Digital control electronics for electro-hydraulic injection molding machines (12 pages)
Summary of Contents for REXROTH IndraDrive Mi
Page 1
Electric Drives Linear Motion and and Controls Hydraulics Assembly Technologies Pneumatics Service Rexroth IndraDrive Mi R911339094 Edition 01 Distributed Drive Controller KMS01 Operating Instructions...
Page 3
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG I/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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*-KMS01******-IT01-EN-P Bosch Rexroth AG III/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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*-KMS01******-IT01-EN-P Bosch Rexroth AG V/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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*-KMS01******-IT01-EN-P Bosch Rexroth AG VII/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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*-KMS01******-IT01-EN-P Bosch Rexroth AG IX/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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*-KMS01******-IT01-EN-P Bosch Rexroth AG XI/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Table of Contents Page Preparation............................. 38 How to Proceed..........................38 5.3.2 Notes on Operation........................... 38 5.3.3 Diagnostic Functions......................... 38 Diagnostic Display KSM/KMS......................38 Firmware Functions........................40 5.3.4 Service Functions / Troubleshooting....................40 General Information........................
If you do not have the user documentation for the components, contact your re‐ sponsible Rexroth sales partner. Ask for these documents to be sent im‐ mediately to the person or persons responsible for the safe operation of the components.
14/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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*-KMS01******-IT01-EN-P Bosch Rexroth AG 15/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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
16/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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*-KMS01******-IT01-EN-P Bosch Rexroth AG 17/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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‐...
18/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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
19/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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
20/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01...
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 21/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Identification Identification Type Code Fig.2-1: Type Code KMS...
22/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Identification Type Plates 2.2.1 Structure Trademark Type designation Product range Output frequency range Output current Output voltage Country of manufacture Manufacturing plant CE conformity label UL label 2-D bar code...
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 23/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Ratings and Dimensions Ratings and Dimensions Ratings A distributed drive controller KMS may only be operated in con‐ junction with an electronic control system KCU. UL Ratings and Dimensions...
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 25/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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...
26/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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*-KMS01******-IT01-EN-P Bosch Rexroth AG 27/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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
28/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01...
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 29/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use Instructions for Use Mounting 5.1.1 Preparations Make the following preparations for mounting: 1. Procure tools, auxiliary materials, measuring and test equipment. 2. Check all components for visible damage. Defective components mustn't be mounted.
Parts and tools (place them on a conductive support) Endangered components may only be stored or dispatched in conductive packaging. Rexroth connection diagrams are only to be used for producing installation circuit diagrams! The machine manufacturer’s installa‐ tion circuit diagrams must be used for wiring the installation! ●...
32/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use View Connection Signal name Function S1, M1 (HIPERFACE®) VCC_Encoder Power supply GND_Encoder Power supply reference potential Track A positive Track A negative Track B positive...
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 33/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use Output for controlling the motor holding brake (X156.7/8) Output current (A) n.s. Continuous power overvoltage protection (B) n.s. Energy absorption (B) n.s. Order type of cable...
34/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use Setting Description "00" "00" is the factory setting of the address selector switches. S5 = 0 This setting is not applied. You have to set the individual drive address in parameter "P-0-4025, Drive address of...
Page 37
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 35/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use Hybrid cable RKH (with different outgo‐ ing directions from connection point X3.1 or X3.2 at KSM and KMS) X3.1 X3.1 X3.1 X3.2 X3.2 X3.2 RKH0700...
36/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use Selection of Hybrid Cables Fig.5-7: Example of Drive System With Hybrid Cable Each string of distributed servo drives KSM must be terminated with the ter‐...
Page 39
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 37/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use ment grounding conductor in the hybrid cable, because the leakage current of a distributed servo drive KSM/KMS is greater than 3.5 mA. Additionally connect the KSM/KMS housing via a second equipment ground‐...
38/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use Commissioning, Operation, Diagnostics and Maintenance 5.3.1 Notes on Commissioning General Information High electrical voltage! Danger to life, electric WARNING shock and severe bodily injury! Read and observe the detailed safety instructions contained in this documen‐...
Page 41
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 39/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use Diagnostic Display as of MPB-07V12 / MPx-08VRS LED H14 Significance Measures Color / status Supply unit not switched on Check supply unit and, if necessary, switch it on...
Easy Startup Mode The easy startup mode is intended for initial commissioning. Easy startup can be carried out with the commissioning software "Rexroth IndraWorks D". For this purpose, connect KSM/KMS via the serial interface X2 to a PC (e.g. lap‐...
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 41/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use The following section explains the tasks required to eliminate errors or mal‐ function. We distinguish the following actions: ● Replacing Fuses F4 and F5 ●...
Saving Parameters For servicing, the drive parameters must be saved and archived at initial commissioning (e.g. with the software Rexroth IndraWorks D); this is neces‐ sary, because you won't probably be able to read the parameters of the de‐ fective drive.
MMC or the device might be damaged when you screw the MMC cover. Contacts of MMC Fig.5-13: Plugging in the MMC Use the software "Rexroth IndraWorks D" to configure the data transfer from the MMC after control voltage has been switched on. 5.3.5 Maintenance Maintenance of the Motor Component...
Page 46
● the nominal bearing service life has been reached ● running noise can be heard We recommend that you have the bearings replaced by Rexroth. Connection Cables Check connection cables for damage in regular intervals and replace them, if necessary.
Resurfacing routine by superior control. Here, special control programs adapted to the machine and system concepts are required. If necessary, please contact your Bosch Rexroth distribution partner and discuss the resurfacing routine parameters for your application. For more detailed information about software functions refer to the func‐...
Page 48
46/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 Instructions for Use ever, operation under unfavorable conditions (e.g. increased ambient temper‐ ature) can lead to limitations in availability. Risk of burns by hot surfaces with tempera‐ CAUTION tures of more than 60 °C!
The following rules are the basics for designing and installing drives in com‐ pliance with EMC. Mains Filter Correctly use a mains filter recommended by Rexroth for radio interference suppression in the supply feeder of the drive system. Control Cabinet Grounding Connect all metal parts of the cabinet with one another over the largest possi‐...
48/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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*-KMS01******-IT01-EN-P Bosch Rexroth AG 49/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 EMC Measures for Design and Installation 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 52
50/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 EMC Measures for Design and Installation Infeeding Supply Unit or Converter Mains choke (optional) E1…E5 Equipment grounding conductor of the components...
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 51/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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 54
52/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 EMC Measures for Design and Installation Motor Blower at Mains Filter Single-phase or three-phase supply lines of motor blowers, that are usually routed in parallel with motor power cables or interference-susceptible lines, must be filtered: ●...
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 53/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 EMC Measures for Design and Installation 6.2.5 Design and Installation in Area B - Interference-Susceptible Area of Control Cabinet Arranging Components and Lines Modules, components and lines in area B should be placed at a distance of at least d1 = 200 mm from modules and lines in area A.
54/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 EMC Measures for Design and Installation connections, you can establish the contact to lacquered surfaces by using tooth lock washers. Metal Surfaces Always use connection elements (screws, nuts, plain washers) with good electroconductive surface.
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 55/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 EMC Measures for Design and Installation General Measures of Radio Interference Suppression for Re‐ lays, Contactors, Switches, Chokes and Inductive Loads If, in conjunction with electronic devices and components, inductive loads, such as chokes, contactors, relays are switched by contacts or semiconduc‐...
Page 58
56/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01...
DOK-INDRV*-KMS01******-IT01-EN-P Bosch Rexroth AG 59/67 Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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 62
60/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01...
Used batteries can contain hazardous substances, which can harm the envi‐ ronment or the people´s health when they are improper stored or disposed of. After use, the batteries or accumulators contained in Rexroth products have to be properly disposed of according to the country-specific collection.
Page 64
62/67 Bosch Rexroth AG DOK-INDRV*-KMS01******-IT01-EN-P Rexroth IndraDrive Mi Distributed Drive Controller KMS01 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.