Bosch Rexroth VFC 610 Series Operating Instructions Manual
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Bosch Rexroth VFC 610 Series Operating Instructions Manual

Bosch Rexroth VFC 610 Series Operating Instructions Manual

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VFC x610 Series
Brake Chopper
Operating Instructions
R912007234
Edition 01

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Summary of Contents for Bosch Rexroth VFC 610 Series

  • Page 1 VFC x610 Series Brake Chopper Operating Instructions Edition 01 R912007234...
  • Page 2 This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth (Xi'an) Electric Drives and Controls Co., Ltd. It may not be reproduced or given to third parties without its consent.

  • Page 3: Table Of Contents

    Brake Chopper Bosch Rexroth AG Table of Contents Table of Contents Page Safety Instructions for Electric Drives and Controls......1 Definitions of Terms................1 Explanation of signal words and the Safety alert symbol...... General Information................4 1.3.1 Using the Safety Instructions and Passing Them on to Others....4 1.3.2...
  • Page 4 Bosch Rexroth AG Brake Chopper Table of Contents Page Brake Chopper and Brake Resistor............19 4.5.1 Braking Ratio..................4.5.2 Recommended Brake Chopper and Brake Resistor......19 Brake Chopper Mounting..............21 Installation Conditions................. 21 Figures and Dimensions............... 22 5.2.1 Figures....................5.2.2 Dimensions..................
  • Page 5 Brake Chopper Bosch Rexroth AG Table of Contents Page Parameter and Typical Application............Parameter Descriptions............... 9.1.1 Terminology and Abbreviation in Parameter List......... 9.1.2 Parameter List..................9.1.3 Parameter Setting Description............Typical Application................48 9.2.1 Quick Start-up at Default Parameter Setting........9.2.2 Master / Slave Control Mode...............
  • Page 6 Bosch Rexroth AG Brake Chopper Table of Contents Page 14.1.1 CE......................14.1.2 EAC...................... 14.2 Appendix II: Type Coding..............DOK-RCON04-VFC*BRAKE**-IT01-EN-P...

  • Page 7: Safety Instructions For Electric Drives And Controls

    Brake Chopper Bosch Rexroth AG Safety Instructions for Electric Drives and Controls 1 Safety Instructions for Electric Drives and Controls 1.1 Definitions of Terms Documentation A documentation comprises the entire documentation used to inform the user of the product about the use and safety-relevant features for configuring, integrat- ing, mounting, installing, commissioning, operating, maintaining, repairing and decommissioning the product.

  • Page 8: Explanation Of Signal Words And The Safety Alert Symbol

    Bosch Rexroth AG Brake Chopper Safety Instructions for Electric Drives and Controls as well as control and power circuits, which have been assembled for a specific application. A machine is, for example, intended for processing, treatment, movement or packaging of a material. The term "machine" also covers a combi- nation of machines which are arranged and controlled in such a way that they function as a unified whole.
  • Page 9 Brake Chopper Bosch Rexroth AG Safety Instructions for Electric Drives and Controls DANGER In case of non-compliance with this safety instruction, death or serious injury will occur. WARNING In case of non-compliance with this safety instruction, death or serious injury could occur.

  • Page 10: General Information

    You must follow these safety instructions. Bosch Rexroth is not liable for damages resulting from failure to observe the ● safety instructions.

  • Page 11: Hazards By Improper Use

    Brake Chopper Bosch Rexroth AG Safety Instructions for Electric Drives and Controls which measures of risk reduction for personal safety depend on electrical, electronic or programmable control systems. The information given in the application documentation with regard to the use ●...
  • Page 12 Bosch Rexroth AG Brake Chopper Safety Instructions for Electric Drives and Controls High electrical voltage by incorrect connection! Danger to life or injury by ● electric shock! Dangerous movements! Danger to life, serious injury or property damage by ● unintended motor movements! Health hazard for persons with heart pacemakers, metal implants and hearing ●...

  • Page 13: Instructions With Regard To Specific Dangers

    Brake Chopper Bosch Rexroth AG Safety Instructions for Electric Drives and Controls 1.4 Instructions with Regard to Specific Dangers 1.4.1 Protection against Contact with Electrical Parts and Housings This section concerns components of the electric drive and control system with voltages of higher than 50 V.

  • Page 14: Protective Extra-Low Voltage As Protection Against Electric Shock

    If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g., the mains connection) are connected to Bosch Rexroth prod- ucts, the connected extra-low voltage circuits must comply with the require- ments for PELV ("Protective Extra-Low Voltage").
  • Page 15 Brake Chopper Bosch Rexroth AG Safety Instructions for Electric Drives and Controls that faulty drive movements will occur. The extent of faulty drive movements de- pends upon the type of control and the state of operation. Dangerous movements! Danger to life, risk of injury, serious injury or property...

  • Page 16: Protection Against Magnetic And Electromagnetic Fields During Operation And Mounting

    Bosch Rexroth AG Brake Chopper Safety Instructions for Electric Drives and Controls and radio equipment in its possible positions of normal use. It might possibly be necessary to perform a special electromagnetic compatibility (EMC) test. 1.4.4 Protection Against Magnetic and Electromagnetic Fields During...

  • Page 17: Protection During Handling And Mounting

    Brake Chopper Bosch Rexroth AG Safety Instructions for Electric Drives and Controls be, for example: Warnings at the machine or installation, guards (shieldings or barriers) or safety instructions in the application documentation. 1.4.6 Protection during handling and mounting Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting! Observe the relevant statutory regulations of accident prevention.

  • Page 18: Important Directions For Use

    The user alone carries all responsibility of the risks. Before using Bosch Rexroth products, make sure that all the pre-requisites for appropriate use of the products are satisfied. Personnel that in any way or form use our products must first read and under- ●...

  • Page 19: Delivery And Storage

    3.1 Product Identification 3.1.1 Packing Nameplate Check if the model information on the packing nameplate is the same as you or- dered immediately after receipt. If the model is wrong, please contact Bosch Rexroth distributor. Product series Production week: e.g., 14W20 means...

  • Page 20: Product Nameplate

    In case of damage, contact the forwarder at once and arrange for a thorough review of the situation. This is also applicable if the packaging is undamaged. 3.3 Scope of Supply If any of the following standard supply items is missing, please contact Bosch Rexroth distributor. Brake chopper ●...

  • Page 21: Transport Of The Components

    Brake Chopper Bosch Rexroth AG Delivery and Storage 3.4 Transport of the Components Description Symbol Unit Value Temperature range ℃ -25…70 a_tran Relative humidity – 5…95 Absolute humidity – 1…60 Climate category (IEC 721) – – Moisture condensation – –...

  • Page 22: Brake Chopper Overview

    Bosch Rexroth AG Brake Chopper Brake Chopper Overview 4 Brake Chopper Overview 4.1 Work Principle Brake chopper is used to consume the electrical energy returned from the exter- nal motor to frequency converter during braking, and limit the DC-bus voltage of frequency converter into a rational range to improve the braking performance and finally stop motor quickly.

  • Page 23: Product Features

    Brake Chopper Bosch Rexroth AG Brake Chopper Overview 4.2 Product Features 4.2.1 Conditions Rated ambient temperature -10...40 ℃ Derating / ambient tempera- 1.5 % / 1 °C (40...50 °C) ture Rated storage temperature -20...60 ℃ Rated altitude ≤ 1,000 m Derating / altitude 1 % / 100 m (1,000...4,000 m)

  • Page 24: Technical Data

    Bosch Rexroth AG Brake Chopper Brake Chopper Overview 4.3 Technical Data 4.3.1 Electric Data Voltage class 3P 380...480 VAC (-15 % / +10 %); 50 / 60 Hz (±5 %) Brake chopper model FEAE07.1-VA1-NNNN FEAE07.1-VA2-NNNN Output current 0.0...80.0 A 0.0...125.0 A...

  • Page 25: Brake Chopper And Brake Resistor

    Brake Chopper Bosch Rexroth AG Brake Chopper Overview 4.5 Brake Chopper and Brake Resistor 4.5.1 Braking Ratio Brake resistors with different power ratings are available to dissipate braking en- ergy when the frequency converter is in generator mode. The following table lists the details of brake chopper and brake resistor corresponding to each brake power in the condition that a certain braking ratio is given.
  • Page 26 Bosch Rexroth AG Brake Chopper Brake Chopper Overview Power of brake resis- Brake resistence(Ω) Number of tor(KW) Number of Brake pow- Brake chopper paralleled brake Recom- Recom- er (KW) type code brake re- choppers mended Min. value mended Min. value...

  • Page 27: Brake Chopper Mounting

    Brake Chopper Bosch Rexroth AG Brake Chopper Mounting 5 Brake Chopper Mounting 5.1 Installation Conditions The brake chopper must be vertically installed. If one brake chopper is arranged above another, make sure the upper limit of air temperature (50 ℃) into the inlet is not exceeded. An air guide is recommended between the brake choppers to prevent the rising hot air being drawn into the upper brake chopper if the upper limit of air temperature is exceeded.

  • Page 28: Figures And Dimensions

    Bosch Rexroth AG Brake Chopper Brake Chopper Mounting 5.2 Figures and Dimensions 5.2.1 Figures Fig. 5-2: Brake chopper dimensions figure 5.2.2 Dimensions Screw Model Ø size weight [kg] FEAE07.1- 2.24 VA1-NNNN FEAE07.1- 2.34 VA2-NNNN Tab. 5-1: Brake chopper dimensions (unit: mm)

  • Page 29: Brake Chopper Wiring

    Brake Chopper Bosch Rexroth AG Brake Chopper Wiring 6 Brake Chopper Wiring 6.1 System Wiring 6.1.1 Electrical Interface Fig. 6-1: Electrical interface of brake chopper 23/65 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...

  • Page 30: Typical Connection Mode 1

    Bosch Rexroth AG Brake Chopper Brake Chopper Wiring 6.1.2 Typical Connection Mode 1 Fig. 6-2: Typical connection mode 1 6.1.3 Typical Connection Mode 2 Fig. 6-3: Typical connection mode 2 24/65 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...
  • Page 31 Brake Chopper Bosch Rexroth AG Brake Chopper Wiring Make sure that terminals (+), (-) of frequency converter are con- ● nected to the corresponding terminals P, N of brake chopper re- spectively. Incorrect connection may damage the brake chopper. Please connect to frequency converter directly or install a termi- ●...

  • Page 32: Cable Specifications

    Bosch Rexroth AG Brake Chopper Brake Chopper Wiring 6.2 Cable Specifications 6.2.1 Power Cables Power cables installation mode Brake chopper PE cable Torque / Screw Fuse (gG) model [N·m / lb·in] (Mx) ] [mm ] [mm FEAE07.1-VA1-NNNN 10.0 10.0 10.0 10.0...
  • Page 33 Brake Chopper Bosch Rexroth AG Brake Chopper Wiring B1 Conductors in installation pipes and Cables or lines on walls in installation channels that can be Cables or lines on open cable trays opened B2 Cables or lines in installation pipes...

  • Page 34: Control Cables

    Bosch Rexroth AG Brake Chopper Brake Chopper Wiring 6.2.2 Control Cables The requirements of control cables are as follows: Cable Unit Min. Max. Type Shielded cable Wire-end ferrule w/plastic collar Cross-section Ferrule length Stripped length Wire-end ferrule w/o plastic collar...

  • Page 35: Terminals

    Brake Chopper Bosch Rexroth AG Brake Chopper Wiring 6.3 Terminals 6.3.1 Power Terminals Fig. 6-5: Power terminals Terminal Description Mains supply input terminals Output terminals Tab. 6-4: Power terminals description Fig. 6-6: Grounding and PE terminals 1: Power circuit terminal...

  • Page 36: Control Terminals

    Bosch Rexroth AG Brake Chopper Brake Chopper Wiring 6.3.2 Control Terminals Control terminals figure Fig. 6-7: Control circuit terminals CAUTION The brake chopper might be damaged! Please make sure that the power supply of the brake chopper has been switch- ed off before plugging or unplugging the connector.
  • Page 37 Brake Chopper Bosch Rexroth AG Brake Chopper Wiring Control terminals description Digital signal terminals Terminal Signal function Description Signal requirement Control signal input terminals Digital inputs when brake chopper is set to slave OUT+ Control signal output terminals Digital outputs...

  • Page 38: Digital Signal Internal Wiring

    Bosch Rexroth AG Brake Chopper Brake Chopper Wiring 6.3.3 Digital Signal Internal Wiring ① Use of terminal TG ② Use of terminal Reset Fig. 6-8: Wiring of terminals TG and Reset Terminals Reset and TG are using the switching signals. Do not need external power supply.

  • Page 39: Electromagnetic Compatibility (Emc)

    Brake Chopper Bosch Rexroth AG Electromagnetic Compatibility (EMC) 7 Electromagnetic Compatibility (EMC) 7.1 Cable Connections between Brake Chopper and Frequency Converter Fig. 7-1: Cable connections between brake chopper and frequency converter 33/65 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...

  • Page 40: Mounting And Wiring In Control Cabinet

    Bosch Rexroth AG Brake Chopper Electromagnetic Compatibility (EMC) 7.2 Mounting and Wiring in Control Cabinet Influence of the Motor Power Cable The longer the motor cable, the greater its leakage capacitors. To comply with a certain EMC limit value, the allowed leakage capacitance of he mains filter is limited.

  • Page 41: Installing Signal Lines And Signal Cables

    Brake Chopper Bosch Rexroth AG Electromagnetic Compatibility (EMC) 7.3 Installing Signal Lines and Signal Cables Line Routing The following measures are recommend: Route signal and control lines separately from frequency converter power ca- ● bles , motor power cables and brake chopper power cables with a minimum distance of d = 100 mm or with a grounded separating sheet.

  • Page 42: Operating Panel And Dust Cover

    Bosch Rexroth AG Brake Chopper Operating Panel and Dust Cover 8 Operating Panel and Dust Cover 8.1 LED Panel 8.1.1 Appearance Fig. 8-1: LED panel 36/65 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...

  • Page 43: Operating Descriptions

    Brake Chopper Bosch Rexroth AG Operating Panel and Dust Cover 8.1.2 Operating Descriptions Fig. 8-2: Operating mode 8.1.3 Fast Access to Parameters with Button Combinations Brake chopper provides fast access to parameters within a parameter group with '<Func> + <▲>' or '<Func> + <▼>' combinations.
  • Page 44 Bosch Rexroth AG Brake Chopper Operating Panel and Dust Cover The parameter fast access function is only available to the param- ● eters with a number type setting range, not available to parame- ters with a optional type setting range.

  • Page 45: Lcd Panel

    Brake Chopper Bosch Rexroth AG Operating Panel and Dust Cover 8.2 LCD Panel 8.2.1 LCD Panel Introduction Fig. 8-3: LCD panel appearance (1) Rotary encoder 1. Scroll between parameter and group code 2. Set the parameter value (2) Func button: Enter the parameter group screen and go back to previous screens.

  • Page 46: Operating Example

    Bosch Rexroth AG Brake Chopper Operating Panel and Dust Cover Setting [U2.02] to '1', or ● Pressing Func button with Loc button for longer than 3 s. ● Panel can be unlocked by the following ways: Setting [U2.02] to '0' (only in communication mode), or ●...

  • Page 47: Parameter And Typical Application

    Brake Chopper Bosch Rexroth AG Parameter and Typical Application 9 Parameter and Typical Application 9.1 Parameter Descriptions 9.1.1 Terminology and Abbreviation in Parameter List Code: Function / parameter code, written in bx.xx, Hx.xx, Ux.xx, dx.xx ● Name: Parameter name ●...
  • Page 48 Bosch Rexroth AG Brake Chopper Parameter and Typical Application Code Name Setting range Default Min. Attri. 0: Brake chopper fault H6.10 Relay output selection 1: Brake chopper working – Stop 2: Brake chopper ready 0: Automatic H6.11 Fan control –...

  • Page 49: Parameter Setting Description

    Brake Chopper Bosch Rexroth AG Parameter and Typical Application 9.1.3 Parameter Setting Description b0.10: Parameter initialization Code Name Setting range Default Min. Attri. b0.10 Parameter initialization 0...2 – Stop 0: Inactive ● This parameter will be reset to '0: Inactive' automatically after parameter initi- alization.
  • Page 50 Bosch Rexroth AG Brake Chopper Parameter and Typical Application b0.20: Password Protection User password is used to protect parameter settings from unauthorized or unin- tended changes. Code Name Setting range Default Min. Attri. b0.20 User password 0...65,535 – Possible operations with passwords are as below: Set user password ●...
  • Page 51 Brake Chopper Bosch Rexroth AG Parameter and Typical Application H6.00 is set to '1: Master': when bus voltage is higher than braking start voltage [H6.01], brake chopper starts running. Meanwhile, as the master, brake chopper enables the digital output OUT+ in running status. Digital input IN+ is not detec- ted.
  • Page 52 Bosch Rexroth AG Brake Chopper Parameter and Typical Application Fig. 9-2: Stop voltage point H6.10: Relay output selection Please read through the information on 'Wiring diagram' and 'Terminal' before the selection of 'Relay output'. Code Name Setting range Default Min.
  • Page 53 Brake Chopper Bosch Rexroth AG Parameter and Typical Application The fan for the heat sink is by default switched on / off automatically accord- ing to the temperature of the heat sink. In this mode, the noise level of the brake chopper can be reduced.

  • Page 54: Typical Application

    Bosch Rexroth AG Brake Chopper Parameter and Typical Application 9.2 Typical Application 9.2.1 Quick Start-up at Default Parameter Setting By default, brake chopper works in standalone mode. Its default value of start voltage is 750 V and duty cycle is 100 %.

  • Page 55: Diagnosis

    Brake Chopper Bosch Rexroth AG Diagnosis 10 Diagnosis 10.1 Status Code Code Description '-' '--' '---' '----' '-----' During parameter backup… 10.2 Warning Code Code Description S.Err Parameter change blocked PrSE Parameter setting contradiction 49/65 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...

  • Page 56: Error Code

    Bosch Rexroth AG Brake Chopper Diagnosis 10.3 Error Code 10.3.1 Error 01 (OE-b): Brake Chopper Overvoltage Possible reason Solution Surge voltage from power supply Check input power supply Excessive low resistance of brake resis- Recalculate and choose brake resistor Excessive high setting of brake chopper...

  • Page 57: Error 07 (Oh-R): Brake Resistor Overheat

    Brake Chopper Bosch Rexroth AG Diagnosis 10.3.5 Error 07 (OH-r): Brake Resistor Overheat Possible reason Solution Check power of brake resistor ● Inappropriate type or bad heat of brake resistor Provide good heat condition ● temperature sensor of brake resistor...

  • Page 58: Maintenance

    Bosch Rexroth AG Brake Chopper Maintenance 11 Maintenance 11.1 Safety Instructions WARNING High electric voltage! Risk of death or severe bodily injury by electric shock! Only those trained and qualified to work with or on electric equipment are ● permitted to operate, maintain and repair this equipment.

  • Page 59: Periodic Inspection

    Brake Chopper Bosch Rexroth AG Maintenance 11.3 Periodic Inspection In addition to daily inspection, periodic inspection of brake choppers is also necessary. The inspection cycle should be less than 6 months. For operation de- tails, please see table below: Inspection...

  • Page 60: Removable Components Maintenance

    Bosch Rexroth AG Brake Chopper Maintenance 11.4 Removable Components Maintenance 11.4.1 Construction Overview (1) Dust cover (7) Heat sink (2) Keyboard tray (8) Above baffle (3) Cover (9) Below baffle (4) Control board (10) Fan cover (5) Drive board (11) Frame...

  • Page 61: Disassembly Of Dust Cover

    Brake Chopper Bosch Rexroth AG Maintenance 11.4.2 Disassembly of Dust Cover Fig. 11-2: Disassembly of dust cover Step 1: Press two buckles as circles indicating in the above figure ● Step 2: Hold dust cover and pull it out horizontally from the mounting plate ●...

  • Page 62: Disassembly Of Fans

    Bosch Rexroth AG Brake Chopper Maintenance 11.4.3 Disassembly of Fans Fig. 11-3: Disassembly of fan Step 1: Unscrew the two screws on the fan cover ● Step 2: Take off the fan cover ● Step 3: Slowly remove the fan ●...

  • Page 63: Service And Support

    Brake Chopper Bosch Rexroth AG Service and Support 12 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. You can contact us 24/7. Service Germany Our technology-oriented Competence Center in Lohr, Germany, is responsible for all your service-related queries for electric drive and controls.

  • Page 64: Environmental Protection And Disposal

    Bosch Rexroth AG Brake Chopper Environmental protection and disposal 13 Environmental protection and disposal 13.1 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 environment- friendly alternatives.
  • Page 65 Brake Chopper Bosch Rexroth AG Environmental protection and disposal Batteries and accumulators Batteries and accumulators can be labeled with this symbol. The symbol indicating "separate collection" for all batteries and accu- mulators is the crossed-out wheeled bin. The end user within the EU is legally obligated to return used batteries. Outside the validity of the EU Directive 2006/66/EC keep the stipulated directives.

  • Page 66: Appendix

    Bosch Rexroth AG Brake Chopper Appendix 14 Appendix 14.1 Appendix I: Certification 14.1.1 CE Declaration of conformity For Brake Choppers, there are declarations of conformity which confirm that the devices comply with the applicable EN Standards and EC Directives. If required, you may ask our sales representative for the declarations of conformity.
  • Page 67 Brake Chopper Bosch Rexroth AG Appendix 14.1.2 EAC Brake Choppers have EAC certification. EAC marking is required for Custom Un- ion, including Russia, Belarus and Kazakhstan. EAC marking Fig. 14-2: EAC marking 61/65 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...
  • Page 68 Bosch Rexroth AG Brake Chopper Appendix 14.2 Appendix II: Type Coding Fig. 14-3: Brake chopper type coding 62/65 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...
  • Page 69 Brake Chopper Bosch Rexroth AG 63/65 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...
  • Page 70 Bosch Rexroth AG Brake Chopper 64/65 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...
  • Page 71 Brake Chopper Bosch Rexroth AG Notes...
  • Page 72 Bosch Rexroth (Xi’an) Electric Drives and Controls Co., Ltd. No. 3999, Shangji Road, Economic and Technological Development Zone, 710021 Xi’an, P.R. China Phone +49 9352 40 5060 Fax +49 9352 18 4941 service.svc@boschrexroth.de www.boschrexroth.com *R912007234* R912007234 DOK-RCON04-VFC*BRAKE**-IT01-EN-P...

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