic Display....................................................................................................................... 10-4

11 Disposal and Environmental Protection 11-1

11.1 Disposal ...................................................................................................................................... 11-1

Products ................................................................................................................................. 11-1

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

11.2 Environmental Protection............................................................................................................ 11-1

No Release of Hazardous Substances.................................................................................. 11-1

Materials Contained in the Products...................................................................................... 11-1

Recycling................................................................................................................................ 11-2

12 Service & Support 12-1

12.1 Helpdesk ..................................................................................................................................... 12-1

12.2 Service-Hotline............................................................................................................................ 12-1

12.3 Internet ........................................................................................................................................ 12-1

12.4 Vor der Kontaktaufnahme... - Before contacting us.................................................................... 12-1

12.5 Kundenbetreuungsstellen - Sales & Service Facilities ............................................................... 12-2

IV Contents Rexroth IndraDrive


13 Appendix 13-1

13.1 Connection of Supply Unit by Wires ........................................................................................... 13-1

Supply Unit to the Left of the Drive Controller ....................................................................... 13-1

Supply Unit to the Right of the Drive Controller ..................................................................... 13-2

13.2 Stacked Devices ......................................................................................................................... 13-3

Counterclockwise Cable Routing........................................................................................... 13-3

Clockwise Cable Routing ....................................................................................................... 13-4

13.3 Mains Connection ....................................................................................................................... 13-5

General .................................................................................................................................. 13-5

Mains Supply Requirements .................................................................................................. 13-6

HMV01.1E.............................................................................................................................. 13-7

HMV01.1R.............................................................................................................................. 13-9

Fusing with Direct Mains Supply.......................................................................................... 13-13

13.4 Grounding the Power Supply System....................................................................................... 13-13

13.5 Fault Current Protective Device ................................................................................................ 13-14

13.6 Earth Leakage Monitor.............................................................................................................. 13-14

13.7 Chronological Sequence when Switching ON and OFF........................................................... 13-15

When Switching On ............................................................................................................. 13-15

When Switching Off ............................................................................................................. 13-16

13.8 Auxiliary Components ............................................................................................................... 13-17

Mains Choke ........................................................................................................................ 13-17

Mains Filter HFD .................................................................................................................. 13-19

14 Index 14-1

Rexroth IndraDrive Introduction 1-1


1 Introduction

1.1 About this Documentation

Purpose of DocumentationThis documentation describes

• planning the mechanical control cabinet construction

• planning the electrical control cabinet construction

• logistical handling of the equipment

1.2 Introducing the Devices

Features and Fields of ApplicationThe supply unit …

• supplies IndraDrive M drive controllers with the required DC busvoltage

• loops the 24 V control voltage of an external 24 V power supplythrough to the drive controllers

• communicates with the drive controllers via a module bus

The supply units can be used for realizing a multitude of drive tasks inmost diverse applications. For these purposes there are 2 different devicetypes (regenerative, non-regenerative) with graduated supply poweravailable.

Main Features• design with regeneration back to the mains (HMV01.1R-Wxxxx)

and without regeneration back to the mains (HMV01.1E-Wxxxx)

• external 24 V supply required (signal processing not supplied fromDC bus)

• 3-phase mains connection (380V... 480V, +-10% 50Hz-60Hz)

• integrated mains contactor for E-Stop

• integrated braking resistor (bleeder) for feeding supply units(HMV01.1E-Wxxxx)

• integrated emergency braking resistor for regenerative supply units(HMV01.1R-Wxxxx)

1-2 Introduction Rexroth IndraDrive


Basic Structure

Supply Unit

hmv_aufbau.fh7

2

1

3

1: Signal processing2: Control panel (Display)3: Power connections and control voltage connection

Fig. 1-1: Basic structure

Control PanelThe control panel is a separate part which is plugged on the supply unit.The supply unit is supplied ex works complete with control panel.

Esc Enter

01.F4002

Fig. 1-2: Standard control panel with sample display and control elements

• Operating status, command and error diagnoses, and warnings forproblems requiring attention are shown in the display.

• Using the four buttons, the commissioning operator or serviceengineer can opt, in addition to master communication using thecommissioning tool or NC control, to display further error diagnoses.

Rexroth IndraDrive Introduction 1-3


Drive SystemThe following figure shows the components of the drive system.

Fa5147f1.fh7

drive controller

firmware

RKS - ready-made encoder cable

motor

mains supply

RKG - ready-made power cable

3

supply unit

24 V supply unit

battery

DC bus resistor unit

DC bus capacitor unit

components shown in gray are absolutely necessary

Fig. 1-3: Drive system

1-4 Introduction Rexroth IndraDrive


Tests and Certifications

CEf1.fh7

Fig. 1-4: CE mark

In preparation

Insulation-high-voltage test inaccordance with EN50178

Routine testing with DC 2230 V, 1 minresp.Routine testing with AC 1575 V, 1 min;Power supply with 0,1 A short-circuitcurrent

Separation between control andpower voltage circuits

Safe separation in accordance withEN50178

Air gaps and leakage distances In accordance with EN50178Fig. 1-5: Tests

CE Mark

C-UL-US Listing

Tests

Rexroth IndraDrive 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 firstread and understand the relevant safety instructions and be familiarwith appropriate use.

• If the product takes 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 mannerdescribed in the relevant documentation.

2-2 Important Directions for Use Rexroth IndraDrive


Areas of Use and ApplicationSupply units of Rexroth are designed to supply the Rexroth IndraDrive Mdrive controllers.

Control and monitoring of the motors may require additional sensors andactors.

Note: The supply units may only be used with the accessories andparts specified in this document. If a component has not beenspecifically named, then it may not be either mounted orconnected. 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 function descriptions.

The supply units may only be operated under the assembly, installationand ambient conditions as described here (temperature, system ofprotection, humidity, EMC requirements, etc.) and in the positionspecified.

2.2 Inappropriate Use

Using the supply units outside of the above-referenced areas ofapplication or under operating conditions other than described in thedocument and the technical data specified is defined as “inappropriateuse".

Supply units may not be used if

• they are subject to operating conditions that do not meet the abovespecified ambient conditions. This includes, for example, operationunder water, in the case of extreme temperature fluctuations orextremely high maximum temperatures or if

• Rexroth has not specifically released them for that intended purpose.Please note the specifications outlined in the general safetyinstructions!

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


3 Safety Instructions for Electric Drives and Controls

3.1 Introduction

Read 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.

Do not attempt to install or start up this equipment without first reading alldocumentation provided with the product. Read and understand thesesafety instructions and all user documentation of the equipment prior toworking with the equipment at any time. If you do not have the userdocumentation for your equipment, contact your local Rexrothrepresentative to send this documentation immediately to the person orpersons responsible for the safe operation of this equipment.

If the equipment is resold, rented or transferred or passed on to others,then these safety instructions must be delivered with the equipment.

WARNING

Improper use of this equipment, 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!

3.2 Explanations

The safety instructions describe the following degrees of hazardseriousness in compliance with ANSI Z535. The degree of hazardseriousness informs about the consequences resulting from non-compliance with the safety instructions.

Warning symbol with signalword

Degree of hazard seriousness accordingto ANSI

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: Hazard classification (according to ANSI Z535)

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


3.3 Hazards by Improper Use

DANGER

High voltage and high discharge current!Danger to life or severe bodily harm by electricshock!

DANGER

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

WARNING

High electrical voltage due to wrongconnections! Danger to life or bodily harm byelectric shock!

WARNING

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

CAUTION

Surface of machine housing could be extremelyhot! Danger of injury! Danger of burns!

CAUTION

Risk of injury due to improper handling! Bodilyharm caused by crushing, shearing, cutting andmechanical shock or incorrect handling ofpressurized systems!

CAUTION

Risk of injury due to incorrect handling ofbatteries!



3.4 General Information

• Bosch Rexroth AG is not liable for damages resulting from failure toobserve the warnings provided in this documentation.

• Read the operating, maintenance and safety instructions in yourlanguage 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 equipment.

• Only persons who are trained and qualified for the use and operationof the equipment may work on this equipment or within its proximity.

• The persons are qualified if they have sufficient knowledge of theassembly, installation and operation of the equipment as well as anunderstanding of all warnings and precautionary measures noted inthese instructions.

• Furthermore, they must be trained, instructed and qualified toswitch electrical circuits and equipment on and off in accordancewith technical 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 specificapplication as practiced in the country of use.

• The equipment is designed for installation in industrial machinery.

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

• Use only safety features and applications that are clearly and explicitlyapproved in the Project Planning Manual.For example, the following areas of use are not permitted: constructioncranes, elevators used for people or freight, devices and vehicles totransport people, medical applications, refinery plants, transport ofhazardous goods, nuclear applications, applications sensitive to highfrequency, mining, food processing, control of protection equipment(also in a machine).

• 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 hisindividual 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.



3.5 Protection Against Contact with Electrical Parts

Note: This section refers to equipment and drive components withvoltages above 50 Volts.

Touching live parts with voltages of 50 Volts and more with bare hands orconductive tools or touching ungrounded housings can be dangerous andcause electric shock. In order to operate electrical equipment, certainparts must unavoidably have dangerous voltages applied to them.

DANGER

High electrical voltage! Danger to life, severebodily harm by electric shock!⇒ Only those trained and qualified to work with or on

electrical equipment are permitted to operate, maintainor repair this equipment.

⇒ Follow general construction and safety regulations whenworking on high voltage installations.

⇒ Before switching on power the ground wire must bepermanently connected to all electrical units accordingto the connection diagram.

⇒ Do not operate electrical equipment at any time, evenfor brief measurements or tests, if the ground wire is notpermanently connected to the points of the componentsprovided for this purpose.

⇒ Before working with electrical parts with voltage higherthan 50 V, the equipment must be disconnected fromthe mains voltage or power supply. Make sure theequipment cannot be switched on again unintended.

⇒ The following should be observed with electrical driveand filter components:

⇒ Wait five (5) minutes after switching off power to allowcapacitors to discharge before beginning to work.Measure the voltage on the capacitors before beginningto work to make sure that the equipment is safe totouch.

⇒ 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 equipment on.Prevent contact with live parts at any time.

⇒ A residual-current-operated protective device (RCD)must not be used on electric drives! Indirect contactmust be prevented by other means, for example, by anovercurrent protective device.

⇒ Electrical components with exposed live parts anduncovered high voltage terminals must be installed in aprotective housing, for example, in a control cabinet.



To be observed with electrical drive and filter components:

DANGER

High electrical voltage on the housing!High leakage current! Danger to life, danger ofinjury by electric shock!⇒ Connect the electrical equipment, the housings of all

electrical units and motors permanently with the safetyconductor at the ground points before power isswitched on. Look at the connection diagram. This iseven necessary for brief tests.

⇒ Connect the safety conductor of the electricalequipment always permanently and firmly to thesupply mains. Leakage current exceeds 3.5 mA innormal operation.

⇒ Use a copper conductor with at least 10 mm² crosssection over its entire course for this safety conductorconnection! The cross section must not be smallerthan the cross section of a phase of the mains suppywire.

⇒ Prior to startups, even for brief tests, always connectthe protective conductor or connect with ground wire.Otherwise, high voltages can occur on the housingthat lead to electric shock.

3.6 Protection Against Electric Shock by Protective LowVoltage (PELV)

All connections and terminals with voltages between 0 and 50 Volts onRexroth products are protective low voltages designed in accordance withinternational standards on electrical safety.

WARNING

High electrical voltage due to wrongconnections! Danger to life, bodily harm byelectric shock!⇒ Only connect equipment, electrical components and

cables of the protective low voltage type (PELV =Protective Extra Low Voltage) to all terminals andclamps with voltages of 0 to 50 Volts.

⇒ Only electrical circuits may be connected which aresafely isolated against high voltage circuits. Safeisolation is achieved, for example, with an isolatingtransformer, an opto-electronic coupler or whenbattery-operated.



3.7 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of the 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 errors

Dangerous 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 injury 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!⇒ Ensure personal safety by means of qualified and

tested higher-level monitoring devices or measuresintegrated in the installation. Unintended machinemotion is possible if monitoring devices are disabled,bypassed or not activated.

⇒ Pay attention to unintended machine motion or othermalfunction in any mode of operation.

⇒ Keep free and clear of the machine’s range of motionand moving parts. Possible measures to preventpeople from accidentally entering the machine’s rangeof 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, especially ifthere is a possibility of loose parts flying off.

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

⇒ Isolate the drive power connection by means of anemergency stop circuit or use a starting lockout toprevent unintentional start.

⇒ Make sure that the drives are brought to a safestandstill before accessing or entering the dangerzone. Safe standstill can be achieved by switching offthe power supply contactor or by safe mechanicallocking of moving parts.

⇒ Secure vertical axes against falling or dropping afterswitching off the motor power by, for example:

- mechanically securing the vertical axes

- adding an external braking/ arrester/ clampingmechanism

- 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 equipment cannotbe avoided, verify the system and the installation forpossible malfunctions in all possible positions ofnormal use before initial startup. If necessary, performa special electromagnetic compatibility (EMC) test onthe installation.

3.8 Protection Against Magnetic and Electromagnetic FieldsDuring Operation and Mounting

Magnetic and electromagnetic fields generated near current-carryingconductors and permanent magnets in motors represent a serious healthhazard to persons with heart pacemakers, metal implants and hearingaids.

WARNING

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

metal implants are not permitted to enter the followingareas:

- Areas in which electrical equipment and parts aremounted, being operated or started up.

- Areas in which parts of motors with permanentmagnets are being stored, operated, repaired ormounted.

⇒ If it is necessary for a person with a heart pacemakerto enter such an area, then a doctor must beconsulted prior to doing so. Heart pacemakers thatare already implanted or will be implanted in thefuture, have a considerable variation in their electricalnoise immunity. Therefore there are no rules withgeneral validity.

⇒ Persons with hearing aids, metal implants or metalpieces must consult a doctor before they enter theareas described above. Otherwise, health hazards willoccur.



3.9 Protection Against Contact with Hot Parts

CAUTION

Housing surfaces could be extremely hot!Danger of injury! Danger of burns!⇒ Do not touch housing surfaces near sources of heat!

Danger of burns!⇒ After switching the equipment off, wait at least ten (10)

minutes to allow it to cool down before touching it.⇒ Do not touch hot parts of the equipment, such as

housings with integrated heat sinks and resistors.Danger of burns!

3.10 Protection During Handling and Mounting

Under certain conditions, incorrect handling and mounting of parts andcomponents may cause injuries.

CAUTION

Risk of injury by incorrect handling! Bodilyharm caused by crushing, shearing, cutting andmechanical shock!⇒ Observe general installation and safety instructions

with regard to handling and mounting.⇒ Use appropriate mounting and transport equipment.⇒ Take precautions to avoid pinching and crushing.⇒ Use only appropriate tools. If specified by the product

documentation, special tools must be used.⇒ Use lifting devices and tools correctly and safely.⇒ For safe protection wear appropriate protective

clothing, e.g. safety glasses, safety shoes and safetygloves.

⇒ Never stand under suspended loads.⇒ Clean up liquids from the floor immediately to prevent

slipping.



3.11 Battery Safety

Batteries contain reactive chemicals in a solid housing. Inappropriatehandling may result in injuries or material damage.

CAUTION

Risk of injury by incorrect handling!⇒ Do not attempt to reactivate discharged batteries by

heating or other methods (danger of explosion andcauterization).

⇒ Never charge non-chargeable batteries (danger ofleakage and explosion).

⇒ Never throw batteries into a fire.⇒ Do not dismantle batteries.⇒ Do not damage electrical components installed in the

equipment.

Note: Be aware of environmental protection and disposal! Thebatteries contained in the product should be considered ashazardous material for land, air and sea transport in the senseof the legal requirements (danger of explosion). Disposebatteries separately from other waste. Observe the legalrequirements in the country of installation.

3.12 Protection Against Pressurized Systems

Certain motors and drive controllers, corresponding to the information inthe respective Project Planning Manual, must be provided withpressurized media, such as compressed air, hydraulic oil, cooling fluidand cooling lubricant supplied by external systems. Incorrect handling ofthe supply and connections of pressurized systems can lead to injuries oraccidents. In these cases, improper handling of external supply systems,supply lines or connections can cause injuries or material damage.

CAUTION

Danger of injury by incorrect handling ofpressurized systems!⇒ Do not attempt to disassemble, to open or to cut a

pressurized system (danger of explosion).⇒ Observe the operation instructions of the respective

manufacturer.⇒ Before disassembling pressurized systems, release

pressure and drain off the fluid or gas.⇒ Use suitable protective clothing (for example safety

glasses, safety shoes and safety gloves)⇒ Remove any fluid that has leaked out onto the floor

immediately.

Note: Environmental protection and disposal! The media used in theoperation of the pressurized system equipment may not beenvironmentally compatible. Media that are damaging theenvironment must be disposed separately from normal waste.Observe the legal requirements in the country of installation.



Notes

Rexroth IndraDrive Identifying and Checking the Delivered Components 4-1


4 Identifying and Checking the DeliveredComponents

4.1 Delivery of Components

Packaging

The components are supplied in separate packaging units.

The content of the packed components and the order number may beidentified using the adhesive barcode label on the packaging.

See chapter 11 "Disposal and Environmental Protection".

Accompanying DocumentsA delivery note in duplicate can be found in an envelope on one of thepackages supplied. No other accompanying documents are provided.

The total number of containers supplied is recorded on the delivery noteor consignment note.

4.2 Scope of Delivery

Overview

as standard optional

touch guard rails for connecting the DC bus

grounding bracket rails for connecting the control voltage

connector X31, X32, X33

safety instructions (brochure; DOK-GENERAL-DRIVE******-SVSx-MS-P)

Fig. 4-1: Scope of delivery

Checking the Delivered ComponentsPlease immediately check whether the delivered components are:

• complete

• correct

• intact

Packaging Units

Packaging Labels

Disposal of Packaging Material

4-2 Identifying and Checking the Delivered Components Rexroth IndraDrive


4.3 Component Designation

Each drive component is identified by a type designation.

A type plate is attached to all units, including the motor.

A label (cable marker) is wrapped round the ready-made cable. The typedesignation and length are indicated on this label. (The designation for thecable itself, without connector, is printed on the cable sheath.)

The identification of accessories packed in bags is either printed on thebag or indicated in an accompanying note.

Type Plates on the Unit

Fig. 4-2: Type plate arrangement

Rexroth IndraDrive Identifying and Checking the Delivered Components 4-3


4.4 Device Types

Type Code

Note: The following figure illustrates the basic structure of the typecode. Your sales representative will help with the currentstatus of available versions.

! "#$%

#&#!"! '"()* (#!" "+),-

!

! "#$% &

,#"(.()/ 0 ''' 0 ''

( 12

) *!! 34

+ ,- !)!

' .!!/.!! 0 &31 3 5))"."#)!)$#+6!.)5*5'124)-

Fig. 4-3: Type code

4-4 Identifying and Checking the Delivered Components Rexroth IndraDrive


Notes

Rexroth IndraDrive Transport and Storage 5-1


5 Transport and Storage

5.1 Transporting the Devices

Conditions

temperature -25 ... 70 °C

relative humidity 5 ... 95%;climatic category 2K3

absolute humidity 1 ... 60 g/m3

climatic category 2K3

moisture condensation not allowed

icing not allowed

Shock check not in operationaccording to EN 60068-2-27

Halve sine in 3 axis:10g / 11ms

Fig. 5-1: Conditions for transport

5.2 Storing the Devices

Conditions

temperature -25 ... 55 °C

relative humidity 5 ... 95%;climatic category 1K3

absolute humidity 1 ... 29 g/m3

climatic category 1K3

moisture condensation not allowed

icing not allowed

Fig. 5-2: Conditions for storage

In Case of Long Storage PeriodsThe power supply units contain sensitive electrolytic capacitors.Therefore, in the case of long storage periods, operate the power supplyunits once a year for at least 1 hour with power on (DC bus voltage mustbe applied).

5-2 Transport and Storage Rexroth IndraDrive


Notes

Rexroth IndraDrive Mechanical Mounting 6-1


6 Mechanical Mounting

6.1 Mounting Conditions

Ambient and Operating Conditions

Note: The supply units and their additional components are designedto be built into control cabinets.

Note: The user must check that the ambient conditions, and inparticular the temperature of the control cabinet, are compliedwith by calculating the heat levels in the control cabinet.

Designation Information

Ambient temperature 0 to +40 °C

Ambient temperature with derating 2% per °C to +55 °C

Temperature in storage see chapter 5 "Transport and Storage"

Temperature during transportation see chapter 5 "Transport and Storage"

Mounting altitude at rating 1000 m above sea level

Mounting altitude with derating* Up to 2000 m 2.0% per 100 m from 1000 m

From 2000 m: see characteristic in Fig. 6-3

Maximum mounting altitude* 4000 m(upper temperature limit falls to 40 °C instead of 55 °C)

Relative humidity

(operation)

5% to 95%

Cl.3K5 with reservation, as not –5 °C

Absolute humidity 1 to 29 g/m3

Climatic class Cl.3K5

Contamination level Contamination level 2 in accordance with EN50178

Vibration sinus in operation according toEN 60068-2-6

Amplitude and frequency: 0,15 mm (peak-peak)at 10 ... 57 Hz

Acceleration and frequency: 1 g at 57 ... 150 Hz

Tolerance: ±15 %

Vibration distortion (Random) inoperation according to IEC 68-2-36

Frequency: 20 ... 150 Hz

Spectral acceleration density amplitude: 0,005 g2/Hz

Tolerance: ± 3 dB

Virtual value (r.m.s.) of the total acceleration: 1,0 g

* For mounting altitudes of more than 2000 m, an overvoltage limiterfor transient overvoltage 1.2/50 µs must be installed in theinstallation or building in order to limit the voltage to 1.0 kV betweenthe outer conductors and to 2.5 kV between conductor-ground.

Fig. 6-1: Ambient and operating conditions

6-2 Mechanical Mounting Rexroth IndraDrive


All Rexroth controls and drives are developed and tested according to thestate-of-the-art of 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.

Compatibility with foreignmatters



Duty CapacityWhere conditions differ, the following performance data diminish inaccordance with the diagrams (see “Fig. 6-2: Duty capacity at higherambient temperature” and “Fig. 6-3: Duty capacity at higher mountingaltitude”):

• Permitted DC bus continuous output

• Continuous output of the braking resistor

• Continuous current

If differing ambient temperatures and higher mounting altitudes occursimultaneously, both duty factors must be multiplied. The mountingaltitude must be taken into account just once, differing ambienttemperatures must be considered separately for the motor and drivecontroller.

DG0006F1.FH7

Ambient temperature in °C

0,7

1

40 45 50 555

Load

fact

or

Fig. 6-2: Duty capacity at higher ambient temperature

DG0007F1.FH7

1000 2000

0,8

1

0 3000 4000

0,6

0,4

0,2

Load

fact

or

Installation altitude above sea level in meters

Fig. 6-3: Duty capacity at higher mounting altitude



6.2 Mechanical Technical Data

Dimensions

Dimensional Drawing for HMV01.1E-W0*** andHMV01.1R-W00**

maszblatt_hmv.fh7A)

A)

!"

#$

! !

%

A) minimum mounting clearanceFig. 6-4: Dimensional drawing for HMV01.1E-W0*** and HMV01.1R-W00**

Device L [mm] L1 [mm]

HMV01.1E-W0030 150 100

HMV01.1E-W0075 250 200

HMV01.1E-W0120 350 300

HMV01.1R-W0018 175 125

HMV01.1R-W0045 250 200

HMV01.1R-W0065 350 300

Fig. 6-5: L and L1 dimensions



Installation OrientationInstall supply units in such a way that their longitudinal axis correspondsto the natural direction of convection (connections for motor and powerdownwards).

In this way the natural convection supports the forced cooling air current.This avoids the generation of pockets of heat.

Arrangement of Components in the Control Cabinet

Power-dependent Arrangement

versorg_antrieb_sym.FH7

supply unit

drive controllers

high power low powerhigh powerlow power

drive controllers

Fig. 6-7: Example of an arrangement

• Arrange the drive controllers with higher power needs and highcurrents as close to the supply unit as possible. Ideally the drivecontrollers should be distributed equally to the left and right side of thepower supply.

• Position DC bus capacitor unit next to drive with the greatest DC buscontinuous output.

• Position DC bus resistor unit next to drive with the greatest negativefeed power.



Control Cabinet with Multiple Line Structure

Note: Particular attention should be paid to the maximumpermissible air intake temperature of components when theyare arranged in multiple lines in the control cabinet. Wherenecessary, cooling air guides are to be allowed for withventilators specially inserted for this purpose.

Forexample: airbaffleAdditional

fan

Discharge direction of thewarmed air in the flow-off area

Discharge direction of thewarmed air in the flow-off area

Entry area of the cooling airfor the upper device line

Entry area of the cooling airfor the lower device line

Exhaust airfrom the airconditioner

Supply airfrom the airconditioner

Fig. 6-8: Example of arrangement for multiple line structure with components



6.3 Cooling and Cooling Units

Power DissipationThe power dissipation of a drive system radiated to the control cabinet iscalculated from the sum of the power dissipation of the supply unit, thepower dissipation of the mains connecting unit, the power dissipation ofeach drive controller, and the power dissipation of additional units (e.g.DC bus resistor unit or DC bus capacitor unit).

The power dissipation of a supply unit is composed of

• power dissipation of the control voltage supply unit

• current-related power dissipation of rectifier (HMV01.1E) resp. inverter(HMV01.1R), wiring and mains contactor

• power dissipation of braking resistor unit (HMV01.1E) resp.emergency braking resistor (HMV01.1R)



Mounting Cooling UnitsUnless the ratings are reduced the drive controller may only be operatedup to an specified ambient temperature (see chapter 6.1). It is thereforepossible that a cooling unit will be required.

CAUTION

Possible damage to the drive controllerOperational safety of the machine endangered⇒ Note the following instructions

As a matter of principle condensation water is formed when cooling unitsare used. For this reason, please observe the following information:

• Always position cooling units in such a way that condensation watercannot drip onto electrical equipment in the control cabinet.

• Position the cooling unit so that the ventilator for the cooling unit doesnot spray accumulated condensation water onto electrical equipment.

electronicequipment

Eb0001f1.fh7

incorrectcorrect

warm cold

Cooling system

Cabinet

warm cold

Air duct

electronicequipment

Cabinet

Cooling system

Fig. 6-9: Arrangement of the cooling unit on the control cabinet

Avoiding Dripping or SprayedWater



electronic

equip.

Eb0002f1.fh7

incorrect

coolingunit

control cabinet

air inflow

air outflow

correct

control cabinet

air inflow

airduct

electronic

equip.

coolingunit

Fig. 6-10: Arrangement of the cooling unit on the front of the control cabinet

Condensation occurs when the temperature of the unit is lower than theambient temperature.

• Set cooling units with temperature adjustment to the maximumsurrounding temperature and no lower.

• Set cooling units with traced temperature so that the interiortemperature of the control cabinet is no lower than the temperature ofthe surrounding air. Set the temperature delimitation to the maximumsurrounding temperature.

• Only use well-sealed control cabinets so that condensation cannotarise as a result of warm and moist external air entering the cabinet.

• In the event that control cabinets are operated with the doors open(start-up, servicing etc.) it is essential to ensure that after the doors areclosed the drive controllers cannot at any time be cooler than the air inthe control cabinet, as otherwise condensation can occur. For thisreason ample circulation must be provided inside the control cabinet toavoid pockets of heat.

Avoiding Condensation



Notes

Rexroth IndraDrive Electrical Installation 7-1


7 Electrical Installation

7.1 General Information

Damage can be caused to the supply unit or circuit boards if electrostaticcharging present in people and/or tools is discharged across them.Therefore, please note the following information:

CAUTION

Electrostatic charges can cause damage toelectronic components and interfere with theiroperational safety!⇒ Objects coming into contact with components and

circuit boards must be discharged by means ofgrounding. Otherwise errors may occur whentriggering motors and moving elements.

Such objects include:

• the copper bit when soldering

• the human body (ground connection caused by touching a conductive,grounded item)

• parts and tools (placing on a conductive support)

Endangered components may only be stored or dispatched in conductivepackaging.

Note: Rexroth connection diagrams are only to be used forproducing installation connection diagrams. The machinemanufacturer’s installation connection diagrams must be usedfor wiring the installation!

• Lay signal lines separately from the load resistance lines because ofthe occurrence of interference.

• Feed analog signals (e.g., command values, actual values) viasheathed lines.

• Do not connect mains, DC bus or power leads to low voltages or allowthem to come into contact.

• When carrying out a high voltage or insulation test withstand test onthe machine’s electrical equipment, disconnect all connections to theunits. This protects the electronic components (permitted inaccordance with EN 60204-1). During their routine check test, Rexrothdrive components are tested for high voltage and insulation inaccordance with EN 50178.

CAUTION

Plugging and unclamping live connections candamage the controller.⇒ Do not plug in or unclamp live connections.

7-2 Electrical Installation Rexroth IndraDrive


7.2 Interference Elimination and EMC

Interference Elimination

Note: The subject interference elimination and electromagneticcompatibility (EMC) is described in detail in a separatedocumentation. It is absolutely necessary to read thisdocumentation for the proper operation of AC-drives!

The document is titled "Electromagnetic compatibility (EMC) indrive and control systems". Doc-Type: DOK-GENERAL-EMV********-PRxx-EN-P. The item number is 259814.

Note: As the HMV01.1R power supply unit must be operatedtogether with a combining filter, the indications concerning themains filter arrangement apply above all to the HMV01.1E.(The line filter is already included in the combining filter).

To maintain class B limit values (interference suppression N) as perEN 55011 / 3.91 at the machine (required in residential and light industrialareas), suitable interference suppression filters must be installed in themains supply line in the machine. The motor power cable should berouted in a shielded manner or a shielded motor power cable should beused.

CAUTION

Risk of damage!⇒ Only use Rexroth filters. These filters have beenadjusted to the Rexroth supply units, inverters andmotors in the best possible way. If you use differentfilters, the limit values possibly cannot be complied with.Moreover the filters and other components of the drivesystem might be destroyed.

Interference emission



10 Rules for EMC-Correct Installation of DrivesThe following 10 rules are the basics for designing drive systems incompliance with EMC.

Rules 1 to 7 are generally valid. Rules 8 to 10 are especially important tolimit noise emission.

All metal parts of the cabinet should be connected with one anotherthrough the largest possible surface area so that the best electricalconnection is established (not paint on paint!). If required, use serratedwashers which cut through the paint surface. The cabinet door should beconnected to the cabinet using the shortest possible grounding straps.

Signal, line supply, motor and power cables should be routed away fromanother (this eliminates mutual interference!). The minimum clearance is:10 cm. Barriers should be provided between power- and signal cables.These barriers should be grounded at several locations.

Contactors, relays, solenoid valves, electromechanical operating hourcounters etc. in the cabinet must be provided with noise suppressiondevices. These devices must be connected directly at the coil.

Non-shielded cables belonging to the same circuit (feeder and returncables) should be twisted with the smallest possible distance betweenthem. Cores which are not used must be grounded at both ends.

Generally, interference injection can be reduced by routing cables asclose as possible to grounded sheet steel panels. For this reason, cablesand wires should not be routed freely in the cabinet, but as close aspossible to the cabinet itself and the mounting panels. This is also true forreserve cables.

Incremental encoders must be connected using shielded cables. Theshield must be connected at the incremental encoder and at the drivecontroller through the largest possible surface area. The shield may notbe interrupted, e.g. using intermediate terminals.

The shields of signal cables must be connected to ground at both endsthrough the largest possible surface area to establish a good electricalconnection (transmitter and receiver). If the potential bonding between thescreen connections is poor, to reduce the shield current, an additionalpotential bonding conductor with a cross-section of at least 10 mm²should be connected in parallel with the shield. The shield can beconnected to ground (=cabinet housing) at several locations. This is alsotrue outside the cabinet. Foil shields are not recommended. Braidedscreens provide a better shielding effect (factor of 5).

If the potential bonding is poor, analog signal cables may only begrounded at one end to the drive controller in order to prevent low-frequency noise being injected into the screen (50 Hz).

Always locate a radio interference suppression filter close to the noisesource. The filter should be connected through the largest possiblesurface area with the cabinet housing, mounting panel etc. The bestsolution is a bare metal mounting panel (e.g. manufactured from stainlesssteel, galvanized steel), as the complete mounting surface can be used toestablish good electrical contact.

The incoming and outgoing cables of the radio interference suppressionfilter should be separated.

Rule 1

Rule 2

Rule 3

Rule 4

Rule 5

Rule 6

Rule 7

Rule 8



All variable-speed motors should be connected using shielded cables,whereby the shield is connected at both ends to the housings through thelargest possible surface area to minimize the inductance. The motorfeeder cables should also be shielded outside the cabinet, or at leastscreened using barriers.

Cables with steel shield are not suitable.

To connect the shield at the motor, a suitable PG gland with shieldconnection can be used (e.g. "SKINDICHT SHV/SRE/E" from the LappCompany, Stuttgart). It should be ensured that the connection betweenthe motor terminal box and the motor housing has a low impedance.Otherwise, use an additional grounding strap between them. Never useplastic motor terminal boxes!

The shield between the motor and drive controller may not be interruptedby installing components such as output reactors, sinusoidal filters, motorfilters, fuses, contactors. The components must be mounted on mountingpanels which also simultaneously serve as shield connection for theincoming and outgoing motor cables. If required, metal barriers may berequired to shield the components.

Note: Detailed information is available in the instructions in theProject Planning Manual "Electromagnetic compatibility (EMC)in drive and control systems". Doc-Type: DOK-GENERAL-EMV********-PRxx-EN-P. The item number is 259814.

Rule 9

Rule 10



Optimal EMC InstallationWith regard to an optimal EMC installation, a spatial separation of theinterference-free area (mains connection) and the interferencesusceptible area (drive components) is advisable. See the next figure inthis respect.

HMV01.1E-Wxxxx

mains PE

mains

filter

loadearth rail

to the motors

power connection

shielded control cabinetcompartment or intermediatepanel

controlcabinet

connectingclamps

mainswitch

distributorclamps

fuse

HMVE_emv.fh7

supp

ly u

nit

driv

e co

ntro

ller

driv

e co

ntro

ller

mainschoke

Fig. 7-1: HMV01.1E - Separation of interference-free and interferencesusceptible areas



HMV01.1R-Wxxxx

mains PE

earth railto the motors

shielded control cabinet compartmentor intermediate panel

controlcabinet

connectingclamps

mainswitch

distributorclamps

fuse

HMVR_emv.fh7

filter

power connection

mainschoke

shielded cable

ground connection

supp

ly u

nit

driv

e co

ntro

ller

driv

e co

ntro

ller

Fig. 7-2: HMV01.1R - Separation of interference-free and interferencesusceptible areas



7.3 Electrical Data

HMV01.1E-W0030, -W0075, -W0120Designation Symbol Unit HMV01.1E-W0030 HMV01.1E-W0075 HMV01.1E-W0120

kind of connection (mode of operation atthe mains)

- - 3-phase

mains input voltage (rated voltage) ULN V 380 -10% to 480 +10%

transient overvoltage limit values UL trans max V 1200

mains frequency fLN Hz 48 to 62

Maximum mains frequency change pertime unit

dfLN/t Hz/s 2% * fLN

mains input continuous current (r.m.s.value)

ILN cont A 50 125 200

connected mains power without DC buschoke (at max. DC bus power)

1)SLN kW 18 45 72

connected mains power with DC buschoke (at max. DC bus power)

SLN (L_DC) kW 30 75 120

power factor (cosϕ) cosϕ - 1

DC bus voltage (range) UDC V 435 to 710

upper DC bus voltage limit (shutdownthreshold)

2)UDC limit (max) V 900

lower DC bus voltage limit (shutdownthreshold)

3)UDC limit (min) V 0,75 * ¥2 * ULN

continuous DC bus power (at ULN =400V)with choke

4)PDC cont kW 30 75 120

continuous DC bus power (at ULN =400V)without choke

PDC cont kW 18 45 72

continuous DC bus power depending onmains input voltage

at ULN < 400 V: 1% power reduction per 4 V

at ULN > 400 V: 1% power increasing per 4 V

peak DC bus power(for max. 0,3 s with a preload of0,6 x ILN cont and 40 °C ambienttemperature)

PDC peak kW 45 112 180

braking resistor switch-on threshold UDC (R_DC On) V constant 820V orvariable 80V + ¥2 * ULN

continuous brake power kW 1,5 2 2,5

maximum brake power kW 36 90 130

brake energy absorption kWs 100 250 500

DC bus capacity CDC µF 1410 3760 5640

overload capacityfactor / duration

Iout_max1/

Iout_cont1

A factor 2,5(related to rated power without DC bus choke)

power dissipation PDiss W 150 340 500

1) These data refer to a supply impedance of 40 µH.2) When the upper DC bus voltage limit has been reached, the supply unit does

not switch off. The display shows a warning message. The output stages ofthe drive controllers are locked.

3) When the lower DC bus voltage limit has been reached, the supply unit doesnot switch off. The display shows a warning message. At an undervoltage of0,75 * ULN the supply unit switches off.

4) Inductance of the choke:HMV01.1E-W0030: 400 µHHMV01.1E-W0075: 200 µHHMV01.1E-W0120: 100 µH

Fig. 7-3: Technical data



HMV01.1R-W0018, -W0045, -W0065Designation Symbol Unit HMV01.1R-

W0018HMV01.1R-

W0045HMV01.1R-

W0065

kind of connection (mode of operation atthe mains)

- - 3-phase

mains input voltage (rated voltage) ULN V 380 -10% to 480 +10%

transient overvoltage limit values UL trans max V 1200

mains frequency fLN Hz 48 to 62

Maximum mains frequency change pertime unit

dfLN/t Hz/s 2% * fLN

mains input continuous current (r.m.s.value)

IL cont A 30 70 100

connected mains power with DC buschoke (at max. DC bus power)

SLN (L_DC) kW 18 45 65

power factor (cosϕ) cosϕ - 1

DC bus voltage (range) UDC V 750 (controlled)

upper DC bus voltage limit (shutdownthreshold)

UDC limit (max) V 900

lower DC bus voltage limit (shutdownthreshold)

UDC limit (min) V 0,75 * 2 * ULN

continuous DC bus power (at ULN =400V) PDC cont kW 18 45 65

continuous DC bus power depending onmains input voltage

at ULN < 400 V: 1% power reduction per 4 V

at ULN > 400 V: no power increasing

DC bus peak power(for max. 0,3 s with a preload of0,6 x ILN cont and 40 °C ambienttemperature)

PDC peak kW 45 112 162

braking resistor switch-on threshold UDC (R_DC On) V 820

continuous brake power (braking resistor) kW 0,4 0,4 0,4

maximum brake power (braking resistor) kW 36 90 130

brake energy absorption (braking resistor) kWs 80 100 150

DC bus capacity CDC µF 705 1880 2820

output voltage Uout eff V 750 (controlled)

overload capacityfactor / duration

Iout_max1/

Iout_cont1

A factor 2,5(related to rated power)

power dissipation PDiss W 290 680 800

Fig. 7-4: Technical data



Control Voltage(Information at ambient temperature of 25 °C)

Designation Symbol Unit Value

Control voltage UN3 V 24 ±5%

Max. ripple content w - controlled

Max. allowed overvoltage UN3max V 24 +20%

Max. charging current IEIN3 A HMV01.1E-W0030: 7 AHMV01.1E-W0075: 16 AHMV01.1E-W0120: 15 AHMV01.1R-W0018: 6 AHMV01.1R-W0045: 8 AHMV01.1R-W0065: 14 A

Max. pulse duration of IEIN3 tEIN3Lade ms • HMV01.1E-W0120: 50

• all other devices: 15

Max. input capacity CN3 mF 10

Power consumption:

HMV01.1-1E-W0030 PN3 W 24 (preliminary)



HMV01.1-1R-W0018 PN3 W 27 (preliminary)



Fig. 7-5: Control voltage



7.4 Complete Connection Diagram

L1 L2 L3

anschlussplan_hmv.FH7

RS232

acknowledgment power ON

acknowledgment power OFF

24V for interface

DC bus short circuit 24V

mains OFF

mains ON

0V for interface

ready for operation

DC bus ok

prewarning temp./bleeder

mains connection

module bus

mains contactorON

mains contactorOFF

24V

0V

L+

L-

HM

V 0

1.1x

- W

xxxx

X3

24V control voltage

DC bus

mains connectionfor synchronization

braking resistor thresholdfixed/variable **

&' &'

4

3

2

1

9

8

7

6

5

4

3

2

1

6

5

4

3

2

1

8

7

6

5

4

3

2

1

8

7

6

5

4

3

2

1

3

2

1

X33

X32

X31

X2

X1

* only for HMV01.1R-Wxxxx

X14*

** only for HMV01.1E-Wxxxx

Fig. 7-6: Complete connection diagram



7.5 Connecting Cables and Rails

Connections (Power Section)

Overview

installation_hmv_system.fh72 3

A

B

C D

4

5

6

1

No. Designation

A UPS (uninterruptible power system)

B 24 V control voltage supply

C Supply unit

D Drive controller

1 PE connection of mains supply

2 Mains connection

3 PE connection to drive controller;If cables are used for ground connection they must have a cross section of at least 10 mm2.

4 Module bus X1

5 Control voltage connection (+24V, 0V);If connection with contact isn’t possible you can also use wires.

6 DC bus connection (L+, L-);If connection with contact isn’t possible you can also use wires.

Fig. 7-7: Connections - overview



HMV01.1E-W0030 and HMV01.1E-W0075

hmv_e30_front.fh7

+24 V

0 V

L+

L-

control voltage

DC bus

mains

PE

PE

X2

control panel

X1

X33

X32

X31

Fig. 7-8: HMV01.1E-W0030 and HMV01.1E-W0075

Description of connections:

Connection See page

control voltage 7-15

DC bus 7-17

mains voltage (X5) 7-22

PE connection power supply unit resp. neighboring device 7-20

X1 7-21

X2 7-21

X3 7-27

X6 7-29

X7 7-25



HMV01.1E-W0120

hmv_e120_front.fh7

L+

L-

+24 V

0 Vcontrol voltage

DC bus

mains

PE connectionto drive controller

PEPE connectionto drive controller

PE

X33

X32

X31

X2

X1

control panel

Fig. 7-9: HMV01.1E-W0120


Connection See page


DC bus 7-17



X1 7-21

X2 7-21

X3 7-27

X6 7-29

X7 7-25



HMV01.1R-W0018, -W0045, -W0065

hmv_r18_front.fh7

L+

L-

+24 V

0 Vcontrol voltage

DC bus

mains

PE

PE

X2

X14

control panel

X33

X32

X31

Fig. 7-10: HMV01.1R-W0018, -W0045, -W0065


Connection See page


DC bus 7-17



X1 7-21

X2 7-21

X3 7-27

X6 7-29

X7 7-25

X14 7-30



Control Voltage (+24 V, 0 V)The control voltage is supplied by an external 24-V power supply unit.

Note: • Technical data: see page 7-9• Falling short of the permissible control voltage leads to acorresponding error message (=> refer also to firmwarefunction description).• Interruption to the control voltage when the motor isrunning leads to torque-free (brakeless) runout in the motor.• If a power supply unit is used with a DC bus dynamicbraking function, an interruption to the control voltage supplycauses braking to the axes through the DC bus dynamicbraking.

DANGER

Dangerous movement caused by brakelessmotor coasting to stop in the event of aninterruption to the control voltage supply!⇒ Do not stay within the motional range of the machine.

Possible measures to prevent personnel accidentallyaccessing the machine:– protective fencing– protective grid– protective cover– light barrier.

⇒ Fencing and covers must be adequately securedagainst the maximum possible force of movement.

The external 24-V power supply unit is connected to the supply unit bycables with a cross section of 1.5 mm2 at least. The cables must not be tolong in order to keep the claimed tolerance (±5%) of the control voltage.

The control voltage supply is connected by contact rails and screws (M6)to the front of the drive controller (cross section of a contact rail:4 x 12 mm). There are various lengths of contact rail depending on thewidth of the drive controllers.

Design



schienen_steuerspg

BA

A: cables (to the source of control voltage)B: contact rails

Fig. 7-11: Contact rails

6 NmTightening Torque



DC Bus (L+, L-)The DC bus connection connects

• the supply unit to the drive controller

• the supply unit to additional components in order to

• increase the stored power by means of DC bus capacitor unit

• increase the permissible braking resistor continuous output bymeans of DC bus resistor unit

The DC bus is connected by contact rails and screws (M6) to the front ofthe drive controller. There are various lengths of contact rail depending onthe width of the drive controllers.

schienen_zwkreis

Fig. 7-12: Contact rails

6 Nm

If in special cases it is not possible to use the DC bus rails provided tomake the connection, the connection must be made using the shortestpossible twisted wires.

Length of the twisted wire max. 2 mWire cross-section min. 10 mm²,

however, no less than thecross-section of the power

input lineWire protection by means of fuses in the

mains supplyVoltage stability of a single strand againstgrounding

> 750 V(e.g., strand type - H07)

CAUTION

Risk of voltage arcing!⇒ If wires instead of contact rails are used to connect

the supply unit, the connections have to be correctlymade (see page 13-1 onward).

Design

Tightening Torque

DC Bus Wiring



CAUTION

Risk of voltage arcing!⇒ If devices are stacked in the control cabinet, the

connections for the DC buses between the drivecontrollers have to be correctly made. There isotherwise a risk of voltage arcing (see page 13-3onward).



PE Connection of Power Supply

HMV01.1E-W0030, -W0075HMV01.1R-W0018, -W0045, -W0065

HMV01.1E-W0120

hmv_erdanschluss_netz_30.fh7 hmv_erdanschluss_netz_120.fh7

Abb. 7-13: PE connection of power supply

The ground wire is fixed to the supply unit with screws:

HMV01.1E-W0030, -W0075HMV01.1R-W0018, -W0045, -W0065

HMV01.1E-W0120

M6 x 25 M10

HMV01.1E-W0030, -W0075HMV01.1R-W0018, -W0045, -W0065

HMV01.1E-W0120

6 Nm 18 Nm

Design

Tightening Torque



PE Connection, Power Supply Unit and Neighboring DeviceThe PE connection (grounding) to the drive controller can be provided induplicate in the case of the drive controllers through:

• a grounding bracket on the front (see figure below)

• the rear panel of the device if the devices are positioned against ashared, bare metal surface

Note: You must use the grounding bracket on the front for groundconnection in any case. The rear panel of the device can beused in addition.

erdungslasche_hmv

1

1: Grounding bracket for ground connectionFig. 7-14: PE connection to supply unit resp. neighboring device

Note: If cables are used for PE connection they must have a crosssection of at least 10 mm2. The cross section must not besmaller than the cross section of the mains supply cable.

The grounding bracket is fixed to the supply unit with screws (M6 x 25)

6 Nm

Design

Tightening Torque



X1, Bus ModuleThe bus module permits data exchange between the supply unit and thedrive controllers.

X1_hmv

Fig. 7-15: X1

Type Number ofpoles

Type of design

Flat line connector 8 Connector on deviceFig. 7-16: Design

Note: If extension leads are used the leads must be shielded. Theirtotal length must not exceed a maximum of 40 m.

Graphic Representation

Design



X2, RS232

RS232 InterfaceThe RS232 interface is required for diagnosis during commissioning andservicing.

PS2_stecker_hmv.fh7

1

2

3

4

5

6

7

8

Fig. 7-17: X2

Type Number of poles Type of design

MiniDIN 8 socket on deviceFig. 7-18: Design

Cross sectionsingle-wire

[mm²]

Cross sectionmultiwire

[mm²]

Cross sectionin AWG

Gauge No.

-- 0.25 – 0.5 --Fig. 7-19: Connection cross section

n.c. 1

n.c. 2

RS232_TxD 3

GND 4

RS232_RxD 5

n.c. 6

n.c. 7

n.c. 8

GND is connected to the housing.


Design

Connection cross section

Connection



X3, Mains Connection

hmv_X3

L1 L2 L3

Fig. 7-20: X3

HMV01.1E- Type Numberof poles

Type of design

W0030 Terminal block 3 Threaded terminal end



HMV01.1R- Type Numberof poles

Type of design




Fig. 7-21: Design

HMV01.1E- Cross sectionsingle-wire

[mm²]


[mm²]

Cross sectionin AWG

W0030 16 16 6

W0075 50 50 0

W0120 120 120 0000

HMV01.1R- Cross sectionsingle-wire

[mm²]


[mm²]

Cross sectionin AWG

W0018 6 6 10

W0045 25 25 4

W0065 50 50 0

Fig. 7-22: Connection cross sections


Design

Connection Cross Section



HMV01.1E- Torque

W0030 6

W0075 6

W0120 6

HMV01.1R- Torque

W0018 6

W0045 6

W0065 6

Fig. 7-23: Tightening torques

Note: See chapter 13.3 onward for further information on mainsconnection.

Tightening Torque



X31, Connection for MessagesThe X31 interface is used as a connection for messages:

• supply unit ready for operation (Bb1)

• power supply ok (UD)

• warning signal for bleeder overload and overtemperature (WARN)

hmv_X31

6

5

4

3

2

1

Fig. 7-24: X31


LK06-1M WIN R3,5series 0734

6 Bushing on device

Fig. 7-25: Design


[mm²]


[mm²]

Cross sectionin AWG

Gauge No.

0,14 - 1,5 0,14 - 1,5 28 - 16Fig. 7-26: Connection cross section

Description


Design




hmv_X31_schalt

ready for operation

DC busok

warningovertemperature/bleeder overload

Bb1

UD

WARN

6

5

4

3

2

1

X31

Name Pin no. Description Level Notes

Bb1_1 6

Bb1_2 5

supply unit ready foroperation

contact load DC 30V / 1Ainrush current max. 5A

contact closes:if no error is present

contact opens:if error is present

UD_1 4

UD_2 3

power supply ok contact load DC 30V / 1Ainrush current max. 5A

contact closes:if DC bus voltage is within the specifiedrange

contact opens:if DC bus voltage is too low resp. in caseof mains failure

WARN_1 2

WARN_2 1

warning signal for bleederoverload andovertemperature

contact load DC 30V / 1Ainrush current max. 5A

contact closes:in case of bleeder overload resp.overtemperature

contact opens:setting by default

Fig. 7-27: Connection X31

Connection



X32, Mains Contactor Control, DC Bus Short Circuit, Braking ResistorThreshold

The X32 interface is used to connect

• the mains contactor control

• the DC bus short circuit

• the switching signal for braking resistor threshold

Note: See chapter 9 onward for further information on mainscontactor control.

hmv_X32

9

8

7

6

5

4

3

2

1

Fig. 7-28: X32



9 Bushing on device

Fig. 7-29: Design


[mm²]


[mm²]

Cross sectionin AWG

Gauge No.


Description


Design




hmv_X32_schalt

24V for interface

DC bus short circuit 24V

mains OFF

mains ON

24V

0V for interface

braking resistor threshold fixed/variable *

9

8

7

6

5

4

3

2

1

X32

* only for HMV01.1E-Wxxxx

Name Pinno.

Description Level Notes

24V_IF 9 24V supply for interface (input) 24V ±5% 24V supply for interface, because interface inputsare isolated

DC bus s.c. 8 activating DC bus short circuitfunction

24V no DC bus short circuit function => 24V viaexternal contact

OFF1 7

OFF2 6

switching off mains contactor 24V for switching mains contactor on => pins 6 + 7jumpered via N/O

ON1 5

ON2 4

switching on mains contactor 24V switching mains contactor on by closing pins 4 + 5for longer than 200 ms (pushbutton)

brakingresistorthreshold

3 switching signal for brakingresistor threshold

24V for HMV01.1E => switching between brakingresistor threshold fixed <-> variable;input open: threshold variable(concerning braking resistor threshold seeelectrical data HMV01.1E on page 7-7)

24V 2 output 24V 24V for jumper on pin 3 for switching the brakingresistor threshold

0V 1 0V reference signal 0V 0V reference potential for interface


Connection



X33, Acknowledge Messages of Internal Mains ContactorThe X33 interface is used as a connection for acknowledge messages ofthe internal mains contactor.

hmv_X33

4

3

2

1

Fig. 7-32: X33



4 Bushing on device

Fig. 7-33: Design


[mm²]


[mm²]

Cross sectionin AWG

Gauge No.


hmv_X33_schalt

feedback contact mains contactor ON

feedback contact mains contactor OFF

4

3

2

1

X33

Name Pin no. Description Level Notes

MAINS_ON1 4

MAINS_ON2 3

feedback contact mains contactor ON (N/O) contact load DC 30V / 1Ainrush current max. 5A

MAINS_OFF1 2

MAINS_OFF2 1

feedback contact mains contactor OFF (N/C) contact load DC 30V / 1Ainrush current max. 5A


Description


Design


Connection



X14, Mains Voltage SynchronizationThe X14 interface is only available for regenerative supply units(HMV01.1R). It is used to connect the mains voltage synchronization.

hmv_X14

3

2

1

Fig. 7-36: X14


LE 7,62 M PC 4,0 / 3G 3 Connector on deviceFig. 7-37: Design


[mm²]


[mm²]

Cross sectionin AWG

Gauge No.

1,5 - 4 1,5 - 4 16 - 12Fig. 7-38: Connection cross section

Pin no. Description Level Notes

3 mains connection phase L3 before choke max. 900V current load max. 5A




Description


Design


Connection



7.6 Touch Guard

WARNING

Lethal electric shock caused by live parts withmore than 50 V!⇒ The appropriate touch guard must be mounted for

each supply unit following connection work.⇒ Never mount a damaged touch guard.⇒ Immediately replace a damaged touch guard by an

undamaged touch guard.

Cutouts

A

B C

Fig. 7-40: Cutouts at the touch guard

WARNING

Lethal electric shock caused by live parts withmore than 50 V!⇒ You have to provide the best possible protection

against contact. Therefore keep the cutouts at thetouch guard as small as possible.

⇒ Only break off the cutouts if necessary.

• If the DC bus and the control voltage are connected by means ofcontact rails, only the cutout C (see picture) may be broken off thetouch guard.

• If the DC bus and the control voltage are connected by means ofcables (e.g. in the case of multiple-line arrangement of the drivecontrollers), the cutouts A, B and C (see picture) may be broken offthe touch guard.



• At the first and last drive controller in a line of devices connected toeach other there mustn’t any cutout be broken off at the outer side ofthe touch guard.

MountingThe touch guard must always be mounted following connection work.

Fig. 7-41: Touch guard

Note: Risk of damage to the touch guard!The maximum tightening torque for the fixing screw for thetouch guard is 2.8 Nm.

2.8 NmTightening Torque

Rexroth IndraDrive Determination of Appropriate Power Supply Units 8-1


8 Determination of Appropriate Power Supply Units

8.1 Introduction

The mains supply for an AC drive system of the IndraDrive M productfamily mainly consists of the power supply unit. Depending on the tasksand design of the supply unit and the conditions of its use, it may benecessary to add link reactors, auxiliary capacitors, bleeder modules andtransformers as needed.

The mains supply must make available to the drives the DC buscontinuous power and the DC bus peak power for acceleration. Duringregenerative operation it must be able to store continuous and peakregenerated power. The supply unit also makes the control voltage for thedrive controllers available.

Prior to selecting supply unit and auxiliary components it is necessary todetermine the motors and drive controllers which will be used.

It is advisable to carry out calculations in accordance with the followingchapters in order to make sure that the layout of the mains supply iscorrect.

8.2 DC Bus Continuous Power

The DC bus continuous power is calculated from the mechanical powerand based on the efficiency of motor and controller as well as coincidencefactors.

9550n*M

]kW[P

or60

n2*MM]W[P

m

m

=

π=ω∗=

Pm: mechanical powerM: torque [Nm]ω: angular speed [min-1]n: motor speed [min-1]

Fig. 8-1: Mechanical power

The effective motor torque and average motor speed are needed tocalculate the mechanical continuous power of a servo drive.

The effective motor torque of the servo drive calculations can beassumed. The average motor speed is determined as follows:

The average motor speed equals approximately 25% of the rapid motionspeed - in the case of servo drive tasks in conventional NC machine tools.In some cases, however, this approximate estimation is not sufficient. Aprecise calculation of the average motor speed is necessary.

Mechanical power

Continuous mechanical powerfor servo drives

Average motor speed

8-2 Determination of Appropriate Power Supply Units Rexroth IndraDrive


If the duration over which the drive is operated at constant speed isconsiderably greater than the accel and decel time, then it applies:

n21

nn2211av t...tt

t*n...t*nt*nn

+++++

=

nav: average motor speed [min-1]n1 ... nn: motor speed [min-1]t1 ... tn: ON time [s]

Fig. 8-2: Average speed; influence of accel and decel time is not taken intoconsideration

DGoE.fh7

n1

n2

n3

t1 t2 t3 t4

t

Abb. 8-3: Speed cycle; influence of accel and decel time is not taken intoconsideration

Accel and decel times with short cycle times must be taken intoconsideration in such dynamic applications as is the case with rollers andnibble machines:

2B1H

B1H

av tttt

t*2n

t*nt*2n

n+++

++=

nav: average motor speed [min-1]n: motor speed [min-1]t: time [s]tH: accel time [s]tB: decel time [s]

Fig. 8-4: Average speed; influence of accel and decel time is taken intoconsideration

DGmE.fh7

n

t1 t2

t

tH tB

Abb. 8-5: Average speed; influence of accel and decel time is taken intoconsideration

Average speed without acceland decel time

Average speed with accel anddecel times



9550

n*MP aveff

mSe =

PmSe: continuous mech. power for servo drives [kW]Meff: effective motor torque [Nm]nav: average motor speed [min-1]

Fig. 8-6: Mechanical power for servo drives

Main drives are primarily used with constant power over a specific speedrange. This means that when planning power supply, nominal power isimportant. The mechanical nominal power of the main drives is illustratedin the operating characteristics or it can be calculated using nominalspeed and torque.

9550

n*MP nn

mHa =

PmHa: mechanical nominal power for main drives (shaft output) [kW]Mn: motor nominal torque [Nm]nn: motor nominal speed [min-1]

Fig. 8-7: Mechanical power for main drives

The power supply unit must make the DC bus continuous power availableto all servo drives. All drives are operated simultaneously in only a fewapplications which means that only the simultaneously occurring outputneeds to be considered. For the calculation of the required DC buscontinuous power for typical NC feed axes on tool machines, it hasproven in practice that a so-called coincidence factor is included:

Number of Axes 1 2 3 4 5 6

Coincidence factor (FG) 1 1,15 1,32 1,75 2,0 2,25

Fig. 8-8: Coincidence factors

G

mSen2mSe1mSe

F

25,1*)P...PP(P

+++=

PZWSe: DC bus continuous power for servo drives [kW]PmSe1 ... PmSen: cont. mech. power for servo drives [kW]FG: coincidence factor1,25: constant for motor and controller efficiency

Fig. 8-9: DC bus continuous power for servo drives

If several main drives are operated on one DC bus, then add thesimultaneously required power:

25,1*)P...PP(P mHan2mHa1mHaZWHa +++=

PZWHa: DC bus continuous power for main drives [kW]PmHa1 ... PmHan: mech. cont. power for main drives [kW]1,25: constant for motor and controller efficiency

Fig. 8-10: DC bus continuous power for main drives

Chokes and auxiliary capacitors are selected in terms of the actuallyrequired DC bus continuous power. It is fixed by the nominal power of thespindle drives.

Note: When selecting the power supply unit make sure that the DCbus continuous power does not limit the short-term power ofthe main drives.

Mechanical power for servodrives

Mechanical power for maindrives

DC bus continuous power forservo drives

DC bus continuous power formain drives



If main and servo drives are operated on a power supply unit, the requiredDC bus continuous power needs to be added.

It is the spindle drive in a NC machine tool that primarily determines theDC bus power needed. Therefore, the following equation should beapplied in such applications:

25,1*)]P...PP(*3,0P[P mSen2mSe1mSemHaZW +++=

0,3: experimental value for standard machine tools1,25: constant for motor and controller efficiencyPZW: DC bus continuous power [kW]PmSe1 ... PmSen: continuous mech. servo drive output [kW]PZWHa: nominal power for spindle drives (shaft output) [kW]

Fig. 8-11: DC bus continuous power for spindle and servo drives in machinetools

8.3 DC Bus Peak Power

The DC bus peak power is demanded of the power supply unit when, e.g.,several axes of a machine tool simultaneously accelerate to rapidtraverse and then go to a workpiece after a tool change.

CAUTION

Damages due to overloaded power supply unit!⇒ Damages to the power supply unit can be avoided, if

the sum of the peak power of all drives does notexceed the DC bus peak power of the power supplyunit.

9550

25,1*n*)MM(P eilGNC

ZWS±

=

1,25: constant for motor and controller efficiencyMNC: acceleration torque in NC mode [Nm]MG: weight torque in vertical axes [Nm]neil: speed in rapid traverse [min-1]PZWS: DC bus peak power [kW]

Fig. 8-12: DC bus peak power per drive

∑ ≤ 03ZWSZWS PP

PZWS: DC bus peak power [kW]PZWS03: DC bus peak power of the power supply unit [kW]

Fig. 8-13: Sum of DC bus peak powers

DC bus continuous power formain and servo drives



8.4 Regenerated Energy

The energy content of all main and servo drives that brake simultaneouslyunder unfavorable conditions may not be greater than the maximumregenerated energy of the power supply unit as specified in the datasheet. If this is not taken into consideration during the layout stage, thenthere could be thermal damage to the bleeder resistor in the power supplyunit!

CAUTION

Property damages due to overloaded bleederresistor!⇒ Use a power supply unit that is appropriate for the

consumption of the regenerated power which ariseswhen all the main and servo drives connected to thepower supply unit brake simultaneously.

2

eilG

rot 602

*n*2

JW

π=

Wrot: rotary energy [Ws]neil: rapid traverse speed [min-1]JG: inertia of motor and load inertia reduced to shaft [kgm²]

Fig. 8-14: Regenerated energy per drive

∑ ≤ MAXrot WW

Wrot: rotary energy [Ws]WMAX: max. permissible regenerated energy of the power supply module

[kWs]Fig. 8-15: Sum of regenerated energies

In servo drive applications with numerous accel and decel procedures, asis the case, for example, with nibble machines and rollers, it is advisableto connect additional capacitors to the DC bus. The following advantagesresult from this:

• This prevents the bleeder resistor in the HMV01.1E power supply unitfrom being actuated while braking: The heat dissipated within thecontrol cabinet is considerably reduced.

• The stored energy can be used to accelerate thus reducing energyrequirements of the installation.

( )2ZW

2B

ZWZW UU*

2

CW −=

WZW: energy stored in the DC busCZW: DC bus capacitor [F]UB: bleeder actuation thresholdUZW: DC bus nominal voltage

Fig. 8-16: Energy that can be stored in the DC bus

Auxiliary capacitance as energystorage in the HMV01.1E



The auxiliary capacitor must be designed so that it is capable of storingrotary drive energy:

ternHMV01.1EinC1000*2ZWU2

BU

rot2WZuC −

−≥

UB: bleeder actuation threshold (approx. 820 V)UZW: DC bus nominal voltageWrot: rotatory energy [Ws]CZu: auxiliary capacitor [mF]CHMV01.1Ein intern: internal capacitance of supply unit [mF]

Fig. 8-17: Required auxiliary capacitance

In power supply units with regulated DC bus voltage (HMV01.1R)approximately 75 Ws per mF auxiliary capacitance can be stored.

In power supply units with unregulated DC bus voltage (HMV01.1E) theauxiliary capacitance should be designed for 10% overvoltage. Thestorable energy per mF auxiliary capacitance is listed in the table below.

Mains voltage 3 x AC 380 V 3 x AC 400 V 3 x AC 440 V 3 x AC 480 V

storable energy per mF auxiliary capacitance 163 Ws 144 Ws 103 Ws 89 Ws

Fig. 8-18: Storable energy with auxiliary capacitance on an HMV01.1E

8.5 Continuous Regenerated Power

The average sum of the continuous regenerated power of all drives maynot exceed the continuous regenerated power in the HMV01.1R or thecontinuous bleeder power in the HMV01.1E.

Note: For operation with continuous power, an additional loadcaused by DC bus short circuit is no longer allowed.

The processing time in servo drive applications given a typical NCmachine tool, is relatively long in terms of the entire cycle time. There islittle regenerated continuous power. An exact calculation is generally notrequired. It suffices if the peak regenerated power is not exceeded.

An exact calculation is needed in specific cases such as, for example:

• servo drive applications with numerous accel / decel procedures suchas is the case in nibble machines and rollers

• machine tools with modular main drives

• applications in which excessive masses must be lowered as is thecase with those overhead gantries used with storage and transporttechnologies

To calculate continuous regenerated power, the rotary energy of thedrives and the potential energy of non-compensated masses must beknown.

z*602

*n*2

JW

2

eilg

rot

π=

Wrot: rotary energy [Ws]neil: speed in rapid traverse [min-1]Jg: moment of inertia (motor + load) [kgm²]z: number of decels per cycle

Fig. 8-19: Rotary energy



z*h*g*mWpot =

Wpot: potential energy [Ws]m: load mass [kg]g: gravity constant = 9,81 m/s²h: drop height [m]z: number of drops per cycle

Fig. 8-20: Potential energy of non-compensated masses

z

rotgpotgRD t

WWP

+= BDRD PP ≤

PRD: continuous regenerated power [kW]PBD: continuous bleeder power [kW]tz: cycle time [s]Wpotg: sum of potential energy [kWs]Wrotg: sum of rotary energies [kWs]

Fig. 8-21: Continuous regenerated energy

8.6 Peak Regenerated Power

The peak regenerated power usually arises, when an Emergency Stopsignal has been released and all the axes brake simultaneously.

CAUTION

Property damages due to longer brakingperiods/paths!⇒ Choose the power supply unit such that the sum of

the peak regenerated power of the all drives does notexceed the bleeder peak power of the power supplyunit.

The peak regenerated power of the servo drives is listed in the motorselection documentation.

Roughly estimated, the peak regenerated power can be calculated asfollows:

25,1*9550

n*MP maxmax

RS = ∑ ≤ BSRs PP

PRS: peak regenerated power [kW]PBS: peak bleeder power [kW]Mmax: max. drive torque [Nm]nmax: max. NC usable speed [min-1]1,25: constant for motor and controller efficiency

Fig. 8-22: Peak regenerated power



8.7 Connected Load of the Supply Unit

The connected load is calculated to be able to determine mains fuses,line cross sections and, if needed, commutation chokes and transformers.

The connected load is dependent on the continuous power of the drivesand the functional principle of the power supply unit.

15,1*PS :(KD) choke mains with

)0120W,0075WE1.01HMVfor(5,1*PS

)0030WE1.01HMVfor(7,1*PS :(KD) choke mains without

ZW1N

ZW1N

ZW1N

=−−=

−=

SN1: connected load [kVA]PZW: DC bus continuous power [kW]

Fig. 8-23: Connected load for power supply units of the HMV01.1E line

05,1*PS ZW1N =

SN1: connected load [kVA]PZW: DC bus continuous power [kW]

Fig. 8-24: Connected load for power supply units of the HMV01.1R line

1N

1N1N

U*3

1000*SI =

IN1: mains current [I]SN1: connected load [kVA]UN1: mains voltage [U]

Fig. 8-25: Mains current

Rexroth IndraDrive Control Mains Contactor 9-1


9 Control Mains Contactor

9.1 Control Possibilities

The controls of the mains contactor and of the DC bus dynamic brake inthe supply unit, that are suggested in this documentation, explain thefunction principles. In this chapter, several control options are discussedand explained.

Note: Which control and functions are selected ultimately depend onthe extent of functions required and the range of actions of theentire installation and is primarily the responsibility of themanufacturer.

Shutdowns with Faulty Drive ElectronicsAn additional safety for braked shutdowns of the drives in case of faultydrive electronics is to short-circuit the DC bus voltage.

If the DC bus voltage is short-circuited, the motors with permanentenergized magnet will always be shut down to a braked condition. This isthe case whether the drive electronics is operative or not.

Note: Asynchronous drives do not brake when DC bus voltage isshort circuited!

If the drive electronics is interfered and the DC bus voltage is not short-circuited, then the motors with energized permanent magnet will slowdown uncontrolled.

Braking with Emergency Stop or Power FailureIn an emergency stop or power failure situation, drives are generallyshutdown by the drive control.

Given an emergency stop or with actuation of the drive-internal monitor,the drive control command value is set to go to zero and the drives brakecontrolled at maximum torque.

In some applications, however, e.g., electronically-coupled gear cuttingmachines, it is necessary to bring the drives, given an emergency stop orpower failure, to a standstill controlled by the CNC. In an emergency stopsituation or given the actuation of the drive-internal monitor, the drives areshutdown position-controlled by the NC control.

9.2 Controlling the Supply Unit with Emergency Stop Relays

With DC Bus Dynamic BrakeIf the mains contactor in the supply unit is controlled via the emergencystop relay and the DC bus is short-circuited, you will reach maximumsafety possible thus with very little expenditure. The drive systemmonitors are most effectively used.

9-2 Control Mains Contactor Rexroth IndraDrive


You should use this mode, if

• only motors with permanent magnetic excitation have been mounted,

• or if motors with permanent magnetic excitation and asynchronousmotors (induction machines) have been mounted,

• or if the E-Stop circuit must be duplicated or if e.g. a protection doormonitor is required,

• or if your drive system includes an extended and substantial E-Stopcircuit.

Note: As the energizing current of the auxiliary relay for triggering themains contactor flows via the E-Stop circuit, the voltage dropmust not become too great. To ensure a reliable energizing,the total resistance of the E-Stop circuit which comes intoeffect between the connections X3/1 and X3/9 must be under45 Ω!

The DC bus dynamic brake can shutdown motors with permanentmagnetic excitation even with a fault in the drive electronics. In order totrigger the DC bus dynamic brake in such a case, the Bb contacts of thedrive controllers in the E-Stop circuit have to be connected in series withthe CNC contact. The DC bus dynamic brake is only active in the event ofdrive errors. If the emergency stop is actuated, asynchronous drives willalso brake.

When the Bb contacts of the supply unit are connected in series withthe CNC contact in the E-Stop circuit, the DC bus dynamic brake is onlytriggered in the case of a supply unit error.

In an emergency stop situation or with actuation of the monitor in thesupply unit (e.g., power failure), the drives are shutdown by the driveelectronics in the manner set for the specific error reaction.

WARNING

Property damages due to uncontrolled axismovements!The DC bus dynamic brake protects machines againstdrive errors. It alone cannot assume the function ofprotecting personnel. Given faults in the drive and supplyunit, uncontrolled drive movements are still possible evenif the DC bus dynamic brake is activated.Asynchronous machines do not brake if the DC bus isshort-circuited. Depending on the type of machine, injuryto personnel is possible.⇒ Additional monitoring and protective devices should

be installed in the installation.

When actuating the emergency stop key, the mains contactor in thesupply unit immediately falls off. Drive enables are shut off by theemergency stop relay or an auxiliary contact of the mains contactor. Thedrives are shutdown as per the error reaction set in the drive controller.

A drive error message from the supply module (Bb1-contact), an errormessage by the NC control (servo error) or the overtravelling of the endlimit switch causes the mains contactor to be switched off and the DC busdynamic brake to be actuated.

Applications

Features

Function



1 2

K4

K4

Drivecontrollers

0V

U

Bb1

K1

ON delayapprox. 1.5 seconds ... 4 minutes 3)

&

enableconverter

K1

DC busdynamic

brake

Power supply unit

>1

A10

S1

S4

Control voltage

S11

S12

K1

Emergency-stop relayA10

safety doorclosed

Example. Depending on safety requirements atthe machine, additional monitoring devices andlocks may be necessary!

ready-to-operate

K1

RF

Bb

UD

A10 = Emergency-stop relayAF = drive enable of the drive controllersBb1 = power supply unit ready (drive system)Bb = drive controllers readyCNC = lag error message of control (use only contacts that do not open with E-stop switch is open)K1 = mains contactor in power supply unitK4 = drive enable signal controlRF = drive enable signal of the controlS1 = Emergency-stopS2 = axis end positionS4 = power OFFS5 = power ONS11/S12 = safety door monitor

AFAF AF

S2

CNC

S5

K1

1)

1)

bleedercontrol

2)

1) K1 control if no emergency-stop switch is used2) unregulated rectifier in HMV01.1E; regulated one in HMV01.1R3) depending on power supply unit and possibly connected external capacitors

A10

signalprocessing

+24V+/- 5%

HMV01.1E/HMV01.1R

SS2HMV.fh7

24 V +/-5%

0 V

L+

L-

X32/9

X32/8

X32/7

X32/6

X32/5

X32/4

X31/5

X31/6

X33/4

X33/3

X31/4

X31/3

X33/1

X33/2

X3

X32/1

Fig. 9-1: Control of the supply unit with DC bus dynamic brake in the event offaulty drive electronics



Without DC Bus Dynamic Brake• If an uncontrolled running out of the drives cannot damage the

installation.

• If only asynchronous drives are connected to the supply unit.

• If the end positions of the feed axes are sufficiently attenuated.

The DC bus voltage is not short-circuited.

In an emergency stop situation, or if the monitors of the supply unit areactuated (e.g., power failure), then the drives are shutdown by the driveelectronics as per the set error reaction.

The mains contactor in the supply unit immediately falls off when theemergency stop sequence is initiated. The drive enable is removed by theemergency stop relay or by an auxiliary contact of the mains contactor.The drives are shutdown depending on the set error reaction.

CAUTION

Machine damages due to brakeless slowingdown of the drives in the event of faulty driveelectronics!⇒ Use motors with mechanical brakes (a holding brake

must not be used as operating brake).⇒ End positions of feed axes must be sufficiently

attenuated.

Application

Features

Function



1 2

K4

K4

Drivecontrollers

0V

U

K1

&

enableconverter

K1

DC busdynamic

brake

Power supply unit

>1

A10

S1

S4

Control voltage

S11

S12

K1

Emergency-stopA10

safety doorclosed

ready-to-operate

K1

RF

Bb

UD

AFAF AF

S5

K1

1)

1)

bleedercontrol

2)

SS3HMV.fh7

Bb1 for diagnostics

A10

signalprocessing

Example. Depending on safety requirements atthe machine, additional monitoring devices andlocks may be necessary!

A10 = Emergency-stop relayAF = drive enable of the drive controllersBb1 = power supply unit ready (drive system)Bb = drive controllers readyCNC = lag error message of control (use only contacts that do not open with E-stop switch is open)K1 = mains contactor in power supply unitK4 = drive enable signal controlRF = drive enable signal of the controlS1 = Emergency-stopS2 = axis end positionS4 = power OFFS5 = power ONS11/S12 = safety door monitor

+24V+/- 5%

L+

L-

HMV01.1E/HMV01.1R

24 V +/-5%

0 V



X32/9

X31/5

X31/6

X32/1

X32/8

X32/7

X32/6

X32/5

X32/4

X33/4

X33/3

X31/4

X31/3

X33/1

X33/2

X3

Fig. 9-2: Control of the supply unit without DC bus dynamic brake



9.3 Control via NC Controller

If the mains contactor is controlled via NC controller, it is possible toprovide a position controlled shutdown of the drive via the NC controller inthe event of an emergency stop or as reaction of the internal monitoring ofthe drive.

This kind of mains contactor control is mostly used with drives which areelectronically coupled and shutdown synchronously when a power failureoccurs.

The DC bus voltage is not short-circuited so that power for a position-controlled shutdown of the drives is available.

Note: The energy stored in the DC bus or the regenerated energymust be greater than the energy needed to exciteasynchronous machines or for the return motion.

The parameter "Activating NC reactions with a fault" must beprogrammed in the drive controller (P-0-0117, bit 0 = 1).

Given an emergency stop or the actuation of the supply unit monitor (e.g.,power failure), the drives are shutdown position-controlled by the positioncontroller.

Upon initiating the emergency stop sequence, or with the actuation of themonitor in the supply unit (e.g., power failure), the mains contactor in thesupply unit falls off.

Drives with SERCOS interface signal the error to the NC control, meaningthat the drives can be shutdown position controlled.

Drives without SERCOS interface require the control to evaluate the UDcontact. If the UD contact is actuated, then the NC control must shutdown the drives.

CAUTION

Machine damages due to brakeless slowingdown of the drives in case of too little DC busvoltage!⇒ The controller should evaluate the UD contact and

shut down the drives, when the contact reacts.

Application

Features

Function



1 2

Drivecontroller

0V

U V W

K1

&

enableconverter

K1

DC busdynamic

brake

Power supply unit

>1

A10

S1

S4

Control voltage

S11

S12

K1

Emergency-stop ralayA10

safety doorclosed

ready-to-operate

RF

AFAF AF

S5

K1

1)

1)

brakingresistorcontrol

2)

SS4HMV.fh7

Bb1 for diagnostics

UD

3

Machinecontrol

Bb

signalprocessing

Example. Depending on safety requirements atthe machine, additional monitoring devices andlocks may be necessary!A10 = Emergency-stop relay

AF = drive enable of the drive controllersBb1 = power supply units ready (drive system)Bb = drive controllers readyCNC = lag error message of control (use only contacts that do not open with E-stop switch is open)K1 = mains contactor in power supply unitK4 = drive enable signal controlRF = drive enable signal of the controlS1 = Emergency-stopS2 = axis end positionS4 = power OFFS5 = power ONS11/S12 = safety door monitor

+24V+/- 5%

L+

L-

24 V +/-5%

0 V



X32/9

X32/1

X32/8

X32/7

X32/6

X32/5

X32/4

X3

X31/5

X31/6

X33/1

X33/2

X31/4

X31/3

Fig. 9-3: Control for position controlled shutdown of the drives via NC-controller(without DC bus voltage brake)



Notes

Rexroth IndraDrive Troubleshooting 10-1


10 Troubleshooting

10.1 General

Extensive searches for faults and repair of drive components on themachine are not acceptable due to the production downtime involved.

The modular concept of Rexroth drives makes it possible to completelyexchange drive components. Service thus means localizing problemseither on the motor, drive controller or power supply unit and replacing thepart.

Hinweis: No further adjustments are needed.

10.2 Fault Diagnostics and Resetting Faults

The supply unit signals operating states, warnings or faults via a display.

A prerequisite for fault diagnoses is control voltages and processors in thesupply units and drive controllers that are working properly.

Stored fault messages must be reset before the unit will again operate.An error can be reset by

• pressing key "Esc" on the control panel (display),

• switching the control voltage off or

• generating the reset command of the drive controller via the busmodule.

CAUTION

Destruction of the power supply module, if thepower is switched on to a faulty drivecontroller!⇒ Upon RESET of an over current fault and after

replacement of a defective supply module, the faultmemories of the drive controllers must be read outprior to switching it on.

If either checks or repairs are needed, then it applies:

• Checks and repairs may only be conducted by Rexroth customerservice personnel or such personnel that has been trained to do so.

• Observe the applicable safety regulations when checking the unit.

• Repairing drive components on the machine is very time consuming.Replace defective drive components completely.

WARNING

When faults are cleared, damages to themachine and injury to the personnel may occur!⇒ Fault clearance should only be conducted by trained

personnel.⇒ Protective devices must not be switched off.⇒ Note the warnings in chapter 3.

Fault diagnostics

Resetting faults

10-2 Troubleshooting Rexroth IndraDrive


10.3 Checking and Repairing the Unit

When contacting our service personnel we would like to ask you toprovide the following information so that a quick and precise assistancecan be assured:

• type designations and serial numbers of units and motors,

• the status of the fault,

• any diagnostic displays and

• software status, if necessary.

You’ll find the telephone number of our service hotline in the chapter"Service & Support".

Rexroth IndraDrive Troubleshooting 10-3


10.4 Replacing the Unit

Note: Replacing the unit requires, depending upon unit weight, alifting device and an identical replacement unit.

DANGER

Electrical shock due to voltage-containing partsof more than 50 V!⇒ The unit may only be replaced by qualified

personnel, which have been trained to perform thework on or with electrical devices.

Note: Prior to the replacement of the unit please check according tothe type plates, whether these units are of the same types.Replace only units of the same types.

Proceed as follows:

1. Switch voltage to installation off and secure it against being switchedback on.

2. Using an appropriate measuring device, check whether theinstallation is power free. Wait the discharge time.

3. Motors must be standing still.4. Secure vertical axes against motion.5. Release all connections from the defective unit.6. Release the fixing bolts and remove the unit from the control cabinet.

Use the lifting device, if necessary.7. Hang replacement unit into mounting rails. Use the lifting device, if

necessary.8. Reconnect the unit as per the terminal diagram of the machine

manufacturer.9. If vertical axes have been mechanically secured prior to replacement,

then remove these devices at this point.10. While reading out the fault memories of the connected drive

controllers make sure that the device fault has not been triggered bythe drive controllers (see warnings in chapter 10.2 "Fault Diagnosticsand Resetting Faults").

The unit replacement is completed. The system can be put back intooperation.

10-4 Troubleshooting Rexroth IndraDrive


10.5 Diagnostic Display

Concerning error diagnoses displayed on the control panel seeTroubleshooting Guide of firmware documentation.

Rexroth IndraDrive Disposal and Environmental Protection 11-1


11 Disposal and Environmental Protection

11.1 Disposal

ProductsOur products can be returned to us free of charge for disposal. It is aprecondition, however, that the products are free of oil, grease or otherdirt.

In addition, when returned the products mustn’t contain any undue foreignmatter or foreign component.

Please send the products free domicile to the following address:

Bosch Rexroth AGElectric Drives and ControlsBürgermeister-Dr.-Nebel-Straße 2D-97816 Lohr am Main

Packaging MaterialsThe packaging materials consist of cardboard, wood and polystyrene.They can be easily recycled. For ecological reasons you should not returnthe empty packages to us.

11.2 Environmental Protection

No Release of Hazardous SubstancesOur products do not contain any hazardous substances that they canrelease in the case of appropriate use. Normally there aren't any negativeeffects on the environment to be expected.

Materials Contained in the Products

Electronic DevicesElectronic devices mainly contain:

• steel

• aluminum

• copper

• synthetic materials

• electronic components and modules

MotorsMotors mainly contain:

• steel

• aluminum

• copper

• brass

• magnetic materials

• electronic components and modules

11-2 Disposal and Environmental Protection Rexroth IndraDrive


RecyclingDue to their high content of metal most of the product components can berecycled. In order to recycle the metal in the best possible way it isnecessary to disassemble the products into individual modules.

The metals contained in the electric and electronic modules can also berecycled by means of specific separation processes.The synthetic materials remaining after these processes can be thermallyrecycled.

Rexroth IndraDrive Service & Support 12-1


12 Service & Support

12.1 Helpdesk

Unser Kundendienst-Helpdesk im Hauptwerk Lohram Main steht Ihnen mit Rat und Tat zur Seite.Sie erreichen uns

Our service helpdesk at our headquarters in Lohr amMain, Germany can assist you in all kinds of inquiries.Contact us

- telefonisch - by phone: 49 (0) 9352 40 50 60über Service Call Entry Center Mo-Fr 07:00-18:00- via Service Call Entry Center Mo-Fr 7:00 am - 6:00 pm

- per Fax - by fax: +49 (0) 9352 40 49 41

- per e-Mail - by e-mail: [email protected]

12.2 Service-Hotline

Außerhalb der Helpdesk-Zeiten ist der Servicedirekt ansprechbar unter

After helpdesk hours, contact our servicedepartment directly at

+49 (0) 171 333 88 26

oder - or +49 (0) 172 660 04 06

12.3 Internet

Unter www.boschrexroth.com finden Sieergänzende Hinweise zu Service, Reparatur undTraining sowie die aktuellen Adressen *) unsererauf den folgenden Seiten aufgeführten Vertriebs-und Servicebüros.

Verkaufsniederlassungen

Niederlassungen mit Kundendienst

Außerhalb Deutschlands nehmen Sie bitte zuerst Kontakt mitunserem für Sie nächstgelegenen Ansprechpartner auf.

*) Die Angaben in der vorliegenden Dokumentation könnenseit Drucklegung überholt sein.

At www.boschrexroth.com you may findadditional notes about service, repairs and trainingin the Internet, as well as the actual addresses *) ofour sales- and service facilities figuring on thefollowing pages.

sales agencies

offices providing service

Please contact our sales / service office in your area first.

*) Data in the present documentation may have becomeobsolete since printing.

12.4 Vor der Kontaktaufnahme... - Before contacting us...

Wir können Ihnen schnell und effizient helfen wennSie folgende Informationen bereithalten:

1. detaillierte Beschreibung der Störung und derUmstände.

2. Angaben auf dem Typenschild derbetreffenden Produkte, insbesondereTypenschlüssel und Seriennummern.

3. Tel.-/Faxnummern und e-Mail-Adresse, unterdenen Sie für Rückfragen zu erreichen sind.

For quick and efficient help, please have thefollowing information ready:

1. Detailed description of the failure andcircumstances.

2. Information on the type plate of the affectedproducts, especially type codes and serialnumbers.

3. Your phone/fax numbers and e-mail address,so we can contact you in case of questions.

12-2 Service & Support Rexroth IndraDrive


12.5 Kundenbetreuungsstellen - Sales & Service Facilities

Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!from abroad: don’t dial (0) after country code!

Vertriebsgebiet Mitte Germany Centre

Rexroth Indramat GmbHBgm.-Dr.-Nebel-Str. 2 / Postf. 135797816 Lohr am Main / 97803 Lohr

Kompetenz-Zentrum Europa

Tel.: +49 (0)9352 40-0Fax: +49 (0)9352 40-4885

S E R V I C E

C A L L E N T R Y C E N T E RMO – FR

von 07:00 - 18:00 Uhr

from 7 am – 6 pm

Tel. +49 (0) 9352 40 50 [email protected]

S E R V I C E

HOTLINEMO – FR

von 17:00 - 07:00 Uhrfrom 5 pm - 7 am

+ SA / SOTel.: +49 (0)172 660 04 06

oder / o rTel.: +49 (0)171 333 88 26

S E R V I C E

ERSATZTEILE / SPARESverlängerte Ansprechzeit- extended office time -

♦ nur an Werktagen- only on working days -

♦ von 07:00 - 18:00 Uhr- from 7 am - 6 pm -

Tel. +49 (0) 9352 40 42 22

Vertriebsgebiet Süd Germany South

Bosch Rexroth AGLandshuter Allee 8-1080637 München

Tel.: +49 (0)89 127 14-0Fax: +49 (0)89 127 14-490

Vertriebsgebiet West Germany West

Bosch Rexroth AGRegionalzentrum WestBorsigstrasse 1540880 Ratingen

Tel.: +49 (0)2102 409-0Fax: +49 (0)2102 409-406

+49 (0)2102 409-430

Gebiet Südwest Germany South-West

Bosch Rexroth AGService-Regionalzentrum Süd-WestSiemensstr.170736 Fellbach

Tel.: +49 (0)711 51046–0Fax: +49 (0)711 51046–248

Vertriebsgebiet Nord Germany North

Bosch Rexroth AGWalsroder Str. 9330853 Langenhagen

Tel.: +49 (0) 511 72 66 57-0Service: +49 (0) 511 72 66 57-256Fax: +49 (0) 511 72 66 57-93Service: +49 (0) 511 72 66 57-783

Vertriebsgebiet Mitte Germany Centre

Bosch Rexroth AGRegionalzentrum MitteWaldecker Straße 1364546 Mörfelden-Walldorf

Tel.: +49 (0) 61 05 702-3Fax: +49 (0) 61 05 702-444

Vertriebsgebiet Ost Germany East

Bosch Rexroth AGBeckerstraße 3109120 Chemnitz

Tel.: +49 (0)371 35 55-0Fax: +49 (0)371 35 55-333

Vertriebsgebiet Ost Germany East

Bosch Rexroth AGRegionalzentrum OstWalter-Köhn-Str. 4d04356 Leipzig

Tel.: +49 (0)341 25 61-0Fax: +49 (0)341 25 61-111



Europa (West) - Europe (West)

vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählenfrom abroad: don’t dial (0) after country code, Italy: dial 0 after country code

Austria - Österreich

Bosch Rexroth GmbHElectric Drives & ControlsStachegasse 131120 Wien

Tel.: +43 (0)1 985 25 40Fax: +43 (0)1 985 25 40-93

Austria – Österreich

Bosch Rexroth GmbHElectric Drives & ControlsIndustriepark 184061 Pasching

Tel.: +43 (0)7221 605-0Fax: +43 (0)7221 605-21

Belgium - Belgien

Bosch Rexroth AGElectric Drives & ControlsIndustrielaan 81740 TernatTel.: +32 (0)2 5830719- service: +32 (0)2 5830717Fax: +32 (0)2 5830731 [email protected]

Denmark - Dänemark

BEC A/SZinkvej 68900 Randers

Tel.: +45 (0)87 11 90 60Fax: +45 (0)87 11 90 61

Great Britain – Großbritannien

Bosch Rexroth Ltd.Electric Drives & ControlsBroadway Lane, South CerneyCirencester, Glos GL7 5UH

Tel.: +44 (0)1285 863000Fax: +44 (0)1285 863030 [email protected] [email protected]

Finland - Finnland

Bosch Rexroth OyElectric Drives & ControlsAnsatie 6017 40 Vantaa

Tel.: +358 (0)9 84 91-11Fax: +358 (0)9 84 91-13 60

France - Frankreich

Bosch Rexroth SASElectric Drives & ControlsAvenue de la Trentaine(BP. 74)77503 Chelles Cedex

Tel.: +33 (0)164 72-70 00Fax: +33 (0)164 72-63 00Hotline: +33 (0)608 33 43 28

France - Frankreich

Bosch Rexroth SASElectric Drives & ControlsZI de Thibaud, 20 bd. Thibaud(BP. 1751)31084 Toulouse

Tel.: +33 (0)5 61 43 61 87Fax: +33 (0)5 61 43 94 12

France – Frankreich

Bosch Rexroth SASElectric Drives & Controls91, Bd. Irène Joliot-Curie69634 Vénissieux – Cedex

Tel.: +33 (0)4 78 78 53 65Fax: +33 (0)4 78 78 53 62

Italy - Italien

Bosch Rexroth S.p.A.Via G. Di Vittorio, 120063 Cernusco S/N.MI

Hotline: +39 02 92 365 563Tel.: +39 02 92 365 1Service: +39 02 92 365 326Fax: +39 02 92 365 500Service: +39 02 92 365 503

Italy - Italien

Bosch Rexroth S.p.A.Via Paolo Veronesi, 25010148 Torino

Tel.: +39 011 224 88 11Fax: +39 011 224 88 30

Italy - Italien

Bosch Rexroth S.p.A.Via Mascia, 180053 Castellamare di Stabia NA

Tel.: +39 081 8 71 57 00Fax: +39 081 8 71 68 85

Italy - Italien

Bosch Rexroth S.p.A.Via del Progresso, 16 (Zona Ind.)35020 Padova

Tel.: +39 049 8 70 13 70Fax: +39 049 8 70 13 77

Italy - Italien

Bosch Rexroth S.p.A.Via Isonzo, 6140033 Casalecchio di Reno (Bo)

Tel.: +39 051 29 86 430Fax: +39 051 29 86 490

Netherlands - Niederlande/Holland

Bosch Rexroth Services B.V.Technical ServicesKruisbroeksestraat 1(P.O. Box 32)5281 RV Boxtel

Tel.: +31 (0) 411 65 16 40+31 (0) 411 65 17 27

Fax: +31 (0) 411 67 78 14+31 (0) 411 68 28 60

[email protected]

Netherlands – Niederlande/Holland

Bosch Rexroth B.V.Kruisbroeksestraat 1(P.O. Box 32)5281 RV Boxtel

Tel.: +31 (0) 411 65 19 51Fax: +31 (0) 411 65 14 83 www.boschrexroth.nl

Norway - Norwegen

Bosch Rexroth ASElectric Drives & ControlsBerghagan 1 or: Box 30071405 Ski-Langhus 1402 Ski

Tel.: +47 (0)64 86 41 00Fax: +47 (0)64 86 90 62Hotline: +47 (0)64 86 94 82 [email protected]

Spain - Spanien

Bosch Rexroth S.A.Electric Drives & ControlsCentro Industrial SantigaObradors s/n08130 Santa Perpetua de MogodaBarcelona

Tel.: +34 9 37 47 94 00Fax: +34 9 37 47 94 01

Spain – Spanien

Goimendi S.A.Electric Drives & ControlsParque Empresarial ZuatzuC/ Francisco Grandmontagne no.220018 San Sebastian

Tel.: +34 9 43 31 84 21- service: +34 9 43 31 84 56Fax: +34 9 43 31 84 27- service: +34 9 43 31 84 60 [email protected]

Sweden - Schweden

Bosch Rexroth ABElectric Drives & Controls- Varuvägen 7(Service: Konsumentvägen 4, Älfsjö)125 81 Stockholm

Tel.: +46 (0)8 727 92 00Fax: +46 (0)8 647 32 77

Sweden - Schweden

Bosch Rexroth ABElectric Drives & ControlsEkvändan 7254 67 Helsingborg

Tel.: +46 (0) 42 38 88 -50Fax: +46 (0) 42 38 88 -74

Switzerland West - Schweiz West

Bosch Rexroth Suisse SAAv. Général Guisan 261800 Vevey 1

Tel.: +41 (0)21 632 84 20Fax: +41 (0)21 632 84 21

Switzerland East - Schweiz Ost

Bosch Rexroth Schweiz AGElectric Drives & ControlsHemrietstrasse 28863 ButtikonTel. +41 (0) 55 46 46 111Fax +41 (0) 55 46 46 222



Europa (Ost) - Europe (East)

vom Ausland: (0) nach Landeskennziffer weglassen from abroad: don’t dial (0) after country code

Czech Republic - Tschechien

Bosch -Rexroth, spol.s.r.o.Hviezdoslavova 5627 00 Brno

Tel.: +420 (0)5 48 126 358Fax: +420 (0)5 48 126 112

Czech Republic - Tschechien

DEL a.s.Strojírenská 38591 01 Zdar nad SázavouTel.: +420 566 64 3144Fax: +420 566 62 1657

Hungary - Ungarn

Bosch Rexroth Kft.Angol utca 341149 Budapest

Tel.: +36 (1) 422 3200Fax: +36 (1) 422 3201

Poland – Polen

Bosch Rexroth Sp.zo.o.ul. Staszica 105-800 Pruszków

Tel.: +48 22 738 18 00– service: +48 22 738 18 46Fax: +48 22 758 87 35– service: +48 22 738 18 42

Poland – Polen

Bosch Rexroth Sp.zo.o.Biuro Poznanul. Dabrowskiego 81/8560-529 Poznan

Tel.: +48 061 847 64 62 /-63Fax: +48 061 847 64 02

Romania - Rumänien

East Electric S.R.L.Bdul Basarabia no.250, sector 373429 Bucuresti

Tel./Fax:: +40 (0)21 255 35 07+40 (0)21 255 77 13

Fax: +40 (0)21 725 61 21 [email protected]

Romania - Rumänien

Bosch Rexroth Sp.zo.o.Str. Drobety nr. 4-10, app. 1470258 Bucuresti, Sector 2

Tel.: +40 (0)1 210 48 25+40 (0)1 210 29 50

Fax: +40 (0)1 210 29 52

Russia - Russland

Bosch Rexroth OOOWjatskaja ul. 27/15127015 Moskau

Tel.: +7-095-785 74 78+7-095 785 74 79

Fax: +7 095 785 74 77 [email protected]

Russia - Russland

ELMIS10, Internationalnaya246640 Gomel, Belarus

Tel.: +375/ 232 53 42 70+375/ 232 53 21 69

Fax: +375/ 232 53 37 69 [email protected]

Turkey - Türkei

Servo Kontrol Ltd. Sti.Perpa Ticaret Merkezi B BlokKat: 11 No: 160980270 Okmeydani-IstanbulTel: +90 212 320 30 80Fax: +90 212 320 30 81 [email protected] www.servokontrol.com

Slowenia - Slowenien

DOMELOtoki 2164 228 Zelezniki

Tel.: +386 5 5117 152Fax: +386 5 5117 225 [email protected]



Africa, Asia, Australia – incl. Pacific RimAustralia - Australien

AIMS - Australian IndustrialMachinery Services Pty. Ltd.28 Westside DriveLaverton North Vic 3026Melbourne

Tel.: +61 3 93 14 3321Fax: +61 3 93 14 3329Hotlines: +61 3 93 14 3321

+61 4 19 369 195 [email protected]

Australia - Australien

Bosch Rexroth Pty. Ltd.No. 7, Endeavour WayBraeside Victoria, 31 95Melbourne

Tel.: +61 3 95 80 39 33Fax: +61 3 95 80 17 33 [email protected]

China

Shanghai Bosch RexrothHydraulics & Automation Ltd.Waigaoqiao, Free Trade ZoneNo.122, Fu Te Dong Yi RoadShanghai 200131 - P.R.China

Tel.: +86 21 58 66 30 30Fax: +86 21 58 66 55 [email protected] [email protected]

China

Shanghai Bosch RexrothHydraulics & Automation Ltd.4/f, Marine TowerNo.1, Pudong AvenueShanghai 200120 - P.R.China

Tel: +86 21 68 86 15 88Fax: +86 21 58 40 65 77

China

Bosch Rexroth China Ltd.15/F China World Trade Center1, Jianguomenwai AvenueBeijing 100004, P.R.China

Tel.: +86 10 65 05 03 80Fax: +86 10 65 05 03 79

China

Bosch Rexroth China Ltd.Guangzhou Repres. OfficeRoom 1014-1016, Metro Plaza,Tian He District, 183 Tian He Bei RdGuangzhou 510075, P.R.China

Tel.: +86 20 8755-0030+86 20 8755-0011

Fax: +86 20 8755-2387

China

Bosch Rexroth (China) Ltd.A-5F., 123 Lian Shan StreetSha He Kou DistrictDalian 116 023, P.R.China

Tel.: +86 411 46 78 930Fax: +86 411 46 78 932

China

Melchers GmbHBRC-SE, Tightening & Press-fit13 Floor Est Ocean CentreNo.588 Yanan Rd. East65 Yanan Rd. WestShanghai 200001

Tel.: +86 21 6352 8848Fax: +86 21 6351 3138

Hongkong

Bosch Rexroth (China) Ltd.6th Floor,Yeung Yiu Chung No.6 Ind Bldg.19 Cheung Shun StreetCheung Sha Wan,Kowloon, Hongkong

Tel.: +852 22 62 51 00Fax: +852 27 41 33 44

[email protected]

India - Indien

Bosch Rexroth (India) Ltd.Electric Drives & ControlsPlot. No.96, Phase IIIPeenya Industrial AreaBangalore – 560058

Tel.: +91 80 51 17 0-211...-218Fax: +91 80 83 94 345

+91 80 83 97 374

[email protected]

India - Indien

Bosch Rexroth (India) Ltd.Electric Drives & ControlsAdvance House, II FloorArk Industrial CompoundNarol Naka, Makwana RoadAndheri (East), Mumbai - 400 059

Tel.: +91 22 28 56 32 90+91 22 28 56 33 18

Fax: +91 22 28 56 32 93

[email protected]

India - Indien

Bosch Rexroth (India) Ltd.S-10, Green Park ExtensionNew Delhi – 110016

Tel.: +91 11 26 56 65 25+91 11 26 56 65 27

Fax: +91 11 26 56 68 87

[email protected]

Indonesia - Indonesien

PT. Bosch RexrothBuilding # 202, CilandakCommercial EstateJl. Cilandak KKO, Jakarta 12560

Tel.: +62 21 7891169 (5 lines)Fax: +62 21 7891170 - [email protected]

Japan

Bosch Rexroth Automation Corp.Service Center JapanYutakagaoka 1810, Meito-ku,NAGOYA 465-0035, Japan

Tel.: +81 52 777 88 41+81 52 777 88 53+81 52 777 88 79

Fax: +81 52 777 89 01

Japan

Bosch Rexroth Automation Corp.Electric Drives & Controls2F, I.R. BuildingNakamachidai 4-26-44, Tsuzuki-kuYOKOHAMA 224-0041, Japan

Tel.: +81 45 942 72 10Fax: +81 45 942 03 41

Korea

Bosch Rexroth-Korea Ltd.Electric Drives and ControlsBongwoo Bldg. 7FL, 31-7, 1GaJangchoong-dong, Jung-guSeoul, 100-391

Tel.: +82 234 061 813Fax: +82 222 641 295

Korea

Bosch Rexroth-Korea Ltd.1515-14 Dadae-Dong, Saha-guElectric Drives & ControlsPusan Metropolitan City, 604-050

Tel.: +82 51 26 00 741Fax: +82 51 26 00 747 [email protected]

Malaysia

Bosch Rexroth Sdn.Bhd.11, Jalan U8/82, Seksyen U840150 Shah AlamSelangor, Malaysia

Tel.: +60 3 78 44 80 00Fax: +60 3 78 45 48 00 [email protected] [email protected]

Singapore - Singapur

Bosch Rexroth Pte Ltd15D Tuas RoadSingapore 638520

Tel.: +65 68 61 87 33Fax: +65 68 61 18 25 sanjay.nemade

@boschrexroth.com.sg

South Africa - Südafrika

TECTRA Automation (Pty) Ltd.71 Watt Street, MeadowdaleEdenvale 1609

Tel.: +27 11 971 94 00Fax: +27 11 971 94 40Hotline: +27 82 903 29 23 [email protected]

Taiwan

Bosch Rexroth Co., Ltd.Taichung Branch1F., No. 29, Fu-Ann 5th Street,Xi-Tun Area, Taichung CityTaiwan, R.O.C.

Tel : +886 - 4 -23580400Fax: +886 - 4 [email protected]@[email protected]

Thailand

NC Advance Technology Co. Ltd.59/76 Moo 9Ramintra road 34Tharang, Bangkhen,Bangkok 10230

Tel.: +66 2 943 70 62 +66 2 943 71 21Fax: +66 2 509 23 62Hotline +66 1 984 61 52 [email protected]



Nordamerika – North AmericaUSAHeadquarters - Hauptniederlassung

Bosch Rexroth CorporationElectric Drives & Controls5150 Prairie Stone ParkwayHoffman Estates, IL 60192-3707

Tel.: +1 847 6 45 36 00Fax: +1 847 6 45 62 [email protected] [email protected]

USA Central Region - Mitte

Bosch Rexroth CorporationElectric Drives & ControlsCentral Region Technical Center1701 Harmon RoadAuburn Hills, MI 48326

Tel.: +1 248 3 93 33 30Fax: +1 248 3 93 29 06

USA Southeast Region - Südwest

Bosch Rexroth CorporationElectric Drives & ControlsSoutheastern Technical Center3625 Swiftwater Park DriveSuwanee, Georgia 30124

Tel.: +1 770 9 32 32 00Fax: +1 770 9 32 19 03

USA SERVICE-HOTLINE

- 7 days x 24hrs -

+1-800-REX-ROTH+1 800 739 7684

USA East Region – Ost

Bosch Rexroth CorporationElectric Drives & ControlsCharlotte Regional Sales Office14001 South Lakes DriveCharlotte, North Carolina 28273

Tel.: +1 704 5 83 97 62+1 704 5 83 14 86

USA Northeast Region – Nordost

Bosch Rexroth CorporationElectric Drives & ControlsNortheastern Technical Center99 Rainbow RoadEast Granby, Connecticut 06026

Tel.: +1 860 8 44 83 77Fax: +1 860 8 44 85 95

USA West Region – West

Bosch Rexroth Corporation7901 Stoneridge Drive, Suite 220Pleasant Hill, California 94588

Tel.: +1 925 227 10 84Fax: +1 925 227 10 81

Canada East - Kanada Ost

Bosch Rexroth Canada CorporationBurlington Division3426 Mainway DriveBurlington, OntarioCanada L7M 1A8

Tel.: +1 905 335 5511Fax: +1 905 335 4184Hotline: +1 905 335 5511 [email protected]

Canada West - Kanada West

Bosch Rexroth Canada Corporation5345 Goring St.Burnaby, British ColumbiaCanada V7J 1R1

Tel. +1 604 205 5777Fax +1 604 205 6944Hotline: +1 604 205 5777 [email protected]

Mexico

Bosch Rexroth Mexico S.A. de C.V.Calle Neptuno 72Unidad Ind. Vallejo07700 Mexico, D.F.

Tel.: +52 55 57 54 17 11Fax: +52 55 57 54 50 [email protected]

Mexico

Bosch Rexroth S.A. de C.V.Calle Argentina No 3913Fracc. las Torres64930 Monterrey, N.L.

Tel.: +52 81 83 65 22 53+52 81 83 65 89 11+52 81 83 49 80 91

Fax: +52 81 83 65 52 [email protected]

Südamerika – South AmericaArgentina - Argentinien

Bosch Rexroth S.A.I.C."The Drive & Control Company"Rosario 2302B1606DLD CarapachayProvincia de Buenos Aires

Tel.: +54 11 4756 01 40+54 11 4756 02 40+54 11 4756 03 40+54 11 4756 04 40

Fax: +54 11 4756 01 36+54 11 4721 91 53

[email protected]

Argentina - Argentinien

NAKASEServicio Tecnico CNCCalle 49, No. 5764/66B1653AOX Villa BalesterProvincia de Buenos Aires

Tel.: +54 11 4768 36 43Fax: +54 11 4768 24 13Hotline: +54 11 155 307 6781 [email protected] [email protected] [email protected] (Service)

Brazil - Brasilien

Bosch Rexroth Ltda.Av. Tégula, 888Ponte Alta, Atibaia SPCEP 12942-440

Tel.: +55 11 4414 56 92+55 11 4414 56 84

Fax sales: +55 11 4414 57 07Fax serv.: +55 11 4414 56 86 [email protected]

Brazil - Brasilien

Bosch Rexroth Ltda.R. Dr.Humberto Pinheiro Vieira, 100Distrito Industrial [Caixa Postal 1273]89220-390 Joinville - SC

Tel./Fax: +55 47 473 58 33Mobil: +55 47 9974 6645 [email protected]

Columbia - Kolumbien

Reflutec de Colombia Ltda.Calle 37 No. 22-31Santafé de Bogotá, D.C.Colombia

Tel.: +57 1 368 82 67+57 1 368 02 59

Fax: +57 1 268 97 [email protected]@007mundo.com

Rexroth IndraDrive Appendix 13-1


13 Appendix

13.1 Connection of Supply Unit by Wires

CAUTION

Risk of voltage arcing!⇒ If wires are used to connect the supply unit, the

connections have to be correctly made.

If the contact rails supplied for connecting the supply unit cannot be usedyou can use wires, too. The wires used must comply with the specification(see page 7-17).

The connection depends on the cable routing (to the left or to the right ofthe supply unit).

The following figure shows the correct DC bus connection of the drivecontroller to the supply unit. The illustrated way of connection keeps barewire sections from being situated directly vis-à-vis. This avoids voltagearcing.

Supply Unit to the Left of the Drive Controller

( )%

#($

Fig. 13-1: Connection of supply unit by wires to the DC bus connection of thedrive controller

13-2 Appendix Rexroth IndraDrive


Supply Unit to the Right of the Drive Controller

(

#($

Fig. 13-2: Connection of supply unit by wires to the DC bus connection of thedrive controller



13.2 Stacked Devices

CAUTION

Risk of voltage arcing!⇒ If devices are stacked in the control cabinet, the

connections for the DC buses between the deviceshave to be correctly made.

The connection depends on the cable routing (clockwise orcounterclockwise).

The following figures show the correct DC bus connection for stackeddevices. The illustrated way of connection keeps bare wire sections frombeing situated directly vis-à-vis. This avoids voltage arcing.

Counterclockwise Cable Routing

( )

#($

!#($

#($

!#($

Fig. 13-3: DC bus connection for counterclockwise cable routing



Clockwise Cable Routing

(

#($

!#($

#($

!#($

Fig. 13-4: DC bus connection for clockwise cable routing



13.3 Mains Connection

General

DANGER

High electrical voltage on the housing!High leakage current! Danger to life, danger ofinjury by electric shock!⇒ Connect the electrical equipment, the housings of all

electrical units and motors permanently with the safetyconductor at the ground points before power isswitched on. Look at the connection diagram. This iseven necessary for brief tests.

⇒ Connect the safety conductor of the electricalequipment always permanently and firmly to thesupply mains. Leakage current exceeds 3.5 mA innormal operation.

⇒ Use a copper conductor with at least 10 mm² crosssection over its entire course for this safety conductorconnection! The cross section must not be smallerthan the cross section of a phase of the mains supplywire.

⇒ Prior to startups, even for brief tests, always connectthe protective conductor or connect with ground wire.Otherwise, high voltages can occur on the housingthat lead to electric shock.

Supply units of the HMV01.1E and HMV01.1R line can be connected togrounded three-phase without the need of a transformer.(Concerning electrical data of the mains: see chapter 7.3)

For more information about the subject "Mains fuse protection with directmains connection" read the recommendations in chapter "Fusing withDirect Mains Supply" on page 13-13.

A transformer is needed if the mains voltage is smaller than 380 V orgreater than 480 V.

The required transformers power must be equal to or greater than theincoming power.

The isolating transformer must have a short-circuit voltage of UK < 2.5%.

Note: The mains inductance (leakage inductance) of transformersvaries dependent upon power and type.

If no additional capacitance is used, the supply voltage can be cut off for3 ms in case of nominal load and 3 x AC 380 V mains voltage. More than1 second should have passed between successive voltage cutoffs.

With 3 x AC 380 V mains voltage, the supply voltage may drop-out by20% of the peak voltage for a maximum of 10 ms (in case of highersupply voltages proportionally more). More than 1 second should havepassed between successive voltage drop-outs.

Direct mains connection

Mains fuse protection with directmains connection

Connecting the mains via atransformer

(Mains) voltage cutoff

(Mains) voltage drop-outs



Mains Supply RequirementsDepending on the connected load there must be certain necessary short-circuit power of the mains supply present to use HMV01.1x devices.

Connected load[kVA]

Required short-circuitpower SK

[MVA]

Examples of application

6 ... 50 0,6 ... 5

50 ... 150 5 ... 15

500 ... 2000 50 ... 200 several devices in line

Fig. 13-5: Connected load

These values are from a directive of german energy supply companies andare applicable only to european mains supplies. If you need the values fordifferent mains supplies you have to contact your energy supply company.

Supply units HMV01.1E and HMV01.1R tolerance mains supply failures up toa duration of 10 ms.

When the supply voltage falls below its minimal value (see technical data) forlonger than 10 ms or when a single phase breaks down for longer than 10 msthe supply unit switches off with a specific dignostic message.

Connected load

Mains supply failure



HMV01.1E

Power SupplyIn case of mains voltages with 3 x AC 380 ... 480 V (±10 %) the powersupply unit can be connected directly to the mains; no other componentsare necessary.

Note: For interference suppression we recommend a line filter HFD.

supply unitHMV01.1E

HMVE_NFD_anschluss.fh7

mains filter

L1L2L3

PE1)

2)

mains choke 3)

1) Like mains wires, but not smaller than 10 mm2

2) Twist main wires - cable selections according to EN 60 2043) Whether a mains choke is necessary or not depnds on the

continuous DC bus power (see electrical data).Fig. 13-6: Direct mains connection via mains filter

Direct mains connection [with3 x AC 380 ... 480 V (±10 %)]



If mains voltages are smaller than 3 AC x 380 V respectively greater than3 AC x 480 V, it is necessary to use a transformer.

HMVE_spartrafo_NFD_anschluss.fh7

autotransformer

1) Like main wires, but not smaller than 10 mm2

2) Twist main wires - cable selections according to EN 60 204

supply unitHMV01.1E

mains filter

L1L2L3

PE1)

2)

mains choke

Fig. 13-7: Mains connection via autotransformer

Connecting the mains viaautotransformer (with mainsvoltages < 3 AC x 380 V e.g.

> 3 AC x 480 V)



HMV01.1R

Power SupplyAs the power part of the HMV01.1R power supply units consists of aclocked 3-phase IGBT bridge, a mains choke KDxx will always be neededfor the mains connection. In addition, a so-called combining filter HFD willbe required.

X3

K1

Supply unitHMV01.1R

powersupply

L2

L1

L3

L2

L1

L3

=~

Q1

U1 V1 W1

U2 V2 W2

PE

L1.1 L2.1 L3.1

to the centralground connection

HFDcombining filter

3 x AC 380 - 480 V50 - 60 Hz

KDxxmains choke

drivecontroller

twisted

HMVR_Netzanschluss.fh7

mains input

L+

L-

+24V

0V

twisted

to the centralground connection

X14 1 2 3

F2

L1 L2 L3

Fig. 13-8: Mains connection via mains choke and combining filter

Basically, the HFD combining filters to be provided for the mainsconnection of the power supply units have two tasks:

• to suppress the current leakages from parasitic capacities of theconstruction (motor cable, winding capacities) and

Mains connection with3 x AC 380 ... 480 V (±10 %)



• to ensure a sufficient interference suppression.

The combining filters are exclusively provided for the operation withHMV01.1R/E supply modules. On the filter outlet side no other devicesmay be connected. If other components in the control cabinet are to besuppressed, it is necessary to employ an appropriate interferencesuppression which should preferably be installed at the control cabinetentry

Note:

• It is not advisable to switch an additional interference suppression withthe HFD in series, as non-linear procedures in the interferencesuppression filter (saturation of the chokes) could affect the combiningfilters’ effect.

• Make sure there aren’t any circuits with resonance produced, forexample, by compensating capacitors, transformers, lines orcapacitive contents of the filters that are not matching.

• Exceeding the allowed limit values for the high-frequency voltagecontents at the filter can damage or destroy the filters and thecapacitors at the mains choke.

• Rexroth does not supply HFD filters for asymmetric mains. If required,the appropriate HFD filters must be selected for the specificinstallation.

It is only allowed to operate combining filters within the allowed mainsvoltage range. Harmonics (fn) on the mains voltage will lead to atemperature rise of the dielectric material of the capacitors built in thefilters.

You can calculate the temperature rise using the following formula:

( )( )

[ ]KU

Ux10T

2Gn

2Mn

n =∆

UMn: measured voltage value at frequency fnUGn: voltage limit value for frequency fn∆Tn: calculated temperature rise of the dielectric material for frequency fn

Fig. 13-9: Calculating the temperature rise of the dielectric material

The temperature rises have to be added up for all frequencies fn ≥ fk

(fk: frequency at which the voltage derating starts; see Fig. 13-11):

( )( )

[ ] [ ]K10KU

Ux10TT

2Gv

2Mv

m

1v

m

1vvges ≤=∆=∆ ∑ ∑

= =

UMv: voltage value at frequency fvUGv: voltage limit value for frequency fv∆Tges: calculated temperature rise of the dielectric material for all

frequenciesFig. 13-10: Calculating the temperature rise of the dielectric material for all

frequencies

By means of the above formulas and the measured voltages it is possibleto determine the real load of a filter with voltages of higher frequencies.To do this, it is necessary to measure by means of Fourier analysis, for allcombinations of line/line and line/PE, the r.m.s. value of the voltage on themains side of the filter with all occurring frequencies (higher than fk). Youalways have to measure the voltages under conditions of operation at thenominal working point, the filter having been installed. By means of themeasured values it is then possible to calculate the temperature rise. To



do this, the limit values of the following diagram are read at the respectivefrequency and used in the formula together with the measured value.

) )

"!

Fig. 13-11: Derating

If the total of the temperature values is greater than 10 K, the harmonicshave to be reduced by means of appropriate measures.

The supply line to the HFD must be shielded in order to avoid guidedinterference emissions.

The connection cables of the mains choke have a connected voltage ofhigh amplitude and frequency. This can result in a possible interference ofsensitive units in the control cabinet. Therefore, the connection cablesneed to be kept as short as possible and absolutely twisted (here it wouldalso be better to use shielded cables).

If a transformer is used, it is possible to connect HMV01.1R supplymodules to networks with mains voltages smaller than 3 x AC 380 V orgreater than 3 x AC 480 V.

Here, it is also required to use a mains choke KDxx and a combining filterHFD just as for the direct mains connection of the HMV01.1R supplymodules.

Mains connection viatransformer (with mains

voltages < 3 x AC 380 V or> 3 x AC 480 V)



Synchronizing to the MainsA separate connection is necessary that the HMV01.1R may be operatedsynchronously to the mains. The synchronizing voltage must be tappedbefore the mains choke KDxx but after the mains filter. Power andsynchronizing voltage connection must be in phase (see figure below).

The synchronizing voltage must be connected to the control voltage inlet(X14) of the HMV01.1R.

X3

L1L2L3

X14

Q1

1 2 3

HMV01.1R

connection must bephase coincident

Combining filter HFD

L1.1

KDxx

HMVR_Netzsynch_anschluss.FH7

F2 1)

L2.1 L3.1

L1 L2 L3

1) Use a motor circuit-breaker (F2; e.g. PKZM6.3) or fuses (6.3 A) toprotect X14.

Fig. 13-12: Synchronizing voltage HMV01.1R

Details of the Mains ChokeThe mains chokes are equipped with a temperature contact which opensat T = 150 °C (connections a - b). The contact can be evaluated by acontroller and is used for example for a regulated shutdown of the unit,should the control cabinet cooling fail.

Note: Technical data of mains chokes: see page 13-17.

Details of the Combining FilterWhen operating combining filters at grounded IT mains, the type ofconstruction causes leakage currents that may cause possibly existingcircuit breakers or voltage monitors to trip. Remedy: Install an isolatingtransformer.

Note: Technical data of HFD filters: see page 13-19.



Fusing with Direct Mains SupplyFusing the mains supply can implement, with power circuit breakers orslow-blow fuses of the gL/gG type:

HMV01.1E- Fusing[A]

Power Circuit BreakerSetting [A]

Wire crosssection[mm²]

W0030 63 50 16

W0075 160 125 50

W0120 250 200 120

HMV01.1R- Fusing[A]

Power Circuit BreakerSetting [A]

Wire crosssection[mm²]

W0018 35 30 6

W0045 80 70 25

W0065 125 100 50

Fig. 13-13: Fusing with direct mains supply

13.4 Grounding the Power Supply System

HMV01.1E and HMV01.1R can be operated from three-phase systemswith grounded neutral points or phases without control-to-load isolation.

With ungrounded mains (IT mains) there is the increased danger thatunacceptably high overvoltages could occur between the phase and thehousing. Both the HMV01.1E and HMV01.1R can be protected againstunacceptable overvoltages,

• if they are connected via an isolating transformer (the star point ofthe output side and the PE connection of the power supply unit areconnected over one grounding rail)

- or -

• if the unit is protected by over voltage suppressers.

Note: Connecting the HMV01.1E and HMV01.1R via an isolatingtransformer offers the best protection against overvoltage andthe greatest operating safety.

Grounded three-phase mains

Ungrounded three-phase mains



13.5 Fault Current Protective Device

DANGER

High electrical voltage! Danger to life, severebodily harm by electric shock!⇒ A residual-current-operated protective device (RCD)

must not be used on electric drives! Indirect contactmust be prevented by other means, for example, byan overcurrent protective device.

• In clocked drive controllers, capacitive leakage currents primarily flowto earth. The extent of this current depends on

• the number of drive controllers used,

• the length of the motor power cable and

• the grounding conditions at the installation.

• If measures are taken to improve the electromagnetic compatibility(EMC) of the installation (mains filters, shielded lines, etc.), then thecurrent leakage is inevitably also increased. In order to avoid faultyreleases when inductive loads and capacitance (interferencesuppression filters, transformers, contactors, magnetic valves) areswitched on, it is necessary to provide an isolating transformer in themains supply line ahead of the power supply unit of the drive system.The over current protective device must be matched to the impedanceof the fault loop so that a shutdown is effected if a fault occurs. Thestar point of the secondary winding must be connected to theprotective circuit of the installation.

13.6 Earth Leakage Monitor

Earth leakage monitors are often used in IT mains. Spurious releases canoccur when operating electronic equipment.

Experience has shown that electronic drive controllers can only beoperated on systems with earth leakage monitors if an isolatingtransformer is situated ahead of the supply unit for the drive system. Thestar point of the isolating transformer and the PE connection of the powersupply unit must be applied to the same potential.



13.7 Chronological Sequence when Switching ON and OFF

When Switching On

t

hmv_einschalt_verlauf.fh7

t2

t3

t6

t5

t4

t1

Control voltageON

Bb1 contactcloses

PowerON

Internaltest routine

DC busloading

Mains contactorON

UD contactcloses

t1: 5,2 s;time for internal booting until Bb1 contact closes

t2: time can be set by the usert3: 400 ms;

time for internal test routine before loading the DC bust4: time depends on DC bus capacitance (internal, external) and supply

voltage. The approximate time can be calculated:t4 = 0,7 x UMains x CDC bus

t5: 500 ms;delay time until mains contactor closes

t6: max. 200 ms;depends on device (ON delay of mains contactor)

Fig. 13-14: Chronological sequence when powering unit up



When Switching Off

thmv_ausschalt_verlauf.FH7

t1

t2

Control voltageOFF

Bb1 contactopens

PowerOFF

UD contactopens

AcknowledgePower OFF

t1: max. 200 ms;depends on device (OFF delay of mains contactor)

t2: time can be set by the userFig. 13-15: Chronological sequence when shutting down the unit



13.8 Auxiliary Components

Mains Choke

For Supply Units HMV01.1E

C

A

EB

long hole in"B" direction

D1

D

F

MB_KD.fh7

U2

V2

W2

PE

circuit diagramm:

U1

V1

W1

a

bϑ

Dimensions [mm]Mains choke

A B C D D1 E F

Weight [kg]

KD 31 180 112 225 125 80 87 7 x 15 13,5

KD 35 230 148 295 180 - 122 8 x 12 24

KD 33 265 152 350 215 - 126 15 x 11 33

Fig. 13-16: Mechanical Data

Mainschoke

Pdcont

[kW]ILN cont at UNetz = 400V

[Aeff]ILN max for 0,3s

[Aeff]LN (Rated

inductance)[µH]

Lmin atILN max

Crosssection[mm²]

Device

KD 31 30 51 77 3 x 400 50% of LN 16(a, b: 2,5)

HMV01.1E-W0030

KD 35 75 125 188 3 x 200 50% of LN 70(a, b: 2,5)

HMV01.1E-W0075

KD 33 120 202 303 3 x 100 50% of LN 150(a, b: 2,5)

HMV01.1E-W0120

Fig. 13-17: Electrical Data

Mains choke Part number

KD 31 R911297065

KD 35 R911299446

KD 33 R911298908

Fig. 13-18: Part number



For Supply Units HMV01.1R

A

EDF

MB_KD32.fh7

a

b

B1

C

PE

U2

V2

W2

U1

V1

W1

C

long hole in"B" direction

circuit diagramm:

B

Dimensions [mm]Mains choke

A B B1 C D E F

Weight [kg]

KD 34 C 210 108 64 245 175 85 8 x 12 16

KD 32 C 300 155 50 360 240 123 11 x 15 44

KD 36 C 340 174 55 385 290 132 11 x 15 65

Fig. 13-19: Mechanical Data

Mainschoke

Pdcont

[kW]ILN cont at ULN

= 400V[Aeff]

ILN max for 0,3s[Aeff]

LN (Ratedinductance)

[µH]

Lmin atILN max

C∆ [µF]

Crosssection[mm²]

Device

KD 34 C 18 26 65 3 x 980 80% von LN 3 x 10 16(a, b: 2,5)

HMV01.1R-W0018

KD 32 C 45 65 163 3 x 590 80% von LN 3 x 20 35(a, b: 2,5)

HMV01.1R-W0045

KD 36 C 65 94 235 3 x 540 80% von LN 3 x 20 70(C: 16

a, b: 2,5)

HMV01.1R-W0065

Fig. 13-20: Electrical Data

Mains choke Part number

KD 34 C R911299364

KD 32 C R911298427

KD 36 C

Fig. 13-21: Part number



Mains Filter HFD

CAUTION

Risk of damage!⇒ Only use Rexroth filters. These filters have beenadjusted to the Rexroth supply units, inverters andmotors in the best possible way. If you use differentfilters, the limit values possibly cannot be complied with.Moreover the filters and other components of the drivesystem might be destroyed.

TypesThere are 2 types of mains filter for IndraDrive M drive controllers toensure interference suppression according to EN61800-3, class A,group 2 and 1 type to ensure interference suppression according toEN61800-3, class B, group 1:

• Type 1:For max. 6 axis with a total motor cable length of 240 m.



For IndraDrive C drive controllers you only need filters Type 1 or Type 3.

Features• mains voltages which can be connected: 380V -15% to 480V +10%

• appropriate mains systems: TN, TT, IT

• maximum allowable ambient temperature: 40 °C (without derating)resp. 55 °C (with 2% derating per °C to 40 °C)

• filters are UL listed



Versions

Filter Type Supply Unit/Frequency Converter

Mains current[Aeff]

Limit ValuesEN61800-3 1)

HFD01.2-480-0026 1 HMV01.1R-W0018 26 class A, group 2 (curve 2.1/2.2)

HFD01.2-480-0065 1 HMV01.1R-W0045; HMV01.1E-W0030

65 class A, group 2 (curve 2.1/2.2)


HFD01.2-480-0125 1 HMV01.1E-W0075 125 class A, group 2 (curve 1.1/1.2)



HFD02.2-480-0065 2 HMV01.1R-W0045; HMV01.1E-W0030

65 class A, group 2 (curve 2.1/2.2)




HFD03.2-480-0026 3 HMV01.1R-W0018 26 class B, group 1 (curve 4.1/4.2)

HFD03.2-480-0065 3 HMV01.1R-W0045; HMV01.1E-W0030

65 class B, group 1 (curve 4.1/4.2)

HFD03.2-480-0094 3 HMV01.1R-W0065 94 class B, group 1 (curve 4.1/4.2)

1) see following figureFig. 13-22: Versions

Limit values for line-based disturbances (DIN EN 55011 / DIN EN 61800-3/A11)

1.1

1.2

2.1

3.1

4.1

2.2

3.2

4.2

1.1 1.2

2.12.2

3.13.2

4.1 4.2

130

120

100

90

79

66

56

125

115

86

76

60

5646

115

105

73

5060

70

class A, group 2 , QSP, I > 100A(second environment)

class A, group 2 , AV, I < 100A(second environment)

class A, group 1 , QSP,(first environment, restricteddistribution, first environment also ifsource of interference in secondenvironment)

class A, group 1 , AV,(first environment, restricteddistribution, first environment also ifsource of interference in secondenvironment)

class B, group 1 , QSP,(first environment, generaldistribution, first environment also ifsource of interference in secondenvironment)

class B, group 1 , AV,(first environment, generaldistribution, first environment also ifsource of interference in secondenvironment)

class A, group 2 , AV, I > 100A(second environment)

class A, group 2 , QSP, I < 100A(second environment)

QSP: quasi peak valueAV: average value

Fig. 13-23: Limit values for line-based disturbances (DIN 55011/DIN 61800-3/A11)



Dimensions

Fig. 13-24: HFD0x.2-480-0065



Fig. 13-25: HFD01.2-480-0026



Fig. 13-26: HFD02.2-480-0026



hfd02_2_480_0202.fh7

*

!"

"%

+" !

,

+"-".

"!

!"/%0

&'1

-%

!""

,

%

0

! !

% "

,

%

"

!"

!"

!

Fig. 13-27: HFD02.2-480-0202

Rexroth IndraDrive Index 14-1


14 Index

AAccompanying documents 4-1Acknowledge messages

internal mains contactor: 7-29Ambient Conditions 6-1Appropriate use 2-1Arrangement

power-dependent 6-5Auxiliary capacitance

calculation 8-5Auxiliary components 13-17

BBattery safety 3-11Bb1 7-26Braking resistor threshold

switching signal 7-27value 7-7

Bus module 7-21

CCE mark 1-4Certifications 1-4Chronological sequence

switching on and off 13-15Compatibility

with foreign matters 6-2Component designation 4-2Condensation 6-9Condition as supplied 4-1Conditions

ambient 6-1mounting 6-1operating 6-1storing 5-1transporting 5-1

Connected loadof supply unit 8-8

Connectionmains 13-5mains 7-23

Connection diagram 7-10Control cabinet

arrangement of components 6-6multiple line structure 6-6power-dependent arrangement of components 6-5

Control mains contactor 9-1Control panel 1-2Control voltage 7-9

connection 7-15Cooling 6-7Cooling units

mounting 6-8C-UL-US listing 1-4

DData

electrical 7-7mechanical 6-4

DC bus 7-17DC bus continuous power

calculation 8-1

14-2 Index Rexroth IndraDrive


DC bus dynamic brake 9-2DC bus peak power

calculation 8-4DC bus short circuit 7-27Delivery

scope 4-1Device types 4-3Diagnostic Display 10-4Dimensional drawing 6-4Display 1-2Dissipation

power 6-7Drawing

dimensional drawing 6-4Dripping or sprayed water 6-8Drive system 1-3Duty Capacity 6-3

EEarth

connection 7-19Earth leakage monitor 13-14Electrical data 7-7Electromagnetic compatibility 7-2EMC 7-2

correct installation of drives 7-3optimal installation 7-5

Emergency stop relays 9-1

FFault current protective device 13-14Fusing

with direct mains supply 13-13

GGround

connection 7-19Grounding

power supply system 13-13Grounding bracket 7-20

HHazards by Improper Use 3-2HFD 13-19HMV01.1E

power supply 13-7type code 4-3

HMV01.1Rpower supply 13-9synchronizing to the mains 13-12type code 4-3

IIdentification

of components 4-2Improper use

hazards 3-2Inappropriate use 2-2Installation

complete connection diagram 7-10electrical 7-1orientation 6-5

Interference elimination 7-2Internal mains contactor



acknowledge messages 7-29

KKD 31 13-17KD 32 C 13-18KD 33 13-17KD 34 C 13-18KD 35 13-17KD 36 C 13-18

LL+, L- 7-17

MMains

connection 13-5connection 7-23synchronizing 13-12

Mains chokes 13-17Mains contactor control (X32) 7-27Mains contactor control possibilities 9-1Mains filters HFD 13-19Mains supply

fusing 13-13introduction 8-1

Mains voltagesynchronization 7-30

Mechanical Data 6-4Messages

acknowledge for internal mains contactor: 7-29Bb1, UD, WARN 7-25

Mounting 6-1

NNC controller 9-6

OOperating conditions 6-1

PPackaging

labels 4-1material 4-1units 4-1

Panel 1-2PE

connection (neighboring device) 7-20connection (power supply) 7-19

Power dissipation 6-7Power supply

HMV01.1E 13-7HMV01.1R 13-9

Protectionagainst contact with electrical parts 3-5against contact with hot parts 3-10against dangerous movements 3-7against electric shock by protective low voltage (PELV) 3-6against live parts 7-31against magnetic and electromagnetic fields during operation and mounting 3-9against pressurized systems 3-11during handling and mounting 3-10

Protective devicefault current 13-14



RRegenerated energy 8-5Regenerated power

continuous 8-6peak 8-7

Repairing 10-2Replacing 10-3RS232 7-22

SSafety Instructions

for electric drives and controls 3-1Scope of delivery 4-1Stacked devices 13-3Standard control panel 1-2Storing 5-1Supply unit

appropriate use 2-1basic structure 1-2connection by wires (instead of rails) 13-1device types 4-3inappropriate use 2-2main features 1-1repairing 10-2storing 5-1transport 5-1type code 4-3

Switching On/Offchronological sequence 13-15

Synchronizationmains voltage 7-30

Synchronizing to the mains 13-12

TTechnical data

electrical 7-7mechanical 6-4

Tests 1-4Touch guard 7-31Transporting 5-1Troubleshooting 10-1Type code 4-3Type plate 4-2

UUD 7-26Use

directions for use 2-1hazards by improper use 3-2inappropriate 2-2

Vvibration

distortion 6-1sinus 6-1

WWARN 7-26Warning symbols 3-1

XX1 7-21



X14 7-30X2 7-22X3 7-23X31 7-25X32 7-27X33 7-29



Notes

Printed in GermanyDOK-INDRV*-HMV-*******-PR01-EN-PR911299229

Bosch Rexroth AGElectric Drives and ControlsPostfach 13 5797803 Lohr, DeutschlandBgm.-Dr.-Nebel-Str. 297816 Lohr, DeutschlandTel. +49 (0)93 52-40-50 60Fax +49 (0)93 52-40-49 [email protected]

Rexroth IndraDrive Supply Units Edition 01 Project ... Rexroth/Drives/Indradrive... · Project...

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