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Manuals and User Guides for REXROTH IndraDrive. We have
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REXROTH IndraDrive manual available for free PDF download: Project Planning Manual
REXROTH IndraDrive Project Planning Manual (312 pages)
Drive Systems with HMV01/02; HMS01/02; HMD01; HCS02/03
Brand:
REXROTH
| Category:
DC Drives
| Size: 9.42 MB
Table of Contents
Table of Contents
3
1 System Presentation
13
System Platform
13
Drive System Rexroth Indradrive C - Compact Converters
14
Drive System Rexroth Indradrive M - Modular System
16
Drive System Rexroth Indradrive MI
19
Drive Systems with KCU01
19
Drive Systems with KCU02
22
Combinations of Rexroth Indradrive C with Rexroth Indradrive M and Rexroth Indradrive MI
26
Basic Design of the Devices
26
General Information
26
Power Section
26
Control Section
27
Overview of Type Currents and Type Performances
28
General Information
28
Drive Controllers
28
Supply Units and Converters
29
Overview of Functions
30
Supply Units and Power Sections
30
Control Sections
30
Documentations
30
About this Documentation
30
Overview of Documentations
31
Drive Systems, System Components
31
Motors
32
Cables
33
Firmware
33
Your Feedback
36
2 Important Directions for Use
37
Appropriate Use
37
Introduction
37
Areas of Use and Application
37
Inappropriate Use
38
3 Safety Instructions for Electric Drives and Controls
39
Definitions of Terms
39
General Information
40
Using the Safety Instructions and Passing Them on to Others
40
Requirements for Safe Use
40
Hazards by Improper Use
41
Instructions with Regard to Specific Dangers
42
Protection against Contact with Electrical Parts and Housings
42
Protective Extra-Low Voltage as Protection against Electric Shock
43
Protection against Dangerous Movements
44
Protection against Magnetic and Electromagnetic Fields During Operation and Mounting
45
Protection against Contact with Hot Parts
46
Protection During Handling and Mounting
46
Battery Safety
46
Protection against Pressurized Systems
47
Explanation of Signal Words and the Safety Alert Symbol
47
4 Brief Description, Usage
49
General Information
49
Applications of the Drive System Rexroth Indradrive
49
Mains Transformers DST and DLT
49
Mains Filters HNF, HNK, NFE, HNS02 and NFD
49
Mains Chokes HNL01 and HNL02
50
Supply Units HMV01 / HMV02
51
Drive Controllers HMS01, HMS02 and HMD01
51
Control Sections CSB, CSE, CSH, CDB
51
Drive Controllers HCS02
52
Drive Controllers HCS03
52
Components KCU, KSM, KMS
52
DC Bus Resistor Unit HLB01
53
Braking Resistor HLR01
53
DC Bus Capacitor Unit HLC01
54
Fan Unit HAB01
54
Motor Filters HMF01
54
Accessories HAS
54
Housing for Control Sections HAC01
54
Hall Sensor Box SHL
54
5 General Data and Specifications
57
Acceptance Tests and Approvals
57
Transport and Storage
59
Transport of the Components
59
Storage of the Components
60
Installation Conditions
60
Ambient and Operating Conditions
60
Mounting Position
64
Mounting Positions of Components
64
Mounting Positions of Motor-Integrated Servo Drives
65
Compatibility with Foreign Matters
65
Motor Paint Coat
66
Voltage Test and Insulation Resistance Test
66
Control Voltage (24V Supply)
67
6 Project Planning of Control Voltage (24V Supply)
69
General Information
69
Selecting the 24V Supply
69
Electrical Requirements
70
Installing the 24V Supply
72
Looping through the Control Voltage Supply
73
7 Project Planning of Mains Connection
75
General Information
75
Mains Voltage Supply
75
Mains Types
78
TN-S Mains Type
78
TN-C Mains Type
78
IT Mains Type
79
TT System
80
Mains Grounded Via Outer Conductor (Corner-Grounded Delta Mains)
81
Mains Short-Circuit Power and Mains Connected Load
81
General Information
81
Mains Short-Circuit Power
82
Mains Connected Load
83
Protection Systems at the Mains Connection
86
General Information
86
Protective Grounding
87
General Information
87
Fusing by Protective Grounding in TN-S Mains
88
Fusing by Protective Grounding in TN-C Mains
89
Fusing by Protective Grounding in IT Mains (Ungrounded Mains)
90
Connection for the Equipment Grounding Conductor
91
General Information
91
Equipment Grounding Connection between the Components
91
Connecting Equipment Grounding Conductor to Mains
91
Residual-Current-Operated Circuit Breakers (RCD, RCCB) as Additional Fusing
91
Cause of Leakage Currents
92
Possibilities of Use
92
Using Residual-Current-Operated Circuit Breakers at HCS Drive Controllers
93
Using Residual-Current-Operated Circuit Breakers at HMV Supply Units
94
Insulation Monitoring Devices
94
8 Configuring the Drive System
95
General Information
95
Type of Supply for Power Sections
95
HMV Supply Units for HMS/HMD Power Sections
98
Central Supply HMV
98
Parallel Operation HMV - Group Supply with DC Bus Connection HMV01, HMV02
100
Converter HCS as Supply Unit
101
General Information
101
Central Supply - HCS Supply HCS or HMS/HMD Drive Controllers
101
Parallel Operation HCS - Group Supply with DC Bus Connection of the Groups
104
Third-Party Supply Units
107
General Information
107
Mains Connection Supply Units and Converters
108
General Information
108
Mains Connection of HMV Supply Units
111
Mains Connection of HMV Supply Units - Additional Components
111
Mains Connection of HMV01.1E Supply Units
112
Mains Connection of HMV01.1R Supply Units
113
Mains Connection of HMV02.1R Supply Units
114
Mains Connection for HCS Converters
115
Mains Connection for HCS Converters - Additional Components
115
Mains Connection for HCS02 Converters
116
Mains Connection for HCS03 Converters
118
Additional Components
122
Additional Components at the DC Bus
122
General Information
122
HLR Braking Resistors and DC Bus Resistor Units HLB
124
Additional Components at the Motor Output
127
General Information
127
HMF01 Motor Filters
128
Power Section, Control Section, Firmware
128
General Information
128
Power Section - Control Section
129
Control Section - Firmware
129
Power Section - Firmware
130
Motor - Firmware
135
Encoder System - Encoder Evaluation
135
Combination with Other Rexroth Components
138
Combination with Components of the Control Range Rexroth Indracontrol V
138
Operator Terminals VCP
138
Sercos Analog Converter
138
General Information
138
Connection Cables to Motor
139
General Information
139
Motor Cable
139
Motor Cable Selection
140
Allowed Length of Motor Cable
140
Voltage Drop on Connection to Motor Holding Brake
141
Mechanical Requirements
141
Third-Party Power Cables
141
Encoder Cables
142
Using Rexroth Indradyn Motors
142
Rexroth Indradyn H - Synchronous Kit Spindle Motors
142
9 Circuits for the Mains Connection
143
General Information
143
Mains Contactor, Bb Contact
143
Circuits for Mains Connection of Rexroth Indradrive C Drive Controllers
147
General Information
147
Control of External Mains Contactor for HCS02 and HCS03
147
Standard Design for HCS02 and HCS03 Drive Controllers
148
Design for HCS02 and HCS03 Drive Controllers with Integrated 24V Control Voltage Supply
149
Circuits HCS02 and HCS03 with DC Bus Resistor Unit HLB01.1C or HLB01.1D
150
Circuits for Mains Connection of Rexroth Indradrive M Supply Units
156
General Information
156
Parallel Operation HMV01
157
Deceleration in the Case of Disturbed Electronic System of Drive (DC Bus Short Circuit Is Activated)
157
General Information
157
Control Circuits with DC Bus Short Circuit (ZKS)
159
Deceleration in the Case of Emergency Stop or Mains Failure
168
General Information
168
Control Circuit "Position-Controlled Deceleration by the Control Unit" Without DC Bus Short Circuit (ZKS)
169
Control Circuit Emergency Stop Relay Without DC Bus Short Circuit (ZKS)
171
Signal Sequences When Switching HMV Supply Units on and off
179
Switching on
179
Switching off
181
10 Electromagnetic Compatibility (EMC)
183
EMC Requirements
183
General Information
183
Noise Immunity in the Drive System
183
Basic Structure for Noise Immunity
183
Limit Values for Noise Immunity
184
Noise Emission of the Drive System
184
Causes of Noise Emission
184
Limit Values for Line-Based Disturbances
185
Ensuring the EMC Requirements
188
Measures to Reduce Noise Emission
189
General Information
189
Shielding
189
Grounding
189
Filtering
189
11 Arranging the Components in the Control Cabinet
191
Dimensions and Distances
191
Main Dimensions of the System Components
191
General Information
191
Device Depths and Device Heights
191
Distances
192
General Information
192
Distance between the Devices
192
Distance to the Bottom of the Devices
193
Distance to the Top of the Devices
193
Lateral Distance at Drive System
195
Boring Dimensions for the Mounting Plate
196
Individually Arranged Devices
196
Combination of Devices of the Rexroth Indradrive M Product Range
198
Combination of Drive Controllers of the Rexroth Indradrive C Product Range
201
Combination of Drive Controllers of the Rexroth Indradrive C and M Product Ranges
202
Arranging Components from Electrical Point of View
203
General Information
203
Performance-Dependent Arrangement
204
EMC Measures for Design and Installation
205
Rules for Design of Installations with Drive Controllers in Compliance with EMC
205
EMC-Optimal Installation in Facility and Control Cabinet
206
Ground Connections
213
Installing Signal Lines and Signal Cables
214
General Measures of Radio Interference Suppression for Relays, Contactors, Switches, Chokes and Inductive Loads
214
12 Project Planning of Cooling System
217
Control Cabinet
217
Control Cabinet Design and Cooling
217
Arranging the Cooling Units
218
Multiple-Line Design of the Control Cabinet
220
13 Connections of the Components in the Drive System
223
System Connections of the Components
223
General Information
223
Position of System Connections
224
Ground Connection of Housing
224
Connection Point of Equipment Grounding Conductor and Equipment Grounding Connections
225
General Information
225
Equipment Grounding Connections between Devices
226
Connection to Equipment Grounding System in Control Cabinet
227
Connection to Mains Choke and Mains Filter
228
Connection of the DC Bus Connections
230
General Information
230
Minimum Requirements to Connection Lines
231
Maximum Allowed Line Length at DC Bus Connection
232
Cable Routing to the Left
233
Cable Routing to the Right
233
Connection of the Control Voltage Connections
234
General Information
234
Cable Routing to the Left
236
Cable Routing to the Right
237
Module Bus Connection X1
237
Connection of Motor to Drive Controller
238
General Information
238
Shield Connection with Accessory HAS02
239
Shield Connection Without Accessory HAS02
239
Overall Connection Diagrams of Drive Systems
242
14 Third-Party Motors at Rexroth Indradrive Controllers
243
General Information on Third-Party Motors
243
Why Use Third-Party Motors at Rexroth Indradrive Controllers
243
Which Are the Important Directives
243
Third-Party Motors to be Controlled
243
Requirements on Third-Party Motors
244
General Information
244
Voltage Load of the Third-Party Motor
244
Minimum Inductance of Third-Party Motor
245
Temperature Evaluation of Third-Party Motor
246
Requirements on the Encoder of the Third-Party Motor
247
Motor Encoder of Asynchronous Third-Party Motor
247
Motor Encoder of Synchronous Third-Party Motor
247
Motor Encoder Resolver - Notes on Selection
247
Notes on Selection and Commissioning
247
Selecting the Controller as Regards Continuous Current
247
Selecting the Connection Technique
248
Notes on Commissioning
248
15 Calculations
249
Determining the Appropriate Drive Controller
249
Introduction
249
DC Bus Continuous Power
249
DC Bus Peak Power
253
Regenerative Power
253
Reduction of Generated Power Dissipation - Additional External Capacitors at DC Bus
254
Continuous Regenerative Power
257
Peak Regenerative Power
259
Calculating the Control Factor
260
Calculations for the Mains Connection
262
Calculating the Mains-Side Phase Current
262
Calculating the Inrush Current
263
Calculations for the Mains Harmonics
263
Harmonic Load THD
263
Harmonic Content / Distortion Factor K
263
Power Factor Cosφ1 or DPF for Calculating the Wattless Power Load of the Mains
264
Power Factor Cosφ or TPF (Λ)
264
Mains Voltage Unbalance
264
Calculating the Allowed Continuous Power in the Common DC Bus
265
Determining Components in the Mains Connection
266
Determining the Mains Choke
266
Determining the Mains Filter
266
Determining Mains Transformer DLT
267
Mains Contactor and Fusing
267
Dimensioning the Line Cross Sections and Fuses
268
Determining the Leakage Capacitance
274
Determining the Allowed Operating Data of Mains Filters
275
Reducing Allowed Operating Voltage Depending on Actual Temperature Rise Due to Harmonics
275
Current Reduction in the Case of Overtemperature
276
Other Calculations
278
Charging the DC Bus
278
Calculating Speed Characteristic and Braking Time with DC Bus Short Circuit (ZKS)
279
16 Environmental Protection and Disposal
283
Environmental Protection
283
Disposal
283
17 Service and Support
285
18 Appendix
287
System Elements - Product Overview, Short Designations
287
Leakage Capacitances
289
Leakage Capacitance of Motors
289
Leakage Capacitance of Power Cables
290
Emitted Harmonics on Mains Current and Mains Voltage
292
General Information
292
Harmonics of Mains Current
292
Harmonics on Mains Voltage
296
Voltage Pulse for Test According to EN61000
296
Discharging of Capacitors
298
Discharging DC Bus Capacitors
298
Glossary, Definitions of Terms, Abbreviations
299
Index
303
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