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Bosch rexroth KMS03.1B-A036-P-D7-ET-END-L3-TO-FW User Manual

Bosch rexroth KMS03.1B-A036-P-D7-ET-END-L3-TO-FW
422 pages
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IndraDrive Mi
Drive Systems with
KCU02, KSM02, KMS02/03, KMV03, KNK03, KLC03
Project Planning Manual
R911335703
Edition 04

Table of Contents

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Bosch rexroth KMS03.1B-A036-P-D7-ET-END-L3-TO-FW Specifications

General IconGeneral
BrandBosch
Modelrexroth KMS03.1B-A036-P-D7-ET-END-L3-TO-FW
CategoryDC Drives
LanguageEnglish

Summary

IndraDrive Mi

Project Planning Manual

Identifies the document type as a manual for project planning.

1 System presentation

1.1.1 IndraDrive Mi

Describes the IndraDrive Mi as an innovative system solution.

1.3 Type code

1.3.2 KSM02 motor-integrated servo drive

Details the KSM02 type code structure and its various designations.

1.3.3 KMS02 near motor servo drive

Explains the KMS02 type code structure and its various designations.

1.3.4 KMS03 near motor servo drive

Details the KMS03 type code structure and its various designations.

1.3.5 KCU02 drive connection box

Explains the KCU02.2 type code structure and its various designations.

1.3.6 KMV03 supply unit

Details the KMV03 type code structure and its various designations.

1.3.7 KNK03 mains filter

Explains the KNK03 type code structure and its various designations.

1.3.8 KLC03 DC bus capacitor unit

Details the KLC03 type code structure and its various designations.

2 Important directions for use

2.1 Intended use

Defines the intended use of Rexroth products and emphasizes avoiding incorrect usage.

2.1.1 Introduction

States that Rexroth products are state-of-the-art and tested for operational safety.

3 Safety instructions for electric drives and controls

3.2.2 Requirements for safe use

Outlines essential requirements for safe operation and use of components.

3.2.3 Hazards by improper use

Lists various hazards associated with improper use of components, including electrical voltage and dangerous movements.

3.3 Instructions with regard to specific dangers

Provides safety measures for preventing contact with electrical parts, dangerous movements, and hot surfaces.

3.3.1 Protection against contact with electrical parts and housings

Provides safety measures for preventing contact with electrical parts and housings, especially those above 50 volts.

3.3.2 Protective extra-low voltage as protection against electric shock

Explains the use of PELV systems for connecting devices with basic insulation.

3.3.3 Protection against dangerous movements

Discusses causes of dangerous movements and necessary safety measures.

3.3.4 Protection against electromagnetic and magnetic fields during operation and mounting

Warns about hazards to persons with medical implants due to electromagnetic and magnetic fields.

3.3.5 Protection against contact with hot parts

Advises caution when touching hot surfaces of components to avoid burns.

3.3.6 Protection during handling and mounting

Provides safety guidelines for handling and mounting components to prevent injuries.

4 General data and specifications

4.3.3 Mounting position

Specifies allowed mounting positions for components and provides details on mounting clearance.

5 Technical data of the components

5.2 KSM02 motor-integrated servo drive

Provides detailed technical data for KSM02 servo drives, with and without holding brake.

5.2.1 KSM02 without motor holding brake, data sheet

Presents technical data for KSM02 without a motor holding brake, covering various model specifications.

5.2.2 KSM02 with motor holding brake, data sheet

Provides technical data for KSM02 with a motor holding brake, highlighting differences from the non-brake version.

5.2.3 KSM02 characteristics

Shows characteristic curves (torque vs. speed) for KSM02 motors under different supply conditions.

5.2.4 Dimensions and technical design

Provides detailed dimensions and technical design specifications for KSM02.

Dimensions

Displays dimensional drawings for KSM02.1B-041C, including mounting clearance.

5.2.5 Bearing load and shaft load

Explains allowed radial and axial forces, shaft load, and bearings, with diagrams and tables.

5.3 KMS02 near motor servo drive

Presents technical data for KMS02 near motor servo drive, including UL/CSA standards and operating conditions.

5.3.1 KMS02 data sheet

Presents technical data for KMS02 near motor servo drive, including UL/CSA standards and operating conditions.

5.3.2 KMS02 dimensional drawing

Provides dimensional drawings for KMS02, including mounting clearance and boring dimensions.

5.4 KCU02 drive connection box

Describes the KCU02 drive connection box and its primary functions.

5.4.1 Brief description and use

Describes the KCU02 drive connection box and its primary functions.

5.4.2 KCU02 data sheet

Lists currents, voltages, and power data for the KCU02 drive connection box.

5.4.3 KCU02 dimensional drawing

Displays dimensional drawings for the KCU02, including minimum mounting clearance.

5.5 KMV03 supply unit

Specifies ambient and operating conditions, including UL ratings, for KMV03 supply units.

5.6 KLC03 DC bus capacitor unit

Presents technical data for the KLC03 DC bus capacitor unit, including mass, voltage, and capacitance.

5.6.1 KLC03 data sheet

Presents technical data for the KLC03 DC bus capacitor unit, including mass, voltage, and capacitance.

5.6.2 KLC03.1N-B04M7 dimensional drawing (thermal interface)

Shows dimensional drawings for the KLC03.1N-B04M7 in thermal interface configuration.

5.6.3 KLC03.1N-A04M7 dimensional drawing (natural convection)

Displays dimensional drawings for the KLC03.1N-A04M7 in natural convection configuration.

5.6.4 KLC03.1N-W04M7 dimensional drawing (forced cooling)

Provides dimensional drawings for the KLC03.1N-W04M7 in forced cooling configuration.

5.7 KNK03 mains filter

Lists technical data for KNK03 mains filter, including currents, voltages, and power specifications.

5.7.1 KNK03 data sheet

Lists technical data for KNK03 mains filter, including currents, voltages, and power specifications.

5.7.2 KNK03.1A-NR-B/Ixxxx dimensional drawing (thermal interface)

Shows dimensional drawings for KNK03.1A-NR-B/Ixxxx with thermal interface.

5.7.3 KNK03.1A-NR-Axxxx dimensional drawing (natural convection)

Displays dimensional drawings for KNK03.1A-NR-Axxxx with natural convection.

5.7.4 KNK03.1A-NR-Wxxxx dimensional drawing (forced cooling)

Provides dimensional drawings for KNK03.1A-NR-Wxxxx with forced cooling.

5.8 KMS03 near motor servo drive

Presents technical data for KMS03 near motor servo drive, including UL/CSA standards and operating conditions.

5.8.1 KMS03 data sheet

Presents technical data for KMS03 near motor servo drive, including UL/CSA standards and operating conditions.

5.8.2 KMS03 dimensional drawing

Shows dimensional drawings for KMS03.1B-A036 and KMS03.1B-B036.

6 Connection points

6.1.1 Connection point of equipment grounding conductor

Explains the connection point for equipment grounding conductors in cabinet-bound and cabinet-free drive systems.

6.1.2 Ground connection

Describes how to ground device housings and drive lines for functional safety and protection.

6.2 KCU02 connection points

Identifies and describes the significance of various connection points on the KCU02.

6.2.1 Positions of the connection points

Identifies and explains the significance of various connection points on the KCU02.

6.2.4 X49, L3 - Safe Torque Off

Explains the function, pin assignment, and data for the X49 Safe Torque Off connection.

6.2.5 X50, E-Stop Input

Details the function, pin assignment, and properties of the X50 E-Stop input.

6.2.7 X53, Control Voltage Output

Explains the X53 connection for control voltage output, including function, pin assignment, and electrical data.

6.2.8 X54, DC Bus, Equipment Grounding Conductor Output KSM02/KMS02

Details the function of the X54 connection for DC bus and equipment grounding conductor output.

6.2.9 DC Bus Connection L+, L-

Provides technical data for the DC bus connection points L+ and L-, including screw connection details.

6.2.10 Control Voltage Supply +24V, 0V

Explains the PELV for 24V power supply units and provides technical data for the connection points.

6.3 KSM02 connection points

Identifies and describes the significance of various connection points on the KSM02.

6.3.1 Positions of the connection points

Identifies and describes the significance of various connection points on the KSM02.

6.3.2 X37, X38, digital inputs/outputs

Details the function, pin assignment, and properties of the X37 and X38 digital inputs/outputs.

6.3.3 X103.1, X103.2, hybrid cable connection point

Explains the hybrid cable connection points X103.1 and X103.2, including codings and plugging cycles.

6.3.4 X104, motor encoder connection

Describes the X104 connection for motor encoders, specifying compatible encoder types and cable requirements.

6.3.7 X141, safety technology and service input "release brake"

Details the function of connection point X141 for safety technology and service input, noting its difference based on device options.

6.3.8 Second connection point of equipment grounding conductor

Explains the necessity and procedure for connecting a second equipment grounding conductor.

6.4 KMS02 connection points

Identifies and describes the significance of various connection points on the KMS02.

6.4.1 Positions of the connection points

Identifies and describes the significance of various connection points on the KMS02.

6.4.4 X104, motor encoder connection

Describes the X104 connection for motor encoders, specifying compatible encoder types and cable requirements.

6.4.9 X156, motor connection

Details the X156 connection for motor power and holding brake, including pin assignment and cable specifications.

6.4.10 X156, motor/motor encoder connection (single-cable connection)

Describes the X156 connection for single-cable motor and motor encoder connection.

6.5 KMS03 connection points

Identifies and describes the significance of various connection points on the KMS03.

6.5.1 Positions of the connection points

Identifies and describes the significance of various connection points on the KMS03.

6.5.3 XD3, motor connection

Explains the XD3 connection for motor power, including pin assignment and mechanical/electrical data.

6.5.4 XG3, motor temperature monitoring and motor holding brake

Discusses connections for motor temperature monitoring and motor holding brake control, including safety warnings.

6.5.5 XG4, digital motor encoder connection

Describes the XG4 connection for digital motor encoders, listing compatible encoder types and pin assignments.

6.5.6 XG8, analog motor encoder connection

Details the XG8 connection for analog motor encoders, specifying signal types and cable information.

6.6 KMV03 connection points

Identifies and describes the significance of various connection points on the KMV03.

6.6.1 Positions of the connection points

Identifies and describes the significance of various connection points on the KMV03.

6.6.5 X141, safety technology (KMV03)

Explains X141 safety technology function for KMV03, noting it's not a safety zone node.

6.6.7 XD1, mains voltage

Details the XD1 connection for mains voltage, including pin assignment and mechanical/electrical data.

6.6.8 XD10, control voltage

Explains the XD10 connection for control voltage, including pin assignment and mechanical data.

6.7 KNK03 connection points

Identifies and describes the significance of various connection points on the KNK03.

7 Notes on project planning

7.1.10 Zone setup

Defines safety zones and illustrates a system with two safety zones.

Safety zones

Defines safety zones and illustrates a system with two safety zones.

7.2.1 Address Selector Switch

Explains how to set the address for KSM/KMS using H and L rotary switches.

7.3.4 Holding brakes

Details how integrated holding brakes are supplied and controlled, including safety requirements.

Brake control and supply

Details how integrated holding brakes are supplied and controlled via firmware or SERCOS commands.

Safety requirements

Outlines safety requirements for using holding brakes, including proper operation and system design.

9 Mounting and installation

9.1.1 Safety

Provides safety warnings regarding live parts and lifting heavy loads, emphasizing de-energization and protective clothing.

9.4.2 Touch guard

Provides safety warnings for touch guards and instructions on proper mounting and use.

9.6 Electrical connection

Provides general information and warnings regarding electrical connections.

9.6.1 General information

Provides general safety warnings regarding live parts and emphasizes the need for skilled electricians and proper safety procedures.

10 Accessories

10.14 RKB0033, cable for safety technology

Details the RKB0033 cable for safety technology, used for forming new safety zones.

10.19 RBS0023, connector for safety zone node

Explains the RBS0023 connector for KMS/KMS safety zone nodes and its function.

11 Commissioning, operation, diagnostics and maintenance

11.3 Diagnostic functions

Explains diagnostic functions for KMV and KCU02 using LEDs, and KSM/KMS using LED H14.

11.3.2 KCU02 diagnostic display

Details the KCU02 diagnostic display, explaining the status and measures for various LEDs (H49, H52.1-H54).

11.3.3 KSM/KMS diagnostic display

Explains the KSM/KMS diagnostic display using LED H14, detailing color/flashing patterns and significance for various drive statuses.

11.4 Service functions/troubleshooting

Provides general information and outlines tasks for eliminating errors or malfunctions.

11.4.1 General information

Provides general safety warnings before working on live parts and outlines tasks for eliminating errors.

11.4.2 Replacing fuses F4 and F5

Gives step-by-step instructions for replacing fuses F4 and F5, including safety precautions.

11.4.3 Deactivating and Dismounting the Drive

Outlines the procedure for deactivating motors and dismounting components, including safety precautions.

Deactivation

Outlines the procedure for deactivating motors by following machine-specific instructions and safety measures.

11.4.4 Replacing the component

Details the procedure for replacing defective components, emphasizing safety and proper handling.

11.4.5 "Release holding brake" service function

Explains the X141 interface for releasing the integrated holding brake and provides safety warnings.

13 Service and support

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