Summary of Contents for Bosch Rexroth IndraDrive Mi KCU01
Page 1
Electric Drives Linear Motion and and Controls Hydraulics Assembly Technologies Pneumatics Service Rexroth IndraDrive Mi R911339082 Edition 01 Electronic Control System KCU01 Operating Instructions...
Page 3
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG I/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Deutsch English Français Lebensgefahr bei Danger to life in case of Danger de mort en Nichtbeachtung der nachstehenden non‑compliance with the below-mentioned cas de non‑respect des consignes de...
Page 4
II/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Deutsch English Français Unsachgemäße Improper handling during Manipulation incorrecte lors Handhabung bei Transport und Montage! transport and mounting! Risk of injury! du transport et du montage ! Risque de...
Page 5
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG III/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Español Português Italiano Campi elettromagnetici / ¡Campos Campos eletromagnéticos / magnetici! Pericolo per la salute delle electromagnéticos/magnéticos! ¡Peligro magnéticos! Perigo de saúde para pessoas persone portatrici di pacemaker, protesi para la salud de las personas con com marcapassos, implantes metálicos ou...
Page 6
IV/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Svenska Dansk Nederlands Farliga rörelser! Livsfara! Farlige bevægelser! Risicovolle Livsfare! bewegingen! Levensgevaar! Uppehåll dig inte inom maskiners och maskindelars rörelseområde. Du må ikke opholde dig inden for maskiners Houdt u niet op in het bewegingsbereik van og maskindeles bevægelsesradius.
Page 7
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG V/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Suomi Polski Český Näiden turvaohjeiden Zagrożenie życia w razie Nebezpečí života v případě noudattamatta jättämisestä on seurauksena nieprzestrzegania poniższych wskazówek nedodržení níže uvedených bezpečnostních hengenvaara! bezpieczeństwa! pokynů! Ota tuote käyttöön vasta sen jälkeen, kun Nie uruchamiać...
Page 8
VI/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Suomi Polski Český Epäasianmukainen käsittely Niewłaściwe Nesprávné zacházení při kuljetuksen ja asennuksen yhteydessä! obchodzenie się podczas transportu i přepravě a montáži! Nebezpečí zranění! Loukkaantumisvaara! montażu! Ryzyko urazu! Používejte vhodná montážní a dopravní...
Page 9
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG VII/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Slovensko Slovenčina Română Elektromagnetna / Elektromagnetické/ Câmpuri electromagnetice / magnetna polja! Nevarnost za zdravje za magnetické polia! Nebezpečenstvo pre magnetice! Pericol pentru sănătatea osebe s spodbujevalniki srca, kovinskimi zdravie osôb s kardiostimulátormi, kovovými...
Page 10
VIII/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Magyar Български Latviski Опасни движения! Veszélyes mozgás! Bīstamas kustības! Опасност за живота! Életveszély! Dzīvības apdraudējums! Не стойте в обсега на движение на Ne tartózkodjon a gépek és a Neuzturieties mašīnu un mašīnas detaļu...
Page 11
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG IX/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Lietuviškai Eesti Ελληνικά Alljärgnevate ohutusjuhiste Κίνδυνος θανάτου σε Pavojus gyvybei nesilaikant eiramine on eluohtlik! περίπτωση μη συμμόρφωσης με τις toliau pateikiamų saugumo nurodymų! παρακάτω οδηγίες ασφαλείας! Võtke tooted käiku alles siis, kui olete Naudokite gaminį...
Page 12
X/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Lietuviškai Eesti Ελληνικά Asjatundmatu Ακατάλληλος χειρισμός κατά τη Netinkamas darbas käsitsemine transportimisel ja montaažil! μεταφορά και συναρμολόγηση! Κίνδυνος transportuojant ir montuojant! Susižalojimo Vigastusoht! τραυματισμού! pavojus! Kasutage sobivaid montaaži- ja Χρησιμοποιείτε...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG XI/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Table of Contents Table of Contents Page Important Notes......................13 Safety Instructions..........................13 1.1.1 General Information........................... 13 1.1.2 Protection Against Contact With Electrical Parts and Housings............14 1.1.3 Protection Against Dangerous Movements..................
Page 14
XII/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Table of Contents Page EMC Measures for Design and Installation..............45 Rules for Design of Installations With Drive Controllers in Compliance With EMC......45 EMC-Optimal Installation in Facility and Control Cabinet..............46 6.2.1...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 13/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Important Notes Important Notes Safety Instructions 1.1.1 General Information ● Do not attempt to install and operate the components of the electric drive and control system without first reading all documentation provided with the product.
14/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Important Notes 1.1.2 Protection Against Contact With Electrical Parts and Housings This section concerns components of the electric drive and con‐ trol system with voltages of more than 50 volts.
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 15/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Important Notes ● Connect the equipment grounding conductor of the components of the electric drive and control system permanently to the main power supply at all times. The leakage current is greater than 3.5 mA.
Page 18
16/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Important Notes Dangerous movements! Danger to life, risk of injury, serious injury or property damage! A risk assessment must be prepared for the installation or machine, with its specific conditions, in which the components of the electric drive and control system are installed.
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 17/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Important Notes normal use. It might possibly be necessary to perform a special electro‐ magnetic compatibility (EMC) test. 1.1.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐ ation and Mounting Magnetic and electromagnetic fields generated by current-carrying conduc‐...
18/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Important Notes ● Observe the relevant statutory regulations of accident prevention. ● Use suitable equipment for mounting and transport. ● Avoid jamming and crushing by appropriate measures. ●...
Page 21
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 19/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Important Notes Components of the Rexroth IndraDrive Mi system are products of category C3 (with limited availability) according to IEC 61800‑3. To ensure that this category (limit values) is maintained, suitable line filters must be used in the drive system.
Page 22
20/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 21/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Identification Identification Type Code The figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of availa‐ ble versions.
22/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Identification Type Plates Type Plate (Example) Device type Part number Serial number Bar code Country of manufacture Production week; example 07W16: year 2007, week 16 Hardware revision index Fig.2-2:...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 23/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Ratings and Dimensions Ratings and Dimensions UL Ratings and Dimensions Description Symbol Unit KCU01.2N-SE-SE*-025-NN-S-NN-NW Listing according to UL standard UL 508 C (UL) Listing according to CSA standard Canadian National Standard(s) C22.2 No.
Page 26
24/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Ratings and Dimensions Distances Air intake Air outlet Mounting surface in control cabinet Distance top Distance bottom Distance horizontal Fig.3-2: Air Intake and Air Outlet at Device...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 25/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Documentations Documentations Drive Systems, System Components Title Kind of documentation Part number Document typecode Rexroth IndraDrive … R911… DOK-INDRV*-… Drive Systems With HMV01/02 Project Planning Manual SYSTEM*****-PRxx-EN-P 309636...
26/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Documentations Cables Title Kind of documentation Part number Document typecode R911… DOK-… Rexroth Connection Cables Selection Data CONNEC-CABLE*INDRV-CAxx- 322949 EN-P IndraDrive and IndraDyn In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: CA02 is the second edition of the docu‐...
Page 29
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 27/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Documentations Title Kind of documentation Part number Document typecode R911… Productivity Agent Application Manual DOK-INDRV*-MLD-PAGENT*- 323947 AWxx-EN-P Extended Diagnostic Functions With Rexroth IndraDrive In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: AW01 is the first edition of an Applica‐...
Page 30
28/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 29/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Instructions for Use General The electronic control system KCU01 may only be used in con‐ junction with HMV01, HMV02, HCS02 or HCS03. Short circuit current rating (SCCR) Suitable for use on a circuit capable of delivering not more than 42000 rms symmetrical amperes.
30/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Connection Points 5.2.1 Wiring Diagrams Wiring Diagram with HMV as Supply Unit und KSM as Power Section 24V supply Transformer (optional) Fuses HMD, HMS Inverter (optional)
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 31/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Wiring Diagram with HCS02 as Supply Unit und KSM as Power Section 24V supply Transformer (optional) Fuses HCS02 Converter (HCS02.1E-W0054 or HCS02.1E-W0070) Mains filter Mains choke (optional)
32/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Wiring Diagram with HCS03 as Supply Unit und KSM as Power Section 24V supply Transformer (optional) Fuses HCS03 Converter Braking resistor (optional) Mains filter Mains choke (optional)
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 33/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use 5.2.2 Connection Diagram Fig.5-4: Connection Diagram KCU...
34/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use 5.2.3 Position of Connection Points SERCOS Status messages 42 V, 0 V DC bus, equipment grounding conductor X3.2 Connection of hybrid cable at first KSM Shield of hybrid cable Parts of accessory HAS02.1-015-NNN-NN for shield connection of hy‐...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 35/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use 5.2.4 Connection Point of Equipment Grounding Conductor Dangerous contact voltage at device housing! WARNING Lethal electric shock! The devices of the Rexroth IndraDrive Mi product range are devices with in‐...
36/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use 5.2.5 Terminal Block, 24 - 0V (24V Supply) PELV for 24V power supply unit For the 24V supply of the devices of the Rexroth IndraDrive Mi range, use a power supply unit or a control-power transformer with protection by PELV according to IEC 60204-1 (section 6.4).
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 37/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use HCS02 HCS03, HMV01, HMV02 For HCS03, HMV01 and HMV02 devices, the 24V supply is connected to the electronic control system KCU with contact For HCS02 devices, the 24V supply is connected to the bars.
Page 40
38/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Screw connection Unit Min. Max. M6 thread at device (terminal block) Tightening torque Short circuit protection Via fusing elements connected in the incoming circuit to the...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 39/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Installation 5.3.1 General Information on How to Install the Drive Controller Lethal electric shock by live parts with more WARNING than 50 V! Before working on live parts: De-energize installation and secure power switch against unintentional or unauthorized re-energization.
40/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Risk of damage to the drive controller by con‐ NOTICE necting and disconnecting live connections! Do not connect and disconnect live connections. 5.3.2 Touch Guard at Devices...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 41/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Mounting Fig.5-12: Touch Guard at Device The touch guard is fixed to the device with screws. Tightening Torque Max. 2.8 Nm Diagnostics Fig.5-13: LEDs at KCU...
Page 44
42/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Color / status Significance Measures H52.1 E-Stop not activated Deactivate E-Stop, if necessary E-Stop E-Stop active (/E_Stop) Activate E-Stop, if necessary (see con‐ nection point X50) H52.2...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 43/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Instructions for Use Replacing Fuses F4 and F5 Lethal electric shock by live parts with more WARNING than 50 V! Before working on live parts: De-energize installation and secure power switch against unintentional or unauthorized re-energization.
Page 46
44/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 45/63 Rexroth IndraDrive Mi Electronic Control System KCU01 EMC Measures for Design and Installation EMC Measures for Design and Installation Rules for Design of Installations With Drive Controllers in Compliance With EMC The following rules are the basics for designing and installing drives in com‐...
46/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 EMC Measures for Design and Installation Connecting the Mains Choke Keep connection lines of the mains choke at the drive controller as short as possible and twist them.
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 47/63 Rexroth IndraDrive Mi Electronic Control System KCU01 EMC Measures for Design and Installation Recommendation for complex systems: Install drive components in one cabi‐ net and the control units in a second, separate cabinet. Badly grounded control cabinet doors act as antennas. Therefore, connect the control cabinet doors to the cabinet on top, in the middle and on the bot‐...
Page 50
48/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 EMC Measures for Design and Installation Infeeding Supply Unit or Converter Mains choke (optional) E1…E5 Equipment grounding conductor of the components...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 49/63 Rexroth IndraDrive Mi Electronic Control System KCU01 EMC Measures for Design and Installation External mains contactor for supply units and converters without inte‐ grated mains contactor Motor fan Power supply unit Fusing Transformer Z1, Z2...
Page 52
50/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 EMC Measures for Design and Installation Routing and Connecting a Neutral If a neutral conductor is used together with a three-phase connection, it must Conductor (N) not be installed unfiltered in zones B and C, in order to keep interference off the mains.
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 51/63 Rexroth IndraDrive Mi Electronic Control System KCU01 EMC Measures for Design and Installation conductor is bigger, the cross section of the equipment grounding conductor must be accordingly bigger. 6.2.5 Design and Installation in Area B - Interference-Susceptible Area of...
52/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 EMC Measures for Design and Installation nection points, remove the lacquer so that there is safe electrical contact over a large surface area. You achieve contact over a large surface area by means of bare connection surfaces or several connection screws.
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 53/63 Rexroth IndraDrive Mi Electronic Control System KCU01 EMC Measures for Design and Installation In the case of non-shielded lines belonging to the same circuit, twist feeder and return cable. General Measures of Radio Interference Suppression for Re‐...
Page 56
54/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 55/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Accessories Accessories Overview Overview Content and usage Accessory HAS01 contains: a) Screws to fix the device in the control cabinet b) Adhesive labels with notes on safety in the English and French languages.
56/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Accessories Information on Accessory HAS02 The supplied product insert shows how the parts of the acces‐ sory are arranged. Fig.7-2: Product Insert Mounting Example Accessory HAS02.1-002 Screw in thread at bottom of device...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 57/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Service and Support Service and Support Our worldwide service network provides an optimized and efficient support. Our experts offer you advice and assistance should you have any queries.
Page 60
58/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01...
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 59/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Environmental Protection and Disposal Environmental Protection and Disposal Environmental Protection Production Processes The products are made with energy- and resource-optimized production pro‐ cesses which allow re-using and recycling the resulting waste. We regularly try to replace pollutant-loaded raw materials and supplies by more environ‐...
Page 62
60/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Environmental Protection and Disposal Metals contained in electric and electronic modules can also be recycled by means of special separation processes. Products made of plastics can contain flame retardants. These plastic parts are labeled according to EN ISO 1043.
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 61/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Index Index Symbols 24V supply............36 Environmental protection........59 Equipment grounding conductor Connection point .......... 35 Accessories HAS01, HAS02, HAS03 ....... 55 Accumulators............59 F4, F5 Additional documentations........25 Replacing fuses ..........
Page 64
62/63 Bosch Rexroth AG DOK-INDRV*-KCU01******-IT01-EN-P Rexroth IndraDrive Mi Electronic Control System KCU01 Index Power consumption..........23 Type code............21 Production processes......... 59 Type plates............22 Project planning manuals........25 Ratings..............23 Instructions ........... 29 Recycling............59 Reference documentations......... 25 Return of products..........59 Voltage load capacity..........
Page 65
DOK-INDRV*-KCU01******-IT01-EN-P Bosch Rexroth AG 63/63 Rexroth IndraDrive Mi Electronic Control System KCU01 Notes...