Bosch Rexroth IndraDrive ML Series Manuals

Manuals and User Guides for Bosch Rexroth IndraDrive ML Series. We have 1 Bosch Rexroth IndraDrive ML Series manual available for free PDF download: Project Planning Manual

Bosch Rexroth IndraDrive ML Series Project Planning Manual

Bosch Rexroth IndraDrive ML Series Project Planning Manual (410 pages)

Drive Systems with HMU05

Brand: Bosch | Category: Inverter | Size: 15.13 MB

Table of Contents

Table of Contents
3
1 System Presentation

13
- Rexroth Indradrive ML Range
  13
- Overview - Rexroth Indradrive ML
  13
- Target Applications
  15
- Features
  16
  - Functional Features
    16
  - Performance Features
    17
  - Interfaces
    17
  - Supported Encoder Systems
    18
- System Configuration
  19
- System Structure
  19
- System Components
  20
  - HMU05 Universal Inverter
    20
    
    HMU05 Type Code
    20
  - Control Sections
    22
  - Optional Cards
    26
  - Installing and Removing Control Sections and Optional Cards
    27
    
    Training
    27
    
    ESD Protection
    27
    
    Limited Number of Insertions and Removals
    27
    
    Instructions
    28
  - Firmware
    29
- About this Documentation
  30
  - Purpose
    30
  - Documentations
    30
    
    Drive Systems, System Components
    30
    
    Firmware
    30
  - Your Feedback
    31
2 Important Directions for Use

33
- Appropriate Use
  33
- Introduction
  33
- Areas of Use and Application
  33
- Inappropriate Use
  34
3 Safety Instructions for Electric Drives and Controls

35
4 Combining the Individual Components

47
- Documentations
  47
- Brief Description of Individual Components
  47
- HMU05 - Brief Description and Design
  47
- Configuring the Drive System
  49
- Firmware
  49
  - Firmware and Device Types
    49
- Motors
  49
  - Third-Party Motors
    49
    
    General Information on Third-Party Motors
    49
    
    Requirements on Third-Party Motors
    50
    
    Third-Party Motor Encoder Requirements
    52
    
    Notes on Selection and Commissioning
    53
- Cables
  54
  - Motor Power Cable
    54
  - Encoder Cables
    54
- Leakage Capacitances
  55
- Installation Conditions
  62
- Ambient and Operating Conditions
  62
- Control Cabinet
  64
  - Air Cooling
    64
    
    Control Cabinet Design and Cooling
    64
  - Liquid Cooling
    65
    
    General Information
    65
    
    Cooling Devices
    65
    
    Cooling Device Components
    67
    
    Cooling of the Drive Components
    75
    
    Coolant
    79
    
    Sizing Liquid Cooling
    80
- UL Ratings
  81
  - Introduction
    81
  - Inverter
    81
  - Supply Units
    82
- Compatibility with Foreign Matters
  83
- Mechanical Project Planning
  84
- Dimensions
  84
  - Hmu05.1N-F0140-0350
    84
  - Hmu05.1N-F0170-0430
    85
  - Hmu05.1N-F0220-0510
    86
  - Hmu05.1N-F0270-0660
    87
  - Hmu05.1N-F0340-0820
    88
  - Hmu05.1N-F0430-1040
    89
  - Hmu05.1N-F0540-1300
    90
- Dimensions, Mass, Insulation, Sound Pressure Level
  91
- Temperatures, Cooling, Power Dissipation, Distances
  92
- Mounting Positions of Components
  95
- Electrical Project Planning
  96
- Overall Connection Diagram (HMU05 as Drive Controller)
  96
- Overall Connection Diagram (HMU05 as Supply Unit)
  97
  - Overall Connection Diagram with Load Contactor
    97
  - Overall Connection Diagram with a Controllable Main Switch
    98
- Project Planning of Control Voltage
  100
  - Control Voltage for Drive Systems
    100
  - Sizing the Control Voltage Supply
    100
    
    Determining the Power Requirements
    100
    
    Requirements on the 24V Power Supply Unit
    102
    
    Installing the 24V Supply
    103
- Mains Connection
  104
- Running Multiple Hmu05S in Parallel
  116
- Acceptance Tests and Approvals
  119
5 Condition as Supplied, Identification, Transport and Storage

121
- Condition as Supplied
  121
- Factory Testing
  121
  - Voltage Testing and Insulation Resistance Testing
    121
- Customer Testing
  121
- Identification
  122
- Type Plates
  122
  - Design
    122
- Contents of Delivery
  122
- Transporting Components
  122
- Storing Components
  123
6 Mounting and Installation

125
- Mounting HMU05 Devices in Control Cabinet
  125
- Electrical Connection
  125
- Overall Connection Diagram (HMU05 as Drive Controller)
  125
- Overall Connection Diagram (HMU05 as Supply Unit)
  125
  - Overall Connection Diagram with Load Contactor
    125
  - Overall Connection Diagram with Controllable Main Switch
    125
- Connection Points
  126
  - Arrangement of HMU05 Connection Points
    126
  - Connection Point of Equipment Grounding Conductor
    127
  - L1, L2, L3, Mains/Motor Connection
    128
    
    Important Notes
    128
  - XG3, Motor Temperature Monitoring, Motor Holding Brake, Motor Fan Control
    129
  - XG32, HNA Bus
    131
  - XG1, Indrabus
    131
  - XD10, 24 V Supply (Control Voltage)
    131
  - L+ L-, DC Bus Connection
    132
  - Shield Connection
    133
  - Ground Connection
    135
- Optional Cards
  136
  - HPC01.1-Mn0X-NN
    136
  - Hpc01.1-P001-Nn
    136
- WATER IN/OUT, Cooling Liquid Connection
  137
7 Technical Data of the Components

139
- Ambient and Operating Conditions
  139
- Power Section
  139
- Control Voltage
  139
- Mains Voltage
  141
- DC Bus
  143
- Inverter
  145
8 Cables, Accessories, Additional Components

149
- Overview
  149
- Cables
  149
- Accessories
  149
- Additional Components
  149
- Accessories
  150
- Mounting and Connection Accessories (HAS03)
  150
- Cabinet Installation Kit (HAS08.1-008)
  151
  - Type Code
    151
  - Parts
    152
  - Mounting
    153
    
    On Top of Control Cabinet
    153
    
    In Front of Control Cabinet
    154
    
    Mounting the Device
    156
    
    Dismounting the Device
    158
- Blank Covers, Motor Monitor Grounding, Mounting Plates (HAS10)
  159
- Additional Components
  168
- HNA05 Mains Connection Module
  168
  - HNA05 Type Code
    168
  - Dimensions
    169
  - Data
    171
  - Connection Points
    173
    
    Overview
    173
    
    Equipment Grounding Conductor Connection Point
    174
    
    XD1, Mains Voltage, Equipment Grounding Conductor
    175
    
    XD2, DC Bus
    176
    
    XD10, 24 V Supply (Control Voltage)
    177
    
    XG1, Indrabus
    178
    
    XG31, Messages
    179
    
    XG32, HNA Bus
    181
    
    XG33, On, Off, ZKS (DC Bus Short Circuit) Status
    182
    
    XG34, Mains Contactor (Contact)
    184
    
    XG40, Mains Contactor (Acknowledgment Messages)
    185
  - Display Elements
    186
- HNC05 Mains Capacitor
  187
  - HNC05 Type Code
    187
  - Dimensions
    188
    
    Hnc05.1N-0050
    188
    
    Hnc05.1N-0075
    189
    
    Hnc05.1N-0100
    190
  - Data
    191
  - Assignment to HMU05
    191
- HNF05 Mains Filter
  192
  - HNF05 Type Code
    192
  - Dimensions
    194
    
    Hnf05.1A-500N-R0250
    194
    
    Hnf05.1A-500N-R0320, -R0400
    195
    
    Hnf05.1A-500N-R0600
    196
    
    Hnf05.1A-500N-R1000
    197
    
    Hnf05.1A-500N-R1600
    198
  - Mounting
    198
  - Data
    199
  - Assignment to HMU05
    199
- HNL05 Mains Choke
  200
  - HNL05 Type Code
    200
  - Type Plate
    204
  - Dimensions
    205
    
    Hnl05.1R-0219-N0218
    205
    
    Hnl05.1R-0182-N0262
    206
    
    Hnl05.1R-0045-N0327
    207
    
    Hnl05.1R-0135-N0327
    208
    
    Hnl05.1R-0054-N0409
    209
    
    Hnl05.1R-0117-N0409
    210
    
    Hnl05.1R-0043-N0514
    211
    
    Hnl05.1R-0130-N0514
    212
    
    Hnl05.1R-0050-N0652
    213
    
    Hnl05.1R-0113-N0652
    214
    
    Hnl05.1R-0040-N0811
    215
    
    Hnl05.1R-0100-N0811
    216
    
    Hnl05.1R-0040-N1019
    217
    
    Hnl05.1R-0094-N1019
    218
  - Data
    219
  - Water Cooling
    220
  - Connection
    220
  - Assignment to HMU05
    220
- HML05 Motor Choke/Balancing Choke
  221
  - HML05 Type Code
    221
  - HML05 to HMU05 Assignment
    222
  - Dimensions
    223
  - Data
    231
- HLL05 DC Bus Choke
  233
  - HLL05 Type Code
    233
  - Sizing
    234
  - Dimensions
    235
    
    Hll05.1W-04M0-S0202
    235
    
    Hll05.1F-04M0-S0202
    236
    
    Hll05.1F-04M0-S0243
    237
    
    Hll05.1W-04M0-S0303
    238
    
    Hll05.1F-04M0-S0303
    239
    
    Hll05.1F-04M0-S0380
    240
    
    Hll05.1F-04M0-S0475
    241
    
    Hll05.1F-04M0-S0603
    242
    
    Hll05.1F-04M0-S0720
    243
    
    Hll05.1F-04M0-S0942
    244
  - Data
    245
  - Water Cooling
    246
  - Assignment
    247
  - Circuit Diagram
    248
  - Connection
    248
- Y Capacitor Pair (HAS04.1-003)
  249
  - Type Code
    249
  - Data
    249
- HLR05 External Braking Resistor
  251
  - HLR05 Type Code
    251
  - Dimensions
    252
    
    Hlr05.1W-54K0-N05R4
    252
  - Data
    253
  - Installation
    254
- HLT05 Braking Unit
  257
  - HLT05 Type Code
    257
  - Dimensions
    258
  - Data
    261
  - Connection Diagram
    262
  - Connection Points
    265
    
    Overview
    265
    
    XE01, Equipment Grounding Conductor Connection Point
    267
    
    XD02, DC Bus
    269
    
    XD4, Braking Resistor
    273
    
    XD10, 24 V Supply (Control Voltage)
    274
    
    XG1, Indrabus
    275
    
    XG3, Braking Resistor Overtemperature Signal Contact
    276
    
    XG31, Signal Contact (Bb, Warning) and Reset Input
    277
    
    XG33, DC Bus Short-Circuit (ZKS)
    279
  - SF1 Switch
    280
  - Display Elements
    281
- 24V Power Supply Unit
  282
  - Features
    282
  - Data
    283
  - 24V/20A Connection Diagram
    284
  - 24V/40A Connection Diagram
    285
- Heat Exchanger HAH01
  286
  - Type Code HAH01
    286
  - General Information
    287
    
    Manufacturer's Details and Machine Identification Details
    287
    
    Declaration of Conformity
    288
    
    Disclaimer Notice
    289
  - Safety Information
    290
    
    General Safety Warnings
    290
  - Liquid-Liquid Heat Exchanger
    291
    
    Technical Information
    291
    
    Information Concerning Handling and Installation
    303
    
    Information for Use
    309
    
    Maintenance Information
    317
    
    Breakdown Information
    319
    
    Information Concerning Replacements
    320
    
    Hydraulic Diagrams
    324
  - Air-Liquid Heat Exchanger
    328
    
    Technical Information
    328
    
    Information Concerning Handling and Installation
    341
    
    Information for Use
    348
    
    Maintenance Information
    355
    
    Breakdown Information
    357
    
    Information Concerning Replacements
    358
    
    Hydraulic Diagrams
    364
9 Environmental Protection and Disposal

367
- Environmental Protection
  367
- Disposal
  367
10 Service and Support

369
11 Appendix

371
- Switching Supply Units on and off
  371
- Switching on
  371
- Switching off
  372
- Dimensioning the Line Cross Sections and Fuses
  373
- DC Bus Fuses
  382
- Aluminum Contact Points and Cupal Disks
  383
- Introduction
  383
- Preparation
  383
- Cupal Disk
  383
- Determining the Leakage Capacitance
  385
- Leakage Capacitances
  386
- Leakage Capacitance of Power Cables
  386
- Total Harmonic Distortion (THD)
  387
- Liquid Cooling
  389
- Sizing Liquid Cooling
  389
  - Calculation Criteria
    389
    
    Physical Data
    389
    
    Flow Rate
    389
    
    Pressure Decrease
    390
  - Sizing Aids
    391
- Sizing Example
  396
  - Index
    401

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