Rexroth Frequency Converter Fe

Electric Drives a n d C o n t r o l s Hydraulics

Linear Motion and

Assembly Technologies P n e u m a it c s Service

Bosch Rexroth AG

(Xi’an) Electric Drives and Controls Co., Ltd.

No. 3999, Shangji Road, Caotan Eco-Industrial Park,

Economic and Technological Development Zone,

Xi’an, 710021, P.R. China

Tel.

Fax

+49 (0)93 52-40-50 60

+49 (0)93 52-40-49 41 [email protected]

www.boschrexroth.com

Rexroth Frequency Converter Fe

R912001311

Edition 05

Instruction Manual

R912001311

Printed in China

DOK-RCON01-FE*********-IB05-EN-P

About this Documentation

Rexroth Frequency Converter Fe

Title

Type of Documentation

Rexroth Frequency Converter Fe

Operating Instructions

Document Typecode

Purpose of Documentation

DOK-RCON01-FE********* -IB05-EN-P

This documentation provides information on:

Mechanical & electrical assembly

Connection conditions

Commissioning (trial run)

Basic equipment data

Fault causes and troubleshooting

History of Documentation

Edition






Release Date

Notes

2007-08-28

2008-05-13

Ver 1: Applicable to 0.75 - 7.5 kW

Ver 2: Applicable to 0.75 - 37 kW G/P

2008-06-10

2009-10-30

2010-03-30

Ver 3: Applicable to 0.75 - 110 kW G/P

Ver 4: With CE, UL certification

Ver 5: Company information change

Rexroth

Bosch Group

Copyright

Validity

Published by

All rights reserved by Bosch Rexroth (Xian) Electric Drives and Controls Co., Ltd. No part of this document may be reproduced in any manner without prior permission.

Any breaching individual or organization shall be held liable for any loss due to breach.

Unless specified otherwise in the contract, specified data in product description shall be only used for the purpose of this manual. Bosch Rexroth reserves the right to interpretation of the document and viability of products.

Bosch Rexroth (Xian) Electric Drives and Controls Co., Ltd.

Add.: No. 3999, Shangji Road, Caotan Eco-Industrial Park,

Economic and Technological Development Zone, Xian, 710021,

P.R. China

Tel. +49 (0) 93 52-40-50 60

Fax +49 (0) 93 52-40-49 41

[email protected]

www.boschrexroth.com


Rexroth Frequency Converter Fe About this Documentation


Rexroth

Bosch Group

About this Documentation


Rexroth

Bosch Group


Rexroth Frequency Converter Fe Contents

Contents

1 Introduction ..............................................................................................01

1.1 About this Documentation ...........................................................................................01

1.2 Introducing to the Drive System ..................................................................................03

2 Safety Instructions for Electric Drives and Controls............................04

2.1 General Information ...................................................................................................04

2.2 Hazards by Improper Use ..........................................................................................07

2.3 Instructions with Regard to Specific Dangers ............................................................08

2.4 Protection Against Electric Shock by Protective Low Voltage (PELV)........................09

2.5 Protection Against Dangerous Movements................................................................10

2.6 Protection Against Magnetic and Electromagnetic Fields During Operation

and Mounting .............................................................................................................11

2.7 Protection Against Contact with Hot Parts .................................................................12

2.8 Protection During Handling and Mounting .................................................................12

2.9 Protection Against Pressurized Systems ...................................................................13

3 Important Directions for Use ..................................................................14

3.1 Appropriate Use ..........................................................................................................14

3.2 Inappropriate Use .......................................................................................................14

4 Fe Description ..........................................................................................15

4.1 Properties of the Basic Device Fe..............................................................................15

4.3 Interfaces ...................................................................................................................16

5 Delivery and Storage ...............................................................................17

5.1 The Scope of Supply Consists of ...............................................................................17

5.2 Transport of the Components .....................................................................................17

5.3 Storage of the Components .......................................................................................18

6 Type Coding .............................................................................................19

6.1 Certification ................................................................................................................ 19


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Contents


6.2 Type Coding of Fe Series Converters .........................................................................21

6.3 Type Coding of Fe Function Modules ........................................................................22

6.4 Type Coding of Fe Accessories ...................................................................................24

7

Frequency Converter Mounting

..............................................................28

7.1 Mounting ....................................................................................................................28

7.2 Dimensions ................................................................................................................30

8 Installation ................................................................................................33

8.1 Converter Opening Instruction ....................................................................................

33

8.2 Block Diagram ...........................................................................................................39

8.3 Main Circuit Wiring ....................................................................................................40

8.4 Control Circuit Wiring .................................................................................................41

8.5 Cable and Fuse Dimensions ......................................................................................41

8.6 Connection of Electrical Power ...................................................................................46

8.7 Wiring Terminals .........................................................................................................49

9 Operating Panel ......................................................................................54

9.1 Overview ....................................................................................................................54

9.2 3-Level Menu Structure .............................................................................................56

9.3 Example of Operating Panel Operation .....................................................................58

10.1 Check and Preparation before Commissioning .......................................................61

10.2 Commissioning .........................................................................................................61

10.3 Restore Factory Defaults ..........................................................................................64

10.4 Solutions for Simple Fault during Commissioning ....................................................64

10.5 Notes on Frequent Starting and Stopping ................................................................64

11 Parameter Settings ..................................................................................65

11.1 Converter Functions ..................................................................................................65

11.2 Notes on Function Groups ........................................................................................75

12 Fault

Indication

........................................................................................130

12.1 Fault Types................................................................................................................130

12.2 List of Fault Protection Actions ..................................................................................132

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Rexroth Frequency Converter Fe Contents

13 Technical Data.........................................................................................133

13.1 Fe General Technical Data ........................................................................................133

13.2 Electrical Parameters ................................................................................................136

13.3 Electromagnetic Compatibility (EMC)........................................................................137

13.4 Selection Matrix for the EMC Accessories ................................................................157

14 Accessories .............................................................................................158

14.1 EMC Filter ...............................................................................................................158

14.2 Mains Chokes...........................................................................................................158

14.3 Braking Unit ............................................................................................................159

14.4 Braking Resistor .......................................................................................................166

14.5 dV/dt filter (Motor filter).............................................................................................174

14.6 Communication Interface .........................................................................................174

14.7 Remote Operating Panel .........................................................................................175

14.8 Engineering Software...............................................................................................177

15 Additional Information............................................................................178

15.1 Running Settings Diagram........................................................................................178

15.2 Process Control .......................................................................................................179

15.3 Discharging of Capacitors ........................................................................................182

16

Communication Protocols

.....................................................................184

16.1 ModBus Protocol .....................................................................................................184

16.2 Port...........................................................................................................................185

16.3 P rotocol Functions ...................................................................................................186

16.4 Communication Mapping Register Address Distribution ..........................................192

16.5 ModBus Communication Example ...........................................................................196

16.6 Communication Networking .....................................................................................197

17

Disposal and Environmental Protection

...............................................198

17.1 Disposal ...................................................................................................................198

17.2 Environmental Protection .........................................................................................198

18

Service and Support

...............................................................................199

19 Index.........................................................................................................200


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Introduction 1-1


1 Introduction

1.1 About this Documentation

WARNING

Personal injury and property damage caused by incorrect project planning for applications, machines and installations!

Do not attempt to install or put these products into operation until you have completely read, understood and observed the documents supplied with the product.

If no documents in your language were supplied, please consult your Bosch

Rexroth sales partner.

Purpose of Documentation

This documentation provides information on:

Introduction to Fe drive system

Help information on selecting parts for Fe drive system

Content of this Documentation

This manual covers:

Assembly and installation

Technical data of each component ( mainly regarding operation )

Current, voltage and performance data

Exterior measurements, weight, etc.

Allocation of terminals

This manual covers safety instructions, technical data and use of

Frequency Converter Fe. The chapters are summarized in the table below:

Rexroth

Bosch Group

01 DOK-RCON01-FE*********-IB05-EN-P

Rexroth Frequency Converter Fe 1-2 Introduction

Chapters:

Standards

Feedback

2

16

17

18

19

10

11

12

13

14

15

7

8

9

3

4

5

6

Chapter

1

Title

Introduction

Description

Overview

Safety Instructions for Electric

Drives and Controls

Important Directions for Use

Fe Description

Delivery and Storage

Type Coding

Frequency Converter Mounting

Installation

Operating Panel

Commissioning

Parameter Settings

Fault I ndication

Technical Data

Accessories

Additional Information

Communication Protocols

Disposal and Environmental Protection

Service and Support

Index

Safety cautions

Product information

(project specific)

Actual applications

(for operators and repairers)

General Information

Service Information

Technical standards, codes and sheets referred herein are copyrighted, and

Rexroth does not provide such documents in this manual.

You may contact an authorized distributor of such documents if necessary.

You may directly contact Bosch Rexroth (Xian) Electric Drives and Controls

Co., Ltd. if you are located in China.

Website: Http://www.boschrexroth.com/fe

Your experience is important for us to improve products and this manual.

We will be pleased to receive your feedback on any mistake or request for variation.

Please send your feedback to:

Bosch Rexroth (Xian) Electric Drives and Controls Co., Ltd.

DOK-RCON01-FE*********-IB05-EN-P 02

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Introduction 1-3


1.2 Introducing to the Drive System

Drive System

Rexroth Frequency Converter Fe drive system is composed of individual parts (components) for application in different circumstances.

Definition

FEC: Rexroth Frequency Converter Fe

FECC: Fe operating panel

FSWA: Engineering software

FELR: Fe braking resistor

FELB: Fe braking unit

Rexroth

Bosch Group

03


Rexroth Frequency Converter Fe 2-1 Safety Instructions for Electric Drives and Controls

2 Safety Instructions for Electric Drives and Controls

2.1 General Information

Using the Safety Instructions and Passing them on to Others

Do not attempt to install or commission this device without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation prior to working with the device. If you do not have the user documentation for the device, contact your responsible Bosch Rexroth sales representative. Ask for these documents to be sent immediately to the person or persons responsible for the safe operation of the device. If the device is resold, rented and/or passed on to others in any other form, then these safety instructions must be delivered with the device.

Improper use of these devices, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death!

WARNING

Read these instructions before the initial start-up of the equipment in order to eliminate the risk of bodily harm or material damage. Follow these safety instructions at all times.

Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation.

Read the operating, maintenance and safety instructions in your language before starting up the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify.

Proper and correct transport, storage, assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe operation of this device.

Only assign trained and qualified persons to work with electrical installations.

Only persons who are trained and qualified for the use and operation of the device may work on this device or within its proximity. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and devices on and off in accordance with technical safety regulations and to mark them according to the requirements of safe work practices.


04

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Bosch Group

Safety Instructions for Electric Drives and Controls 2-2


They must have adequate safety equipment and be trained in first aid.

Only use spare parts and accessories approved by the manufacturer.

Follow all safety regulations and requirements for the specific application as practised in the country of use.

The devices have been designed for installation in industrial machinery.

The ambient conditions given in the product documentation must be observed.

Only use safety-relevant applications that are clearly and explicitly approved in the Project Planning Manual. If this is not the case, they are excluded.

Safety-relevant are all such applications which can cause danger to persons and material damage.

The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applications and suggestions.

The machine and installation manufacturer must make sure that the delivered components are suited for each individual application. Check the information given in this document with regard to the use of the components.

The machine and installation manufacturer shall also make sure that this application complies with the applicable safety regulations and standards and carry out required measures, modifications and complements.

Start-up of the delivered components is only permitted after the machine or installation in which they are installed complies with the national standards, safety instructions and application standards.

Operation is only permitted if the national EMC standards for the application are met.

The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in national standards.

Technical data, connections and operational conditions are specified in the product documentation and must be followed at all times.

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05



Explanation of Warning Symbols and Degrees of Hazard Seriousness

The safety instructions describe the following degrees of hazard seriousness.

The degree of hazard seriousness informs about the consequences resulting from non-compliance with the safety instructions.

Warning symbol with signal word Degree of hazard seriousness

Death or severe bodily harm will occur.

DANGER

Death or severe bodily harm may occur.

WARNING

Bodily harm or material damage may occur.

CAUTION


06

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Bosch Group

Safety Instructions for Electric Drives and Controls 2-4 Rexroth Frequency Converter Fe

2.2 Hazards by Improper Use

High electric voltage and high working current! Risk of death or severe bodily injury by electric shock!

DANGER

Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements!

DANGER

Risk of injury by improper handling! Risk of bodily injury by bruising, shearing, cutting, hitting, or improper handling of pressurized lines!

CAUTION

Hot surfaces on device housing! Danger of injury! Danger of burns!

CAUTION

Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment!

WARNING

High electric voltage because of incorrect connection! Risk of death or bodily injury by electric shock!

WARNING

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2.3 Instructions with Regard to Specific Dangers

Protection Against Contact with Electrical Parts

Note:

This section only concerns devices and drive components with voltages of more than 50 volts.

Contact with parts conducting voltages above 50 volts can cause personal danger and electric shock. When operating electrical equipment, it is unavoidable that some parts of the devices conduct dangerous voltage.

DANGER

High electrical voltage! Danger to life, electric shock and severe bodily injury!

Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain and repair this equipment.

Follow general construction and safety regulations when working on electrical power installations.

Before switching on the device, the equipment grounding conductor must have been non-detachably connected to all electrical equipment in accordance with the connection diagram.

Do not operate electrical equipment at any time, even for brief measurements or tests, if the equipment grounding conductor is not permanently connected to the mounting points of the components provided for this purpose.

Before working with electrical parts with voltage potentials higher than

50 volts, the device must be disconnected from the mains voltage or power supply unit.

With electrical drive and filter components, observe the following: Wait

30 minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch.

Never touch the electrical connection points of a component while power is turned on.

Install the covers and guards provided with the equipment properly before switching the device on. Before switching the equipment on, cover and safeguard live parts safely to prevent contact with those parts.

A residual-current-operated circuit-breaker cannot be used for electric drives! Indirect contact must be prevented by other means, for


08

Rexroth

Bosch Group


DANGER

example, by an over current protective device according to the relevant standards.

Secure built-in devices from direct touching of electrical parts by providing an external housing, for example a control cabinet.

Always observe the above requirements, in accordance with relevant international standards.

Always observe the above requirements, in accordance with relevant international standards. With electrical drive and filter components, observe the following:

High housing voltage and large leakage current!

Risk of death or bodily injury by electric shock!

Before switching on, the housings of all electrical equipment and motors must be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests.

The equipment grounding conductor of the electrical equipment and the units must be non-detachably and permanently connected to the power supply unit at all times. The leakage current is greater than 3.5 mA.

Over the total length, use copper wire of a cross section of a minimum

Before start-up, also in trial runs, always attach the equipment grounding conductor or connect with the ground wire. Otherwise, high voltages may occur at the housing causing electric shock.

2.4 Protection Against Electric Shock by Protective

Low Voltage (PELV)

WARNING

High electric voltage by incorrect connection!

Risk of death or bodily injury by electric shock!

To all connections and terminals with voltages between 0 and 50 volts,

only devices, electrical components, and conductors may be connected

which are equipped with a PELV (Protective Extra-Low Voltage) system.

Connect only voltages and circuits which are safely isolated from

dangerous voltages. Safe isolation is achieved for example by isolating

transformers, safe optocouplers or battery operation without mains

connection.

Rexroth

Bosch Group

09



2.5 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of connected motors. Some common examples are:

Improper or wrong wiring of cable connections

Incorrect operation of the equipment components

Wrong input of parameters before operation

Malfunction of sensors, encoders and monitoring devices

Defective components

Software or firmware errors

Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation.

The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily harm and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.

DANGER

Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage!

For the above reasons, ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. They have to be provided for by the user according to the specific conditions within the installation and a hazard and fault analysis. The safety regulations applicable for the installation have to be taken into consideration. Unintended machine motion or other malfunction is possible if safety devices are disabled, bypassed or not activated.

To avoid accidents, bodily harm and/or material damage:

Keep free and clear of the machine's range of motion and moving parts.

Possible measures to prevent people from accidentally entering the machine's range of motion:

use safety fences

use of safety guard (cover)

use of protective coverings

install light curtains or light barrier

Fences and coverings must be strong enough to resist maximum possible momentum.


10

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Bosch Group


Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before start-up. Do not operate the device if the emergency stop is not working.

Isolate the drive power connection by means of an emergency stop circuit or use a safety related starting lockout to prevent unintentional start.

Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone.

The standard equipment motor brake or an external brake controlled directly by the drive controller are not sufficient to guarantee personal safety!

Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for:

Maintenance and repair work

Cleaning of equipment

Long periods of discontinued equipment use

Prevent the operation of high-frequency, remote control and radio equipment near electronics circuits and supply leads. If the use of such devices cannot be avoided, verify the system and the installation for possible malfunctions in all possible positions of normal use before initial start-up. If necessary, perform a special electromagnetic compatibility (EMC) test on the Installation.

2.6 Protection Against Magnetic and Electromagnetic

Fields During Operation and Mounting

Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious personal danger to those with heart pacemakers, metal implants and hearing aids.

WARNING

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Bosch Group

Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment!

Persons with heart pacemakers and metal implants are not permitted to enter following areas:

Areas in which electrical equipment and parts are mounted, being operated or commissioned.

Areas in which parts of motors with permanent magnets are being stored, repaired or mounted.

If it is necessary for somebody with a pacemaker to enter such an area, a doctor must be consulted prior to doing so. The interference immunity of present or future implanted heart pacemakers differs greatly, so that no general rules can be given.



Those with metal implants or metal pieces, as well as with hearing aids must consult a doctor before they enter the areas described above.

Otherwise health hazards may occur.

2.7 Protection Against Contact with Hot Parts

CAUTION

Hot surfaces at motor housings, on drive controllers or chokes!

Danger of injury! Danger of burns!

Do not touch surfaces of device housings and chokes in the proximity of heat sources! Danger of burns!

Do not touch housing surfaces of motors! Danger of burns!

According to operating conditions, temperatures can be higher than 60 ,

140 °F during or after operation.

Before accessing motors after having switched them off, let them cool down for a sufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated, the time required for cooling down is five times the thermal time constant specified in the Technical Data.

After switching drive controllers or chokes off, wait for 15 minutes to allow them to cool down before touching them.

Wear safety gloves or do not work at hot surfaces.

For certain applications, the manufacturer of the end product, machine or installation, according to the respective safety regulations, has to take measures to avoid injuries caused by burns in the end application. These measures can be, for example: warnings, guards (shielding or barrier) technical documentation.

2.8 Protection During Handling and Mounting

In unfavorable conditions, handling and assembling certain parts and components in an improper way can cause injuries.

CAUTION

Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting!

· Observe the general construction and safety regulations on handling and assembly.

· Use suitable devices for assembly and transport.

·

Avoid jamming and bruising by appropriate measures.

· Always use suitable tools. Use special tools in different circumstances.


12

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·

Use lifting equipment and tools in the correct manner.

If necessary, use suitable protective devices (for example safety goggles, safety shoes, safety gloves).

· Do not stand under hanging loads.

·

Immediately clean up any spilled liquids because of the danger of skidding.

2.9 Protection Against Pressurized Systems

According to the information given in the Project Planning Manuals, motors cooled with liquid and compressed air, as well as drive controllers, can be partially supplied with externally fed of pressurized media, such as compressed air, hydraulics oil, cooling liquids, and cooling lubricating agents.

In these cases, improper handling of external supply systems, power supply lines, or connections can cause injuries or damages.

Risk of injury by improper handling of pressurized Lines!

CAUTION

·

Do not attempt to disconnect, open, or cut pressurized lines (risk of explosion).

·

Observe the respective manufacturer's operating instructions.

· Before dismounting lines, relieve pressure and empty medium.

·

Use suitable protective equipment devices (for example safety goggles, safety shoes, safety gloves).

· Immediately clean up any spilled liquids from the floor.

Note:

Environmental protection and disposal! The agents used to operate the product might not be economically friendly. Dispose of ecologically harmful agents separate from other waste. Observe the local regulations in the country of assembly.

Rexroth

Bosch Group

13


Rexroth Frequency Converter Fe 3-1 Important Directions for Use

3 Important Directions for Use

3.1 Appropriate Use

Rexroth products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability.

The products may only be used in the manner that is defined as appropriate. If they are used in an inappropriate manner, then situations can develop that may lead to property damage or injury to personnel.

Note:

Rexroth shall not be held liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks.

Before using 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 understand the relevant safety instructions and be familiar with appropriate use.

If the products take the form of hardware, they must remain in their original state, in other words, no structural changes are permitted.

It is not permitted to decompile software products or alter source codes.

Do not mount damaged or faulty products or use them in operation.

Make sure that the products have been installed in the manner described in the relevant documentation.

3.2 Inappropriate Use

Using the drive controllers outside of the operating conditions described in this manual and outside of the indicated technical data and specifications is defined as "inappropriate use".

Drive controllers shall not be used in following conditions:

They are subject to operating conditions that do not meet the specified ambient conditions. These include, for example, operation under water, extreme temperature fluctuations or extremely high temperatures.

Furthermore, the drive controllers shall not be used in applications which have not been expressly authorized by Rexroth.

Please carefully follow the specifications outlined in the general Safety

Instructions!


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Bosch Group

Fe Description 4-1


4 Fe Description

4.1 Properties of the Basic Device Fe

Control mode: V/F

Power range: 0.75 kW to 110 kW

Power supply voltage: 3 AC 380 to 480 V (-15 % / +10 %)

Output frequency: 0 to 650 Hz

Overload capacity:

G series: 200 % of rated current for 1s; 150 % of rated current for 60s

P series: 120 % of rated current for 60s; 105 % of rated current for 60min

Pulse width modulation (PWM) for converters with

0.75 to 7.5 kW: 1 to 15 kHz, adjustable in 1 kHz steps;

11 to 22 kW: 1 to 8 kHz, adjustable in 1 kHz steps;



Integrated Brake Chopper (braking resistor connected externally, 0.75 to

15 kW only)

Permitted ambient temperature: -10 to 40 °C (output must be reduced from 40 to 50 °C )

Protection class: IP20 (for installation inside control cabinet)

High start-up torque and precise motor speed control

4.2 Functions

Programmable skip frequencies: See Parameters [E00]-[E03]

Upper and lower frequency command, and highest frequency: See

Parameters [b03], [b21] and [b22]

DC braking for starting and stopping: See Parameters [H04]-[H07]

PI control: See Parameters [E24]-[E30]

Energy saving: See Parameters [H23]-[H29]

ModBus and PROFIBUS communication: See Parameters [H08]-[H21]

Fault reset: See Parameters [E42]-[E44]

Drooping control: See Parameters [H37]

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Bosch Group


Rexroth Frequency Converter Fe 4-2 Fe Description

Forward and reverse rotation dead zone setting and reverse rotation prevention: See Parameter [b18]

Constant voltage control: See Parameter [b14]

Jogging control: See Parameters [b35]-[b38]

Automatic adjustment of PWM frequency according to temperature:

See Parameter [H01]

Current no-trip control: See Parameters [H30]-[H33]

Dynamic braking point set with function code: See Parameter [H36]

Zero speed control: See Parameters [b42] and [b43]

Restart after power failure: See Parameter [H02]

Multi-speed and simple PLC: See Parameters [P00]-[P37]

S-curve/Linear acceleration/deceleration: See Parameter [b15]

3-wire/2-wire terminal function: See Parameter [E38]

Automatic adjustment of cooling fan: See Parameter [H22]

4.3 Interfaces

8 digital inputs

3 analog inputs

1 encoder input for speed feedback

2 analog outputs

1 frequency output

2 open collector outputs

1 relay output AC 250 V / DC 30 V, 3 A

1 RS485 port

4.4 Cooling Types

Air cooling

Forced, temperature-controlled air cooling


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5 Delivery and Storage

5.1 The Scope of Supply Consists of

1) Standard model:

Frequency Converter Fe, IP20 protection

Fe firmware

Integrated brake chopper (0.75 to 15 kW only)

Operating panel

Instruction manual

2) Optional accessories:

Operating panel for control cabinet mounting

Operating panel with potentiometer for converters from 11 to 110 kW

PROFIBUS adapter

RS232/485 adapter

Fe engineering software

EMC filter (EN 61800-3 Environment 2)

dV/dt filter

Main choke

Braking resistor

Braking unit

Check the unit for transport damages, e.g. deformation or loose parts,

immediately

after receipt/ unpacking.

In case of damage, contact the forwarder at once and arrange for a thorough review of the situation.

Note:

This is also applicable if the packaging is undamaged.

5.2 Transport of the Components

Ambient and operating conditions - Transport

Unit Description

Temperature range

Relative humidity

Absolute humidity

Climate category (IEC 721)

Moisture condensation

Icing

Symbol

T a_tran

% g/m

3

Value

-25...70

5...95

1...60

2K3 not allowed not allowed

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Bosch Group


Rexroth Frequency Converter Fe 5-2 Delivery and Storage

5.3 Storage of the Components

CAUTION

Damage to the components caused by long storage periods!

Some components contain electrolytic capacitors which may deteriorate during storage.

When storing these components for a long period of time, operate them once a year for at least 1 hour with power on:

Fe with mains voltage U

LN

FELB with DC bus voltage U

DC

Ambient and operating conditions - Storage

Unit Description

Temperature range

Relative humidity

Absolute humidity

Climate category (IEC 721)

Moisture condensation

Icing

Symbol

T a_store

% g/m

3

Value

-25...55

5...95

1...29

1K3 not allowed not allowed


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Bosch Group

Type Coding 6-1 Rexroth Frequency Converter Fe

6 Type Coding

6.1 Certification

Declaration of conformity

For devices, there are declarations of conformity which confirm that the devices comply with the applicable EN standards and EC Directives. If required, you can ask our sales representative for the declarations of conformity.

Description

CE conformity regarding Low-Voltage Directive

CE conformity regarding EMC product standard

Standard

EN 61800-5-1 (IEC 61800-5-1: 2007)

EN 61800-3 (IEC 61800-3: 2004)

CE Label

High-Voltage Test

According to standard, the components of the Rexroth Fe are tested with high

voltage.

Test

High-voltage test

High-voltage insulation test

Test rate

100 % (EN 61800-5-1)

100 % (EN 61800-5-1)

Before making a high-voltage test for the installation in which the components are used, disconnect all connections to the components or disconnect the plug-in connections to protect the electronic components.

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UL Listing

The components are listed by

UL

(underwriters Laboratories Inc . ®).

You can find the evidence of certification on the Internet under http://www.ul.com unde r “C ertifications ” by entering the file number or the “C ompany Name:

Rexroth ” .

IND. CONT. EQ.

46PG

UL standard: UL 508 C

Company Name

BOSCH REXROTH (XIAN) ELECTRIC DRIVES and CONTROLS Co., Ltd.

Category Name

Power Conversion Equipment

File Numbers

E328841

UL Listing UL ratings

For using the components in the scope of UL, take the UL ratings of the individual component into account.

Make sure that the indicated

short circuit rating SCCR

is not exceeded

(5000 A rms

), e.g. by appropriate fuses in the mains supply of the supply unit.

Wiring material UL

In the scope of UL, use copper 60/75 only.

Allowed pollution degree

Comply with the allowed pollution degree of the components (see “

Technical

Data

” ).


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Type Coding 6-3

6.2 Type Coding of Fe Series Converters


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6-4 Type Coding

6.3 Type Coding of Fe Function Modules

Operating panel coding

Example F E C C 0

2 1

T S S T D P O T I N N N N

Product

Operating panel

Generation nd

2 generation

Design

Design 1

Design 2

Panel type

With display

Panel form

Small

Big

Rectangular

Design style

Standard

Other operable elements

With potentiometer

Without potentiometer

Other design

None

F E C C

02

1

2

T

S

B

R

S T D

P O T I

N N N N

N N N N


22

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Type Coding 6-5 Rexroth Frequency Converter Fe

Software coding

Example F S W A F E C * G L P C * C O N

Product

Converter software FSWA

Product name

Engineering software

FEC*GL-PC*

0 4 V 0 1

Software type

Control software

Software version (0 - 99)

Version

CON

04

N N

C D 6 5 0

Software feature

Standard

Software release notes (0 - 99)

Release

Language

Multilingual

V

01

NN

Media

CD: 650 MB

CD650

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6-6 Type Coding

6.4 Type Coding of Fe Accessories

Interface adapter coding

Example F E A A 0 2 1 M O D B *

Product

Interface adapter

Generation st

1 generation nd

2 generation

Design

Design 1

Design 2

Input

ModBus

RS485

Output

PROFIBUS

RS232

Cable

Without cable

Other design

None

FEAA

01

02

1

2

MODB*

RS485

P R O F I

PROFI

RS232

N N N N N N

NNNN

NN


24

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Type Coding 6-7

Interface adapter cable coding

Example F R K B

0 0 0 1 / 0

0 1 , 0

Product

Interface adapter cable

FRKB

Cable number

ModBus to PROFIBUS

ModBus to RS485

Length

1 m

5 m

Additional notes

Does not apply if not used

0001

0002

001,0

005,0

Operating panel cable coding

Example F R K S 0

0 0 1 /

0 0 1 , 0

Product

Operating panel cable

FRKS

Cable number

E.g.1

0001

Length

1 m

3 m

Additional notes

Does not apply if not used

001,0

003,0


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Rexroth Frequency Converter Fe 6-8 Type Coding

Braking resistor coding

Example

F E L R 0 1

Product

Braking resistor

Generation st

1 generation

Design

Design 1

Design 2

Mounting mode

Free mounting solution

Rated power

E.g. 80 W

E.g. 1.04 kW

Additional option

None

FELR

01

1

2

1 N 0 0 8 0 N 7 5 0 R D 5 6 0 N N N N

N

0080

1K04

N

Resistance

E.g. 750 Ù

750R

Protection class

IP33

IP20

DC bus nominal voltage

560 VDC

D

A

560

Other design

None

NNNN


26

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Type Coding 6-9


Braking unit coding

Example F E L B 0 2

Product

Braking unit

Generation nd

2 generation

Design

Design 1

Design 2

Mounting mode

Free mounting solution

Rated power

30 kW

45 kW

Additional option

None

FELB

02

1

2

1 N 3 0 K 0 N N O N E A 5 6 0 N N N N

N

30K0

45K0

N

Resistance

Without resistance NONE

Protection class

IP20

DC bus nominal voltage

560 VDC

A

560

Other design

None

NNNN

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27



7 Frequency Converter Mounting

7.1 Mounting

The equipment must be sufficiently ventilated, to avoid overheating. The recommended minimum clearances between the frequency converter and adjacent items which may disturb the free flow of air are given below.

Note:

The frequency converter must be vertically installed.

(Applicable to: 0.75 to 110 kW frequency converters)

150mm

Rexroth

50mm 50mm

150mm cold air

If one frequency converter is arranged above the other, make sure that the upper limit of air temperature into the inlet is not exceeded (Note: See

Chapter 13 "Technical Data"

). A baffle plate is recommended between the frequency converters, to prevent the rising hot air being drawn into the upper converter.


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CAUTION

Risks of damage to the components!

Allowed Mounting Position of the components

Only operate the components in their allowed mounting positions.

Only the mounting position G1 is allowed for Fe components.

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a Mounting surface g

Direction of gravitational force

G1 Normal mounting positions. The natural convention supports the forced cooling air current. This avoids the generation of pockets of heat in the component.

G2

G3

180 to normal mounting position

Turned by 90 from vertical to horizontal mounting position

G4

G5

Bottom mounting; mounting surface on bottom of control cabinet

Top mounting; mounting surface at top of control cabinet

Efficiency:

Ensure sufficient ventilation for installation in a cabinet. During operation, heat loss is about 5 % of the rated power of the frequency converter, depending on unit dimensions and equipment.

29


Rexroth Frequency Converter Fe 7-3 Frequency Converter Mounting

7.2 Dimensions

G/P Series

FECG02 1-0K75-3P400-A-SP-MODB-01V01






FECG02 1-11K0-3P400-A-BN-MODB-01V01










FECG02 1-110K-3P400-A-BN-MODB-01V01

FECP02 1-5K50-3P400-A-SP-MODB-01V01

FECP02 1-7K50-3P400-A-SP-MODB-01V01

FECP02 1-11K0-3P400-A-BN-MODB-01V01










FECP02 1-110K-3P400-A-BN-MODB-01V01

Weight

[kg]

Screw size

B H

T

b H h t

3.0

3.0

125 220 176 109 204 6 10

3.2

3.2

3.5

3.5

220 392 218 180 372 9.5 2.5

10.7

10.9

275

290

463

574

16.2

16.9

21.5

22.0

33.2

364 602 260 260

33.8

455

570

682 290

50.9

52.5

96.5

M5

M8

125 176 204

3.5

6

3.5

275

10.7

10.9

16.2

16.9

290

455

570

602 260

21.5

22.0

33.2

33.8

50.9

52.5

450 4.5

96.5

M5

M8

Note 1:

G series include 0.75 to 110 kW; P series include 5.5 to 110 kW.

Note 2:

Fix the mounting screws with the following typical tightening torque:

M5: 4 Nm / 35 lb-in

M8: 12 Nm/ 110 lb-in


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Bosch Group

Frequency Converter Mounting 7-4

Applicable to 0.75 to 7.5 kW


Applicable to 11 to 37 k W

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31



Applicable to: 45 to 90 kW

7-5 Frequency Converter Mounting

Applicable to 110 kW


32

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Installation 8-1 Rexroth Frequency Converter Fe

8 Installation

8.1 Converter Opening Instruction

Applicable to 0.75 to 7.5 kW:

Step 3: Remove the front cover

Step 2: Remove the panel

St ep

4:Co and t ect the m he

contr ain term ol ter minals ls

Step 1: Disassemble 2 screws

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Applicable to 11 to 15 kW:

8-2 Installation

Step 1: Disassemble 2 screws Step 2: Lift the cover and remove

the panel cable, then remove

the cover

Notice: When using (+), PB, (-)

remove the small metal cover

Step 3: Remove the front

bottom cover

Step 4: Connect the main terminals

and the control terminals


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Installation 8-3

Applicable to 18.5 to 37 kW:


Step 1: Disassemble 2 screws Step 2: Lift the cover remove the panel

cable, then remove the cover

Notice: When using (+), (-) remove

the small metal cover

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Bosch Group

Step3: Remove the front bottom cover Step 4: Connect the main terminals

and the control terminals

35





Step 1: Disassemble 2 screws Step 2: Remove the lower cover

Step 3: Disassemble 2 screws

Notice: when using the P1, (+), (-) remove

the small metal cover

Step 4: Remove the front bottom cover


and control terminals


36

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Step 3: Disassemble 2 screws Notice: when using the P1, (-)



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and control terminals

37



Applicable to 110 kW:




Step 4: Connect the main

terminals and control

Notice: when using the P1, (+), (-)


terminals


38

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8.2 Block Diagram


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39


Rexroth Frequency Converter Fe 8-8 Installation

8.3 Main Circuit Wiring

Connect power supply only to the main power supply terminals L1, L2 and L3 .

Connecting power supply to other terminals will damage the frequency converter. Ensure that the power supply voltage is within the allowable voltage range specified on the nameplate.

The ground ing terminal must be properly grounded to avoid electric shock and fire and reduce interference noise.

Insulated crimp terminals must be used to connect terminals and conductors, to ensure the reliability of connection.

After wiring connection, remove all residual loose wires, which may fall into the frequency converter and cause a failure. Be careful not to allow swarf from drilling entering the frequency converter. Check the following points after the circuit connection is completed.

Are all connections correct?

Are there any missing connections?

Do short circuits exist between terminals and wires or ground?

To make changes in wiring, disconnect the power and wait for 30 minutes to allow the capacitor of the DC circuit to discharge.

Wiring shall be carried out with wire sizes in accordance with relevant electrical codes.

A fuse must be provided between the main power supply terminals (L1, L2 and L3) and the 3-phase AC input power supply. It is preferable to connect a magnetic contactor (MC) in series to ensure both the action of frequency converter protection and shutting off of power supply (Surge absorbers should be added at both sides of the magnetic contactor).

If the wire between the frequency converter and the motor is very long, particularly with low output power, the voltage drop may lead to a reduced torque output by the motor.

Nothing other than the braking resistor may be connected between the terminal (+) and PB. Do not short circuit!

Electromagnetic interference: The 3-phase inputs/outputs of frequency converter contain harmonic components, which may interfere with nearby communication devices (e.g. AM radio receiver). Therefore, an optional radio noise filter (only for the input side) or line noise filter may be installed to minimize interference.

Do not attach power capacitor, surge suppressor or radio noise filter to the output side of frequency converter. This may cause frequency converter failure or damage the capacitor or suppressor. Immediately remove any such device which has been installed.


40

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8.4 Control Circuit Wiring

Terminal GND is the common terminal for analogue signals, and SC is the common terminal for switch values. Do not ground these terminals. Shielded or twisted-pair cables should be used for wiring terminals for the control circuit and must be separated from the wiring of main circuit and high current circuits (including the control circuit of 200 V relay).

Since the frequency control input signals are low power signals, two contacts in parallel or a twin contact should be used for low power signal current to avoid loose contact.

2

0.3 to 1.0 mm cables are recommended for wiring of the control circuit.

Please strip the wire insulation for wiring of the control circuit. according to the dimensions given below. Too long stripping may cause short circuit of adjacent wires, and too short stripping may lead wires becoming loose.

If a post terminal or single-conductor wire is used, use a cable with a diameter of less than 1.0 mm. If the cable is larger than 1.0 mm, the screw may be stripped when being tightened up.

Tighten up screws wit h typically 0.8 Nm / 7 lb-in torque after the cables are inserted into the terminals.

Cables may become disconnected and cause incorrect operation if not tightened. However, over-tightening screws may break the component to cause short circuit and incorrect operation.

7mm 1mm

8.5 Cable and Fuse Dimensions

The power cable dimensions and the fuse dimensions are based on the VDE 0298

(part 4) and the standard for the European countries EN 60204-1.

The dimension for flexible wiring is according to VDE 0298 (part 4) and for fix wiring according to VDE 0298 (part 4) or IEC 60364-5 (operating temperature at the conductor 90 ).

The cable and fuse dimensions for USA/Canada are based on UL 508A.

The manufacturer of the machine/installation is responsible for conformity with regional provisions and other standards that are relevant for the respective application and the place of installation. Also factors, such as installation methods, grounding, insulation and over-voltage protection must be taken into consideration.

National standards, such as NFPA in the USA, regional provisions, ground, operating temperature, operating cycles, over-voltage protection and system configuration can have a decisive impact on the dimensioning of the cables and therefore they must be given priority over the above factors.

If, as a consequence of this, further requirement and cable designs arise that are not mentioned in this documentation, contact your Bosch Rexroth sales partner.

Rexroth

Bosch Group

41



Cable dimensioning:

1. Determines the power size of the frequency converter;

2. Determines country of use (e.g. “Int ernational without USA/Cana da”);

3. Determines installation type (e.g. B1 or B2);

4. In table row “Nomi nal current fus e” , read corresponding fuse.

kW

30

37

45

55

75

90

110

0.75

1.5

2.2

4

5.5

7.5

11

15

18.5

22

100

125

160

200

35

50

63

80

16

20

25

25

Nominal current of Fuse in A

Input Side

International without USA/Canada

Installation mode B1 Installation mode B2

Installation mode E

Cable size in mm

2


2


2

10

10

1.5

1.5

1

1

1

1

1.5

1.5

2.5

4

1

1.5

2.5

4

1

1.5

2.5

2.5

250

315

350

6

10

10

16

25

25

50

50

95 / 2x 50

2x 50

2x 70

6

10

16

16

25

25

50

2x 35

2x 50

2x 70

2x 95

6

10

10

10

16

25

35

50

70 / 2x 35

95 / 2x 50

120 / 2x 70

Note 1:

Input Side and Output Side: The dimensioning is based on the supply voltage of 3x 380 VAC

Note 2:

For screw torque information, please refer to the table on next page.


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Bosch Group


Rexroth Frequency Converter Fe kW

55

75

90

110

30

37

45

7.5

11

15

18.5

22

0.75

1.5

2.2

4

5.5

Input Side

USA/Canada

Nominal current of fuse in A

Cable size in AWG

40

70

80

80

80

100

125

150

175

225

300

300

6

10

16

25

40

AWG14

AWG14

AWG14

AWG12

AWG10

AWG10

AWG8

AWG6

AWG6

AWG6

AWG4

2x AWG6

AWG1

AWG1/0

AWG3/0 / 2x AWG1

2x AWG1/0

300 kcmil / 2x AWG3/0

Screw torque for power cable terminals in Nm

/ lb-in (screw size)

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

2.7/24 (M5)

2.7/24 (M5)

5/40 (M6)

5/40 (M6)

5/40 (M6)

5/40 (M6)

6/55 (M8)

6/55 (M8)

10/90 (M10)

10/90 (M10)

10/90 (M10)

Cable size

2 in mm /AWG

Input PE

Torque in Nm / lb-in

(screw size)

6 / 8 1.7/15 (M4)

6 / 8

6 / 8

6 / 8

6 / 8

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

6 / 8

10 / 7

10 / 7

16 / 6

16 / 6

25 / 4

25 / 2x6

50 / 1

2x35 / 1/0

95 / 3/0

2x70 / 2x 1/0

2x95 / 2x 3/0

1.7/15 (M4)

2.7/24 (M5)

2.7/24 (M5)

5/40 (M6)

5/40 (M6)

5/40 (M6)

5/40 (M6)

6/55 (M8)

6/55 (M8)

10/90 (M10)

10/90 (M10)

10/90 (M10)

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Output Side

International without USA

/Canada

USA/Canada kW


2

Cable size in AWG

Screw torque for power cable terminals in Nm

/ lb-in (screw size)

37

45

55

18.5

22

30

0.75

1.5

2.2

4

5.5

7.5

11

15

75

90

110

1

(1)

1

(1)

1

(1)

1

(1)

1

(1)

2.5

(1)

6

(1)

6

(1)

10

(1)

10

(1)

16

(1)

25

(1)

35

(2)

35

(2)

70 / 2x 35

(2)

95 / 2x 35

(2)

120 / 2x 50

(2)

AWG14

AWG14

AWG14

AWG14

AWG12

AWG10

AWG8

AWG8

AWG6

AWG6

AWG3

2x AWG6

AWG1/0

AWG2/0 / 2x AWG3

AWG4/0 / 2x AWG1/0

2x AWG2/0

2x AWG3/0

Note:

(1) Installation Mode E

Note:

(2) Installation Mode B2

Dimensioning variables of the table values

1. Installation types:

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

2.7/24 (M5)

2.7/24 (M5)

5/40 (M6)

5/40 (M6)

5/40 (M6)

5/40 (M6)

6/55 (M8)

6/55 (M8)

10/90 (M10)

10/90 (M10)

10/90 (M10)

Output PE

Cable size Torque in Nm / lb-in

(screw size)

10 / 7

10 / 7

10 / 7

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4)

1.7/15 (M4) 10 / 7

10 / 7

10 / 7

10 / 7

10 / 7

10 / 7

10 / 7

16 / 3

1.7/15 (M4)

1.7/15 (M4)

2.7/24 (M5)

2.7/24 (M5)

5/40 (M6)

5/40 (M6)

5/40 (M6)

5/40 (M6) 25 / 2x 6

35 / 1/0

35 / 2/0

6/55 (M8)

6/55 (M8)

10/90 (M10) 70 / 2x 1/0

95 / 2x 2/0

2x 50 / 2x 3/0

10/90 (M10)

10/90 (M10)

B1 according to IEC 60364-5-52, e.g. stranded wires routed in cable duct;

B2 according to IEC 60364-5-52, e.g. multi-core line routed in cable duct;

E according to EN 60204-1, e.g. multi-core line routed on open cable tray

According to NFPA 79 (external wiring), UL 508A (internal wiring),

NEC, NFPA 70:

1 cable with 3 conductors, 1 neutral conductor and 1 equipment grounding conductor;

Routed in pipe on the wall.

Internal wiring: Routing inside of control cabinet or inside of devices;

Field wiring: Routing of cross sections of terminal connectors wired by the user (in the field).


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Bosch Group



2. Recommendation for design of the fuses:

International except for USA/Canada:

Class gL-gG; 500 V, 690 V; design NH, D (DIAZED) or D0 (NEOZED).

Characteristic

In the case of error (e.g. ground fault at connections L+, L-), fuses of characteristic

gL

(general-purpose fuse link for cables and lines) and

gG

(general-purpose fuse link for general installations) protect the

lines

in the frequency converter system.

To

protect the semiconductors

in the input of supply units and converters, you can use fuses of characteristic

gR

.

USA/Canada:

Class J; 600 V

B1

B2

C

B1 Conductors in installation pipes and in installation channels that can be opened

B2 Cables or lines in installation pipes and in installation channels that can be opened

C Cables or lines on walls

E Cables or lines on open cable trays

Installation Types (cf. IEC 60364-5-52; DIN VDE 0298-4; EN 60204-1)

Rexroth

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45



8.6 Connection of Electrical Power

WARNING

The equipment must be grounded.

Professional mounting and commissioning by qualified personnel in accordance with the instructions in this manual is a precondition for the safe operation of the equipment. Especially, observe the general and local mounting instructions, safety instructions for working with the power supply, and professional rules concerning the use of tools. Dangerous voltage may exist at the power input and motor terminals, even the converter is deactivated. Generally, use insulated screwdrivers when working with such terminals. Ensure that the power is shut off and check the actual voltage of the converter and motor, before connection and making any change to the connection.

After connecting the power supply terminals, the motor and the control terminals, replace the cover back before switching on the power.

Take account of the following instructions:

Ensure that the power supply can provide appropriate voltage and current. Ensure that the rated current range is within that of the converter and power supply.

It is recommended to use 4-core cables to connect the motor. Cables are connected to motor terminals PE-U-V-W.

If shielded cables are used, the shield layer should securely connected to the metal surface of cable control cabinet.

Note:

It is recommended to use shielded cables in accordance with specified

EMC classification.

Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the

National Electrical Code and any additional local codes.


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Wire range for field wiring terminals:

Frame Size

A (0.75 - 7.5 kW)

B (11 - 15 kW)

C (18.5 - 22 kW)

D (30 - 37 kW)

E (45 - 55 kW)

F (75 - 90 kW)

G (110 kW)

Terminal Type

Input Terminal Block (DW2) BTB-750

Output Terminal Block (DW1) BTB-750

Terminal Block (CPU Board) Type JTB870

Main Terminal Block Type OK-050






Main Terminal Block HP-RT150-71





Terminal Block (PU Board) Type JTB870


Wire Range (AWG)

10 - 18

10 - 18

12 - 30

6 - 12

12 - 30

6 - 12

12 - 30

(2) 6

12 - 30

2/0-6, STR

12 - 30

4/0-4, STR

12 - 30

350 kcmil-4, STR

12 - 30

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L1 L2 L3 N

Power Supply

Power supply

Ensure that the power supply

meets the rated values in this manual.

L1 L2 L3

Fuse

Fuse

The converter may take a high input current when being switched on.

Select an appropriate fuse in accordance with the table in

8.5

.

X

Magnetic Contactor

Electromagnetic contactor

Do not use an electromagnetic contactor as the power switch, because it will shorten the service life of the converter.

AC reactor

An AC reactor is recommended to improve power factors.

The wiring length must be less than 10 m.

AC Reactor

--

-

AC Filter

AC filter

AC output reactor

When the connecting wire is longer than 80 m, an AC output reactor is suggested to be added in order to avoid motor insulation destruction.

Fe

U V W PB (+)

Rexroth

Braking

Resistor

Motor

Motor


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Bosch Group



8.7 Wiring Terminals

Main circuit terminals

Terminal

U

V

W

L1

L2

L3

PB

P1,

-

Description

Main power supply inputs

Frequency converter outputs (to be connected to the motor)

Reserved terminal for external braking resistor

(applicable to 0.75 to 15 kW frequency converters)

DC positive bus outputs

DC negative bus output

Grounding

Applicable to: 0.75 kW to 7.5 kW

Converter Top:

Converter Bottom:

Note:

There are separate ground connections (for motor cable shield and

PE) at the converter bottom.

Applicable to: 11 kW to 15 kW

Applicable to: 18.5 kW to 37 kW

Applicable to: 45 kW to 90 kW

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Applicable to: 110 kW

Note 1:

For 11 - 110 kW frequency converters, the main circuit terminals are

on the bottom of the converter.

Note 2:

For 45 - 110 kW frequency converters, UL marked connectors and cables should be used for wiring of the terminal blocks. The connectors may be of crimp, ring or fork types or other similar types.

Note 3:

There are two ground connections, one for the input side, the other for

the output side.

49



Control terminal diagram (applicable to 0.75 to 110 kW CPU board)

E-Stop


Switch Wiring (Shown are factory defaults)

1 2

3

JP1

(Programming jumper, not to be modified by the user)

JP2

1

2 3

JP3

1 2 3

JP4

1 2 3

JP5

1

2 3

Position 2-3: encoder signals are input at A+, A-, B+ and B- in a differential manner position 1-2: encoder signals are input at A- and B- by open collector.

position 2-3: external voltmeter at FM2 side position 1-2: external ammeter at FM2 side position 2-3: external voltmeter at FM1 side position 1-2: external ammeter at FM1 side position 2-3: 0 to 10 V analog signal input at VRC side position 1-2: 0 to 5 V analog signal input at VRC side

NPN/ PNP Switch

A three position switch determines:

1. The internal 24 V power supply or an external 24 V power supply is used for the inputs.

2. The inputs are activated by connection of 24 V to an input (PNP/ active input) or connection of 0 V to an input (NPN/ passive input).

Note:

The factory default for the three position switch is NPN

(Switch contact at position 3).


50

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NPN and PNP Modes and Signal Input

Internal Power Supply

SW

Switch contact at position 3

SW (NPN setting)

External +24V

SW


SW (external setting)

Internal Power Supply

SW


SW (PNP setting)

External Power Supply

SW


External +24V

SW (external setting)

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51




Analog input terminal (+10V, VRC, GND, +I)

(1) For connection of low level analog signals, which are easily affected by external interference, the wiring length should be as short as possible

(less than 20 m), shielded cables must be used.

(2) Use twin contacts to handle low level signals if contacts are used in the circuit. In addition, do not ground the GND terminal.

(3) Incorrect operation may occur due to interference on the analog signal.

In such cases, connect a capacitor and ferrite core at the output side of the analog signal, as shown below.

Shielded cable

Potentiometer

Frequency converter

+10V

VRC

GND

0.022

F

50V

Running through or 2-3 windings for the same phase

Frequency converter

+I

C

GND

Ferrite magnetic ring


52

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Control circuit terminals

Type

Communi cation

Terminals

SF

SR

RST

E-Stop

X1, X2, X3

SC

FB

+10 V

VRC

+I

GND

OUT1

OUT2

CME

DO-COM

Ta

Tc

Tb

+24 V

FM1-GND

FM2-GND

PGP/COM

A+

A-

B+

B-

485+

485-

Signal Function

Forward/stop

Reverse/stop

Error reset

Stop converter output

Multi-function inputs

Description

See parameters [b00] and [E38]

See parameters [b00] and [E38] closed for reset

See parameters [E32], [E33] and [E34]

See parameters [b00], [b34],

[b35], [E39], [H07] and [H23]

Signal Requirement

Depend on the position of the NPN/PNP switch

Shared +24 V/COM connection for digital input signals

The common terminal for

SF\SR\RST\E-Stop\X1-X3

Analog feedback signal for

CLOSED LOOP control

Feedback signal, analog voltage input.

Input voltage range: 0 to 5 V

Input resistance: 100 k Ù

Resolution: 1:1000

Supply voltage for external frequency setpoint value specified

Power supply for speed commands

10 V (max. current 10 mA)

Analog main frequency reference

Frame potential (0 V)

Open collector output 1

Open collector output 2

Common terminal for

OUT1 and OUT2

Digital frequency output

Analog frequency command

JP5, position 2-3



Resolution: 1:2000

JP5, position 1-2



Resolution: 1:2000

Analog actual frequency feedback signal

Isolated from COM

Input current range: 4 to 20 mA

Input resistance: 165 Ù

Resolution: 1:1000

-

Programmable output with multiple functions. See parameters [E16],

[E17] for details.

For internal 24 V power supply: to be short circuited to the COM terminal For external power supply: to be short circuited to the “e arth ” of the power supply

Open collector outputs insulated via opto-electric couplers:

Max. output voltage: 24 VDC

Max. output current: 50 mA

Programmable to be pulse output with multiple functions. See parameters [E09] and [E10]

Open collector outputs insulated via opto-electric couplers:

Max. output voltage: 24 VDC

Max. output frequency: 50 mA

Relay changeover contacts

Shared relay contact

Ta-Tb: N.O; Tb-Tc: N.C

(Tb is the common terminal)

Programmable relay output with multiple functions. See parameter

[E18]

Contact transmitter capacity:

250 VAC, 3 A

30 VDC, 3 A

Shared +24 V connection for digital output signals

-

+24 VDC

Analog multi-function output 1

Analog multi-function output 2

Supply voltage +24 VDC

Encoder signal A

Encoder signal B

RS485 interface

Programmable analog output with multiple functions. See parameters

[E04]-[E08]

Output voltage/current settable via JP4 for FM1 and via JP3 for FM2:

Output voltage: 0 or 2 to 10 V

Output current: 0 or 4 to 20 mA

Max. output current: 100 mA Power supply for the encode

Short JP2-3 to select encode r differential inputs from A+, A-, B+ and B-;

Short JP1-2 to select open collector inputs from A-, B-.

Connection voltage: 8 to 24 V

Max. input frequency: 200 kHz

Standard 485 communication port.

Use twisted pair or shielded cables.

-

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9-1 Operating Panel

9 Operating Panel

9.1 Overview

The operating panel is at the center of the converter and composed of two areas: display and keys. The display shows mode settings and state of the converter. The keys allow the user to program the converter.

Display

Indicate output frequency, current, set values of parameters, and abnormalities

Function

Return to the upper level menu.

LED indicator

Indicate the status of frequency converter

Set

Enter next level menu, set parameter, select items to be monitored

Up and down arrows

For selection of parameters and modification of data

Run

Start the frequency converter

Stop

Stop the converter or reset

it after a fault

Potentiometer

For setting of frequency commands

Note:

0.75 to 7.5 kW frequency converters have potentiometer as a standard

configuration, and 11 to 110 kW frequency converters have optional

potentiometer.

LED indication description

SF SR Mode

Being lit indicates the mode of parameter setting

Being off indicates the monitoring mode

Being lit indicates reverse running

Being lit indicates forward running


54

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Operating Panel 9-2 Rexroth Frequency Converter Fe

Digital indication description

1 2 3 4

The LEDs display has four digits, it is sometimes used to show 5 significant digits.

In parameter setting mode, if LED 1 flashes, this indicates the highest place of the 5 significant digits is hidden, to view this press down both

Func

and to show the 4 most significant digits; if LED 4 flashes, this indicates the lowest place of the 5 significant digits is hidden, press down both

Func

and to show the 4 least significant digits.

In the running monitoring mode, no LED flashes; if LED 4 is displayed as a decimal point, it indicates there are 5 significant digits, and the digit of the lowest place is hidden.

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9.2 3-Level Menu Structure

Menu Level 1

(Function group)

Menu Level 2

(Function code)

B b00 b---

Basic function group b43

E00

E---

Extended function group

E48

P00

P---

Programmable control function group

P37

H00

H---

Advanced function group

H49 oUtF

SEtF oUtA d---

Monitoring function group

(The group of parameters can only be displayed and read by the external computer) oUtV dCV inPt t

Menu Level 3

(Parameter value)

0-6

5.0

0.00

0

0-2

10.0

1-15

0

50.00

50.00

5.5

394

530

68

Note:

The digital operating panel can be used to toggle between menu options, set parameters, and reset the converter after fault with the

Func

,

Set

, and buttons.


56

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Rexroth

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Rexroth Frequency Converter Fe 9-5 Operating Panel

9.3 Example of Operating Panel Operation

Display output frequency

Under the frequency monitoring mode, follow the steps to view output current as shown below:

Display frequency setting symbol

Display value of set frequency

Display output current symbol

Display current value

The output current has not reached the displayed value

Automatically return to the frequency monitoring mode after 2 minutes

Under output frequency monitoring mode, follow the steps to frequency given by the digital operating panel to be 50 Hz ([b01]=50.00 Hz) as shown below:

Display output frequency after powering on

Display output frequency symbol

Display function group b

Display function code b-00

Display function code b-01


58

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Bosch Group


Original set value of b-01

Set the frequency to be 50. 00 Hz

Jump to next function code after frequency setting

Return to function group b

Return to frequency monitoring mode

Press and to set frequency

Press and hold

to speed up setting

Note :

To set frequency with the digital operating panel, [b02]=0;

Note :

Frequency setting can be done during stop or running of the

converter.

Display output frequency after powering on

Run/Stop

operation example: [b00]=0, [b02]=1

Running at 50.00 Hz

Motor slows down to stop Being stopped

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Note:

By factory default, SF/SC is closed, and the displayed output will be

50.00 Hz after pressing down

Run

key and rotating the potentiometer

knob to the maximum position.



Operation and resetting in case of fault

Fault indication

Return to frequency monitoring after reset


Note :

A fault code will be displayed in case of fault. In case of several faults, corresponding fault codes will be displayed alternatively.

Note :

Press

Stop

to reset after fault, and the fault code will not be displayed any longer.

Stop

key is valid if the cause of fault has not been removed.

Note :

If a fault code OC-1, OC-2 or OC-3 is displayed, wait for 5 seconds before pressing

Stop

key to activate resetting.

Note :

In case of fault, use

Func

to directly re-enter level 1 menu to work with most of the function codes.


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Commissioning 10-1 Rexroth Frequency Converter Fe

10 Commissioning

10.1 Check and Preparation before Commissioning

Make the following checks before commissioning

(1) Check if the wiring is correct. Particularly, ensure that the output terminals U, V and W of the converter are not connected to the power supply and that the ground terminal is well grounded.

(2) Ensure that there are no short circuits between terminals, live terminals or short circuit to ground.

(3) Ensure that terminal connections, connectors and screws are secure.

(4) Ensure the motor is not connected to other loads.

(5) Check that all inputs are off before powering on, to ensure that the converter will be started as expected and no unexpected action occurs.

(6) Make following checks after powering on:

0.00 flashes on the display (without fault indication)

The cooling fan in the converter works normally (factory default

[H22]=0)

10.2 Commissioning

10.2.1

Overview

(1) The converter has no internal contactor, and will be energized once the main power supply is connected. When the

Run

key is pressed down (or the control through terminals is selected), the converter will give output.

(2) By factory default, the converter initially displays output frequency after being energized. You may change it to another parameter as instructed in Chapter 1 1 “

Para

meter Setti

ngs

”. Th e factory defaults are based on standard applications with standard motors.

(3) The frequency command of the converter is set to be 0.00 Hz upon delivery, meaning that the motor will remain static. Use to change the value to start the motor.

Note :

Ensure the plastic enclosure is in place before the device is powered on. Wait for 30 minutes after powering off, to allow the DC capacitor being discharged, and do not remove the upper cover during the period.

Note :

The starting and stopping of the converter is controlled by the panel as a factory default, and terminal SF and SC are linked.

Note :

The frequency is 0.00 Hz by factory default. This is to avoid uncontrolled motor running during the initial setting. For the motor to run, enter a frequency value by pressing under the monitoring mode or in [b01].

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61



10-2 Commissioning

10.2.2 Fe Basic Parameter Fast Setting

Use the operating panel to set the necessary parameters based on the application loads and specifications, to allow the converter to start rapidly. A basic generic parameter fast setting table is given below.

Function

Code

b03 b04 b05 b16 b17 b21 b22

Function

Highest frequency - HF

Base frequency - BF

Base voltage - BV

Acceleration time

Deceleration time

Upper frequency - UF

Lower frequency - LF b40

Converter input power supply voltage

E32

H38

H39

E-Stop command input modes in the case of external problem

Motor poles

Rated motor power

Parameter Range and Description

50.00 - 650.00 Hz

20.00 - HF

400 V class £º 240.0 V - 480.0 V

0.1 - 6500.0s

0.1 - 6500.0s

LF-HF

0.00-UF

400 V model: 380.0 - 480.0 V

0: Stopping due to connected E-Stop/SC

1: Stopping due to disconnected E-Stop/SC

2 - 14 (input an even number)

0.4 - 999.9 kW

H40

H47

Rated motor current

Auto-tuning of motor parameters

0.1 - 999.9 A

0: no auto-tuning of parameters

1: auto-tuning when the motor is static

2: auto-tuning when the motor is running.

After auto-tuning, [H47] is automatically

set to be 0.

Factory Default

50.00

50.00

380.0

10.0

10.0

50.00

0.50

380.0

0

4

Depending on model

Depending on model

0

Commissioning may be conducted after checks have been done as per section

10.1

. The factory default for the converter is set that it will be controlled by the digital operating panel. Terminals SF and SC have to be shorted.


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Commissioning 10-3


10.2.3 Example: Commissioning of converter with potentiometer

(up to 7.5 kW)

Fe series frequency converter up to 7.5 kW can use the front mounted potentiometer to set the frequency output by the following procedure.

Sequence Operation

1

2

Description

Rotate the potentiometer counterclockwise to the greatest extent.

Press

Run

The initial frequency value is 0.00

Enter the command for running, with 0.00 displayed

3

4

5

6

7

Rotate the potentiometer clockwise

(rightwards) slowly and the displayed value starts to change, until 5.00 is displayed

Observe:

Whether the motor runs in the correct

direction

Whether the motor runs smoothly

Whether there is any abnormal noise or

problem

The motor starts to run.

Observe the running, and immediately stop the motor by shutting off the power if any abnormality occurs.

Restart commissioning only after the fault causes have been removed.

Rotate the potentiometer clockwise

(rightwards)

Rotate the potentiometer counterclockwise

(leftwards)

The motor accelerates.

The motor decelerates.

Press

Stop

Enter the command for stopping. The motor stops.

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Rexroth Frequency Converter Fe 10-4 Commissioning

10.3 Restore Factory Defaults

If the converter fails to run the motor due to incorrect parameters, a simple solution is to initialize the parameters to factory defaults.

Set [b39] = 2 will start initialization to restore factory defaults at 50 Hz. Set

[b39] = 3 will start initialization to restore factory defaults at 60 Hz.

For a fast setting use the basic parameter list once again.

10.4 Solutions for Simple Fault during Commissioning

(1) Over current occurs during acceleration --- Increase the acceleration time.

(2) Over voltage occurs during deceleration --- Increase the deceleration time.

(3) Over current occurs immediately after pressing the

Run

key ---

Incorrect wiring. Check if U, V, W outputs of the main circuit are shorted or grounded.

(4) The motor runs in the direction opposite to the desired one --- Change the sequence of any two phases of U, V and W.

(5) The motor vibrates and runs in uncertain directions after each starting

--- A phase of U, V and W is disconnected (output phase loss).

10.

5 Notes on Frequent Starting and Stopping

(1) Do not use the electromagnetic contactor connected prior to L1, L2 and

L3 terminals to start and stop the converter to avoid early aging and damage of the filter capacitor. External terminals SF, SR and X1-X3 may be used to start and stop the converter.

(2) The current limiting resistor for capacitor recharging may be damaged due to frequent starting and stopping with the electromagnetic contactor connected prior L1, L2 and L3 terminals.


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Parameter Settings 11-1


11 Parameter Settings

11.1 Converter Functions

Basic Function Group (group b)

Function

Running command source

Function

Code

Function Code

Description

b00


Set the source of commands for running

(Option 1 and 3 have frequency command source)

0:

Run/Stop

control with operating panel

1: External via control terminals,

Up/Down

control

2: External via control terminals (including multi-speed),

while

Stop

key is activated

3: Internal PLC control

4: External via control terminals

(X3 is used to switch between internal/external sources

of frequency command, while

Stop

key is activated)

5: External computer controls

Run/Stop

, while

Stop

key is

activated

6: External computer controls

Run/Stop

, while

Stop

key is

deactivated

0

Factory

Default

b01

Frequency command given by digital operating panel

0.00 - HF 0.00

Frequency command source b02

Set the source of commands for frequency

0: Given by the digital operating panel

1: By the operating panel's potentiometer 0 - 5 V

2: Reverse action of the digital operating panel's

potentiometer 5 - 0 V

3: Direct action of external terminal 0 - 5 V

4: Reverse action of external terminal 5 - 0 V

5: Direct action of external terminal 0 -10 V

6: Reverse action of external terminal 10 - 0 V

7: Direct action of external terminal 4 - 20 mA

8: Reverse action of external terminal 20 - 4 mA

9: External terminal (0 - 5 V) (4 - 20 mA)

10: VRC terminal -10 V - 10 V

11: Pulse frequency setting

12: External computer frequency setting

1

Note:

indicates a parameter cannot be modified when the converter is in operation. Without the

symbol, it indicates a parameter can be modified during running.

Note:

indicates values that correspond to the factory default upon initialization at 50 Hz.

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Rexroth Frequency Converter Fe 11-2 Parameter Settings

Function

V/F curve setting

Function

Code

b03 b04 b05 b06 b07 b12 b13

Constant voltage control b14 b15

Acceleration/ deceleration time and type b16 b17

Forward and reverse rotation dead zone time

Torque increasing b18 b19

Electronic thermal relay b20 b21

Output frequency limits

LF mode b22 b23 b24 b25

Analog frequency setting adjustment b26 b27 b28 b29 b30

Slip frequency compensation b31 b08 b09 b10 b11

Function Code

Description


Base frequency - BF

Base voltage - BV

V/F curve mode

Parameter Range and Description Factory

Default

50.00 - 650.00 Hz

20.00 - HF

400 V class: 240.0 V - 480.0 V

OFF: User-defined V/F curve

H-00 - H-15: Constant torque

characteristic

P-00 - P-15: Square descending

torque characteristic

50.00

50.00

380.0

H-03

0.00 - [b09]

0.00

Lowest output frequency - LLF

Lowest output voltage - LLV

Middle frequency1 - Mf1

Middle voltage1 - MV1

0 - 120 %BV

LLF - BF

0 - 120 %BV

Middle frequency2 - MF2

BF - HF

Middle voltage2 - MV2

0 - 120 %BV

Highest voltage - HV

0 - 120 %BV

Constant voltage control

Acceleration/ deceleration curve

Acceleration time

Deceleration time


Automatic torque increasing

OFF/ON

0: Linear; 1: S curve

0.1 - 6500.0s

0.1 - 6500.0s

0.0 - 10.0s

OFF / 1 - 10 %

Electronic t hermal relay


Lower frequency - LF

LF mode

Hysteresis frequency width

50 - 110 % / OFF

LF - HF

0.00 - UF

0 Stop; 1 Run

0.10 - HF

Gain of given channel

0.00 - 9.99

Analog input channel filtering time constant

Minimum curve setting

Frequency corresponding to minimum curve setting

Maximum curve setting

0.0 - 10.0s

0.0 - 100.0 %

0.00 - 650.00 Hz

0.0 - 100.0 %

Frequency corresponding to maximum curve setting

0.00 - 650.00 Hz

Slip frequency compensation 0.00 - 5.00 Hz

1

0.00

1

50.00

100

100

OFF

0

10.0

10.0

1.0

OFF

100

50.00

0.50

0

1.00

1.00

0.5

0.0

0.00

100.0

50.00

0.00


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Function

Starting

Stopping mode

Jogging control

Data protection options and initialization

Converter input power supply voltage setting

Frequency setting saving in case of power down

Zero speed control selection

Voltage command for zero speed control

Changing rate of

Up/Down

Function

Code

b32 b33

Function Code Description

Starting frequency

Starting holding time b34 b35 b36 b37 b38 b39 b40 b41 b42 b43 b44

Stopping mode selection

Jogging mode selection

Jogging frequency

Jogging acceleration time

Jogging deceleration time






Changing rate of

Up/Down


0.00 - 60.00 Hz

0.0 - 10.0s

0: OFF; 1: X1;

2: X2; 3: X3; 4: ON

0: OFF; 1: X1; 2: X2; 3: X3

0.00 - HF

0.1 - 6500.0s

0.1 - 6500.0s

0: All parameters are

readable and rewritable.

1: All parameters are

read-only except [b01]

and [b39]

2: Initialization to factory

defaults at 50 Hz

3: Initialization to factory

defaults at 60 Hz

4: Clear all fault records

400 V model:

380.0 V - 480.0 V

0

380.0

0: Not saved when power is off

or the converter is stopped

1: Not saved when power is off;

saved when the converter is

stopped

2. Saved when power is off;

not saved when the

converter is stopped

3. Saved when power is off or

the converter is stopped

0: No output

1: Output DC voltage as per

[b43] as holding torque

2: Output DC voltage as

per V/F curve

0.0 - 20.0 %BV

1

0

5.0

Factory

Default

0.50

0.0

0

0

0.00

0.1

0.1

0.01 99.99 Hz / s 1.00

Note

:

OFF at the beginning indicates that it represents OFF when the external computer reads 0 .

:

OFF at the end indicates that it represents OFF when the external computer reads

111 .

:

Hold key for 2 seconds to change [b39] from 1 to 2, 3 or 4.

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11-4 Parameter Settings

Extended Function Group (group E)

Function

Skip frequency

FM1and FM2 analog output selection

FM channel mode

DO pulse output

OUT open collector output

E10

E11

E12

E13

E14

E15

Function

Code


E00

E01

E02

E03

E04

E05

E06

E07

E08

E09

Skip frequency 1

Skip frequency 2

Skip frequency 3

Skip frequency range

FM1 selection

FM1 gain setting

FM2 selection

FM2 gain setting

FM channel mode

Pulse output selection


0.00 - HF

0.00 - HF

0.00 - HF

0.00 - 10.00 Hz

0: Output frequency

1: Output voltage

2: Output current

3: PI feedback signal

0.50 - 1.20

0: Output frequency

1: Output voltage

2: Output current

3: PI feedback signal

0.50 - 1.20

0: FM1 outputs 0 - 20mA

or 0 - 10V,

FM2 outputs 0 - 20mA

or 0 - 10V


or 2 - 10V,


or 2 - 10V


or 0 - 10V,


or 2 - 10V


or 2 - 10V,


or 0 - 10V

0: Output frequency

1: Output voltage;

2: Output current

Maximum output pulse frequency

Frequency level detection FDT1

FDT1 lagging frequency

Frequency level detection FDT 2

FDT 2 lagging Frequency

Frequency to reach detection range

0.1 - 50.0 kHz

0.00 - 650.00 Hz

0.00 - 650.00 Hz

0.00 - 650.00 Hz

0.00 - 650.00 Hz

0.00 - 650.00 Hz

1.00

1

1.00

0

2

10.0

50.00

1.00

25.00

1.00

2.00

Factory

Default

0.00

0.00

0.00

0.00

0


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Function

OUT open collector output

Relay output selection

Stall over current protection

Running monitoning display

Function

Code

E16

E17

E18

E19

E20

E21


Open collector output OUT1

Open collector output OUT2

Relay Ry output selection


0: Running

1: Frequency level detection

signal 1 (FDT 1)

2: Frequency level detection

signal 2 (FDT 2)

3: Frequency arrive signal

(FAR)

4: Reserved

5: Under voltage

6: Overload

7: Reserved

8: Zero speed

(lower than

starting frequency)

9: E-Stop

10: Lower voltage

11: No trip action

12: Fault

13: Programmable program

running

14: Programmable program

run

15: Run for one stage

16: Over current stall

17: Over voltage stall

18: In forward rotation

command indication

19: In reverse rotation

command indication

20: Zero speed ( incl. Stop)

21: Being braked

22: Accelerating

23: Decelerating

24: Fan action

25: Reserved

Stall over current protection level during running

50 - 200 % of rated current / OFF

Stall over current protection level during acceleration

Running monitoring display

50 - 200 % of rated current / OFF

0: Display output frequency

1: Display set frequency

2: Display output current

3: Display output voltage

4: Display DC bus voltage

5: Display input signal

6: Display radiator

temperature

E22

Display factor A

-99.9 - 6000.0

Display factor

E23 Display factor B

-99.9 - 6000.0

6

0

Factory

Default

12

OFF

OFF

0

1.0

0.0

Note :

0 read by the external computer corresponds to -99.9

, and 60999

corresponds to 6000.0

.

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69



Function

PI regulator selection

Maximum input pulse

Handing of stopping in the case of external problem

Lower voltage and under voltage protection

Starting upon powering on

SF and SR terminal function

Self-holding function

Function

Code


E24

PI adjustment selection

E25

E26

E27

E28

E29

E30

E31

E32

E33

E34

E35

E36

E37

E38

E39


PI adjustment feedback channel selection

Proportional gain

Integration time constant

Sampling period

PI adjustment upper factor

PI adjustment lower factor

Maximum input pulse frequency


E-Stop modes in the case of external problem

E-Stop alarm modes in the case of external problem

Lower voltage protection mode

Under voltage protection alarm

Converter automatically starts after powering on



70


0: No PI;

1: Direct action;

2: Inverse action

0: Control terminal FB

direct action

(voltage input 0 - 5 V)

1: Control terminal FB

inverse action

(voltage input 5 - 0 V)

2: Control terminal +I

direct action

(current input 4 - 20 mA)

3: Control terminal +I

inverse action

(current input 20 - 4 mA)

4: Single phase

pulse feedback

5: Orthogonal

pulse feedback

0.01 - 99.99 times

0.1 - 60.0s

0.1 - 60.0s

Factory

Default

0

0

1.0 kHz - 200.0 kHz

0: Stopping due to connected E-Stop/SC

1: Stopping due to

disconnected E-Stop/SC

0: Coasting to stop

1: Deceleration to stop

0: No alarm output

1: Alarm output

0: Coasting to stop

1: Deceleration to stop

2: Resume with

previous speed

0: No alarm output

1: Alarm output

0: Forbidden

1: Allowed

0: Forward/reverse mode

1:

Run/stop

, forward/reverse

mode

2: Key control holding mode

0:OFF

1:X1

2:X2

3:X3

10.00

1.0

0.1

OFF

0

20.0

0

0

1

2

0

0

0

0

Rexroth

Bosch Group



Function

Input phase loss protection enabling

Output phase loss protection enabling

Function

Code

E40

E41

Function Code

Description


Fault retry

Fault records

E42

E43

E44

E45

E46

E47

E48


0: Input phase loss protection disabled

1: Input phase loss protection enabled


0: Output phase loss protection disabled

1: Output phase loss protection enabled

Fault retry options

0: Fault retry disabled

1: Retry from over current at constant

speed

2: Retry from over current during

acceleration

3: Retry from over current during

deceleration

4: Retry from over voltage at constant

speed

5: Retry from over voltage during

acceleration

6: Retry from over voltage during

deceleration

7: Retry from overload

8: Retry from overheat

9: Retry from drive protection

10: Retry from EMI

11: Retry from input phase loss

12: Retry from output phase loss

13: Retry from stop after response

to internal abnormality command

14: Retry from any fault

Waiting time for fault retry

Number of fault retries

Current fault record

Last fault record

Last 2 fault records


2.0 - 60.0s

0 - 3

0: No fault record

1: O.C.-1, over current

at constant speed


during acceleration


during deceleration

4: O.E.-1, over voltage

at constant speed


during acceleration


during deceleration

7: O.L., overload

8: O.H., overheat

9: d.r., drive protection;

10:CPU-, EMI

11: IPH.L., input phase loss

12: oPH.L., output phase loss

13: E .-St., stopping by external

abnormality command

Note:

indicates that direct modification is not allowed.

0

10.0

0

0

0

0

0

Factory

Default

1

1

Rexroth

Bosch Group

71




Progammable Control Function Group (group P )

Function

Function code

PLC working mode

P00

Speed 0 setting

Speed 1 setting

Speed 2 setting

Speed 3 setting

Speed 4 setting

Speed 5 setting

Speed 6 setting

Speed 7 setting

P22

P23

P24

P25

P26

P27

P16

P17

P18

P19

P20

P21

P08

P09

P10

P11

P12

P13

P14

P15

P01

P02

P03

P04

P05

P06

P07

P28

P29

P30

P31

P32

P33

P34

P35

P36

P37


PLC working mode

Speed 0 running direction

Speed 0 holding time

Speed 1 frequency setting



Speed 1 acceleration time

Speed 1 deceleration time
































0: Stop after one cycle

1: Cycle operation

2: Running at the last

frequency after one cycle

SF: Forward; SR: Reverse

OFF/1

-

65000s

0.00Hz

-

HF


OFF/1

-

65000s

0.1

-

6500.0s

0.1

-

6500.0s

0.00Hz

-

HF


OFF/1

-

65000s

0.1

-

6500.0s

0.1

-

6500.0s

0.00Hz

-

HF


OFF/1

-

65000s

0.1

-

6500.0s

0.1

-

6500.0s

0.00Hz

-

HF


OFF/1

-

65000s

0.1

-

6500.0s

0.1

-

6500.0s

0.00Hz

-

HF


OFF/1

-

65000s

0.1

-

6500.0s

0.1

-

6500.0s

0.00Hz

-

HF


OFF/1

-

65000s

0.1

-

6500.0s

0.1

-

6500.0s

0.00Hz

-

HF


OFF/1

-

65000s

0.1

-

6500.0s

0.1

-

6500.0s

Factory

Default

0

SF

OFF

10.0

10.0

40.00

SF

OFF

10.0

20.00

SF

OFF

10.0

10.0

30.00

10.0

10.00

SF

OFF

10.0

10.0

SF

OFF

5.00

SF

OFF

10.0

10.0

50.00

SF

OFF

10.0

10.0

50.00

SF

OFF

10.0

10.0


Rexroth

Bosch Group



Advanced Function Group (group H)

Function

PWM frequency

Restarting after transient stopping

DC braking

Communication parameters

Fan control

H13

H14

H15

H16

H17

H18

H19

H20

H21

H22

H03

H04

H05

H06

H07

Function code

Function code description

H00

H01

H02

H08

H09

H10

Parameter range and description

PWM frequency

(range depends on frequency converter rated power)

Automatic adjustment of PWM frequency

OFF/ON

Delay for restarting after transient stopping

Reserved

DC braking time

DC braking initial frequency

DC braking voltage

DC braking hoding options

Communication protocol selection

Local address

0:OFF 1:X1 2:X2 3:X3 4:ON

0: ModBus; 1: PROFIBUS

Baud rate selection

0: 1200 bps 1: 2400 bps

2: 4800 bps 3: 9600 bps

4: 19200 bps 5: 38400 bps

H11 Data format

0: N, 8, 2 (1 start bit, 8 data bits,

2 stop bits, without check)

1: E, 8, 1 (1 start bit, 8 data bits,

1 stop bit, even)

2: O, 8, 1 (1 start bit, 8 data bits,

1 stop bit, odd)

H12

Communication disruption action

Communication disruption detection time

PZD3 settings

PZD4 settings

PZD5 settings

PZD6 settings

PZD7 settings

PZD8 settings

PZD9 settings

PZD10 settings

Fan control

0: Stop; 1: Keep running

0: Output frequency

1: Frequency setting

2: Output current

3: Output voltage

4: Bus voltage

5: Switch value input signal

6: Module temperature

7: PI controlled feedback quantity

0: Auto control; 1: No control

0

0

0.0

0

3

4

1

2

5

6

7

0

OFF

3.00

10

0

0

1

3

Factory d efault

Depending on model

ON

OFF

Rexroth

Bosch Group

73



Function

Energy saving

No-trip control

Stall over voltage level selection

Over voltage protection point setting

Braking voltage setting

Dropping control

H36

H37

H38

H39

H40

H41

Function code

H23

H24

H25

H26

H27

H28

H29

H30

H31

H32

H33

Function code description

Energy saving mode

Voltage resumption time

Voltage gain for energy saving under external terminal control

Parameter range and description

0: Disabled;

3: X3

1: X1; 4: Automatic

2: X2; energy saving

Energy saving initial frequency

Automatic energy saving control gain

Automatic energy saving time

constant

Automatic energy saving rated percentage slip

Automatic current limitation level

Current regulator proportion factor

Current regulator integrating

time constant

Auto current limitation at constant speed

ON/OFF

H34

Stall over voltage selection

H35

Software over voltage protection point

Deceleration braking activation voltage threshold

Dropping control

Motor poles 2 - 14 (put in an even number)

Rated motor power

Rated motor current

No-load current

H42 Stator resistance

H43

Leakage inductance

H44 Rotor resistance

Motor parameters

H45

Mutual inductance

H46 Rated slip frequency

H47

Auto-tuning of parameters

Total working hours

Password input

H48

H49

Total working hours

Password input

Note:

indicates that direct modification is not allowed.

0: No auto-tuning of parameters

1: Auto-tuning when the motor is

static

2: Auto-tuning when the motor is

running. After auto-tuning, [H47]

is automatically set to be 0.

WARNING:

Motor load has to be removed before using auto-tuning function [H47]=2!

Enabling factory function codes


Factory d efault

0

2.0

80

0.00

0.5

1.00

5.0

150

0.060

0.200

ON

OFF

810

770

0.00

4

Depending on model

Depending on model

Depending on model

Depending on model

Depending on model

Depending on model

Depending on model

0.00

0

0

0

Rexroth

Bosch Group



11.2 Notes on Function Groups

Notes on Basic Function Group (group b)

b00 Running command source (Option 1 and 3 have frequency command source)

Setting range

0

1

2

3

Run/Stop


Up/Down


External via control terminals (including multi-speed), while

Internal PLC control

Stop

default

key is activated

4

5

6

External via control terminals (X3 is used to switch between internal/external sources of frequency command), while

Stop

key is activated

External computer controls

Run/Stop

, while

Stop

key is activated

External computer controls

Run/Stop

, while

Stop

key is deactivated

Run/Stop

are used to control starting/stopping; [b02] sets the frequency command source; [b16] and [b17] set acceleration and deceleration time.

When [b02] = 0-9 or 11 or 12, the input state of SF/SR decides the direction of rotation:

SF closed: Forward rotation; SR closed: Reverse rotation

If SF and SR are closed or disconnected simultaneously, the motor will not run even

Run

key is pressed.

If SF and SR are closed or disconnected simultaneously, the converter will stop even

Stop

is not pressed.

When [b02] = 10, the direction of rotation is decided by the polarity of the frequency giving voltage instead of SF/SR control.

[b00] 1:

External via control terminals, Up/Down control

(related setting: [E38])

Run

key is deactivated, and

Stop

is activated.

Running mode is decided by the circuit given by [E38].

While the running command remains valid, closing X1 will lead to frequency increasing, and closing X2 will lead to frequency decreasing.

While the digital operator panel is under running monitoring status, can be used to increase the frequency, and can be used to decrease the frequency.

The changing rate of the output frequency given by

Up/Down

is decided by function code [b44].

A general example is shown as the below chart. When the running command is valid the frequency converter starts running at the startup frequency (set by [b32], startup frequency), and holds at the startup frequency (holding time is set by [b33],). The converter accelerates

(acceleration time is set by [b16]) to the set frequency [b01] and then responds to the commands of

Up/Down

.

In the startup phase, if the startup frequency is higher than the set frequency, the converter will decelerate (deceleration time is set by [b17]) to the set frequency.

Rexroth

Bosch Group

75




If X1 or X2 has already been defined by another function, [b00] can not be set to 1.

[b00]=2: External

via control terminals (including multi-speed), while Stop key is activated (related settings: [E38] and group P parameters)

Run


Stop

is activated.

The running mode and source running commands are decided by the circuit given by [E38].

Speeds 0-7 are selected with binary combinations of the input status of terminals X1, X2 and X3; the holding time of the speed is decided by the holding time of the combination of terminals X1, X2 and X3; the running direction is decided by the circuit given by [E38]; and the frequency acceleration/deceleration time is set by group P parameters.

If X1, X2 or X3 have already been defined by another function, [b00] can not be set to 2. The default input of the occupied X terminal is 0.

[b00]=3:

Internal PLC control (related settings: group b parameters)

Press

Run

key or close SF to start running, and press

Stop

key or close SR to stop running.

For a speed not involved in the programmed running, its holding time is set to be OFF; for a speed involved in the programmed running, the function code for the holding time is set to be the corresponding time, and group P parameters, including frequency, direction and acceleration/deceleration time, should be set.

[b00]=4:

External via control terminals (X3 is used to switch between internal/external sources of frequency command, while Stop key is activated) (related setting: [b02])

Run


Stop

is activated.

The running mode is decided by the circuit given by [E38].

When X3 is effective, frequency is set by external signals

.

If [b02]=0-2, [b02] is considered as 5. Other values of [b02] shall be normally considered.

When X3 is disconnected, the operating panel potentiometer is used to set the frequency.

[b00]=5:

External computer controls Run/Stop, while Stop key is activated (related settings: [H08],

[H09], [H10] and [H11])


76

Rexroth

Bosch Group



[B00]=6: External computer controls Run/Stop, while Stop key is deactivated (related settings:

[H08], [H09], [H10]and [H11])

b01

An external computer controls starting, stopping and direction, and

Stop

is deactivated.

Frequency command given by the digital operating panel

Setting range

0.00

-

HF

Factory default

Minimum unit

0.00

0.01 Hz

Frequency given by the digital panel is the frequency command source, when [b02] 0.

When [b00]=0, the initial frequency is given, and the function code may also be used to directly set the frequency.

When [b00]=3, frequency given by the digital panel is the frequency command source of speed 0.

b02

Setting range

6

7

4

5

8

9

2

3

0

1

10

11

12

Frequency command source

Given by the digital operating panel .

Factory default

1

By the operating panel s potentiometer 0 - 5 V

Inverse action of the digital operating panel s potentiometer 5

-

0 V

Direct action of external terminal 0

-

5 V (input 0

-

5 V between VRC / GND )

Inverse action of external terminal 5

-

0 V (input 0

-



-

10 V (input 0

-



-

0 V (input 0

-



-

20 mA (input 4

-

20 mA between +I / GND )


-

4 mA (input 4

-

20 mA between +I / GND )

External terminals (0

-

5 V) + (4

-

20 mA)

VRC terminal input -10 V

-

+10 V: -10

-

0 reverse; 0

-

1 0 V forward

Run / Stop

signals given by [E38]

Pulse frequency setting

External computer frequency setting

[b30]

Output frequency

4 mA

Direc t acti on

Inve rse acti on

+20 mA

Input

Input current 4 - 20 mA

Output frequency

[b30]

Direc t acti on

Inve rse actio n

Input

0

0

+5 V

+10 V

Panel potentiometer control 0 - 5 VDC

Analog voltage control 0 - 10 VDC

Rexroth

Bosch Group

77




When [b02]=9, the frequency is given by the combination of VRC terminal (0 - 5 V) and +I terminal (4 - 20 mA). 4 mA analog current is equivalent to 0 V, and similarly, 20 mA is equivalent to 5 V, as shown in the diagram below.

Output frequency

[b30]

Input analog signal

(0 5 V) + (4 20 mA)

0

5 V 10 V

When [b02]=10 VRC terminal inputs -10 V to +10 V analog signals, and the direction is decided by the input voltage signal. Negative signal indicates reverse rotation, and positive signal indicates forward rotation.

When [b02]=5, 6 or 10, set switch JP5 to position 2-3.

[b30]

Output frequency

[b30]

Output frequency

Input

-10V

+10V

-[B30]

Pulse input signal

[b31]

[b02]=1

1 pulse frequency setting . Pulse signals are input via terminal A-, set switch JP2 to position 1-2.

When [b02]=11, [E25]=4/5 invalid.

If [b02]=11, then [E25]=4 and [E25]=5 are invalid.

Furthermore the maximum input pulse frequency [E31] has to be set.

Spe cial note: The set value of [E31] must be linked to the frequency corresponding to maximum curve setting [b30].

When [b02]=12, frequency is given by the external computer. Please correctly set function codes [H08], [H09], [H10] and [H11]

.


78

Rexroth

Bosch Group


Rexroth Frequency Converter Fe b03 b04 b10


Setting range

50.00

-

650.00 Hz

Factory default

Minimum value

Sets the highest output frequency of the converter.

50.00

0.01 Hz

Base frequency - B F

Setting range 20.00

-

HF

Factory default

Minimum value

50.00

0.01 Hz

The rated motor frequency is written on the nameplate of the motor .

b05

400V models

b06 b07 b08 b09

Base voltage - BV

Setting range

Factory default

Minimum value

380.0

0.1 V

The rated motor voltage is written on the nameplate of the motor .

V/F curve mode

Setting range

Factory default

OFF: user-defined V/F curve

H-00

-

H-15: constant torque characteristic

P-00

-

P-15: s quare descending torque characteristic

H-03

OFF: For the mode with user-defined V/F curve, hidden function codes

[b07] - [b13] are displayed.

Lowest output frequency - LLF

Setting range

0.00

- [ b09]

Factory default

Minimum value

0.00

0.01 Hz

The lowest allowable motor frequency is used to set the lowest frequency of

the user-defined V/F curve.

Lowest output voltage - LLV

Setting range

0

-

120 %BV

Factory default

Minimum value

1

1 %

The lowest allowable motor voltage is a percentage of the base voltage (BV)

and used to set the lowest voltage of the user-defined V/F curve.

Middle frequency 1 - MF1

Setting range

LLF

-

B F

Factory default

Minimum value

Middle frequency 1 of the user-defined V/F curve.

0.00

0.01 Hz

Middle voltage 1 - MV1

Setting range

0

-

120 %BV

Factory default

Minimum value

1

1 %

The voltage which corresponds to Mf1 of the user-defined V/F curve is a

percentage of the base voltage (BV).

b11

Middle frequency 2 - MF2

Setting range

BF

-

HF

Factory default

Minimum value

Middle frequency 2 of the user-defined V/F curve.

50.00

0.01 Hz

Rexroth

Bosch Group

79



11-16 Parameter Settings b12 b13 b14

Middle voltage 2 - MV2

Setting range

0

-

120 %BV

Factory default

Minimum value

100

1 %

The voltage which corresponds to MF2 of the user-defined V/F curve is a


Highest voltage - HV

Setting range

0

-

120 %BV

Factory default

Minimum value

100

1 %

The voltage which corresponds to HF of the user-defined V/F curve is a


Constant voltage control

Setting range

OFF/ON

Factory default

OFF

When the constant voltage control is enabled (set to be on), the converter can automatically control the voltage of output V/F characteristics within the set value, even if the power supply voltage changes.

However, the output voltage of the converter must not be higher than the input voltage, even if constant voltage control is ON.

No constant voltage control is available when the set value is OFF, and the output voltage will be in direct proportion to the input voltage.

Following are notes on frequently used V/F curves.

(a) General

automation applications

H-0

-

H-15 constant torque characteristic

Example: Constant torque characteristic settings

Function code

b03 b04 b05 b06

Value [50Hz]

70.00 Hz

50.00 Hz

380.0 V

H-02

Output voltage

[b05]

B [2%BV]

0

Frequency

[b04]


80

Rexroth

Bosch Group



[b05]

(b) Fan and pumps

P-00 - P-15 square decreasing torque

Example: Parameters setting for fans and pumps

Function code

b03 b04 b05 b06

Values [50 Hz]

50.00 Hz

50.00 Hz

380.0 V

P-08

Values [60 Hz]

60.00 Hz

60.00 Hz

380.0 V

P-08

Output voltage

B2 [38% BV]

B1 [1% BV]

Frequency

0 50%BF [b03]=[b04]

Voltage of H curve and P curve

Display

H-08

H-09

H-10

H-11

H-12

H-13

H-14

H-15

H-00

H-01

H-02

H-03

H-04

H-05

H-06

H-07

H curve constant torque setting

11

12

13

14

15

7

8

9

10

5

6

3

4

1

2

B [x%BV]

0

P curve square descending torque se tting

Display

P-00

P-01

P-02

P-03

P-04

P-05

P-06

P-07

P-08

P-09

P-10

P-11

P-12

P-13

P-14

P-15

B1 [x%BV]

0

0

0

0

0

1

1

1

1

1

2

2

2

2

2

2

44

46

48

49

50

36

38

40

42

29

30

32

34

B2 [x%BV]

25

27

28

Rexroth

Bosch Group

81




[b13] HV

[b12] MV2

[b05] BV

(c) User-defined V/F curve

When [b06]=OFF, the following curve can be defined with [b03] - [b05] and [b07] - [b13].

Output voltage

[b10] MV1

[b08] LLV

LLF MF1

[b07] [b09]

Frequency

BF

[b04]

MF2

[b11]

HF

[b03]

BV

HV, MV2

The following user-defined V/F curves are common based on the

requirements of loaded motors.

Output voltage

Output voltage

BV

HV, MV2

MV1,LLV

BV

HV, MV2

LLF

MF1

BF

Constant torque type

Output voltage

Freq.

HF

MF2

MV1

LLV

Freq.

LLF MF1 BF HF

MF2

Fan and pump energy saving type

100%

HV

BV

Output voltage

MV1

LLV

LLF

MF1

BF

High starting torque type

Freq.

HF

MF2

LLV

MV 1

Freq.

LLF

MF1

BF

MF2

HF

Higher than the rated frequency

Variable frequency motor with increased voltage


82

Rexroth

Bosch Group



Acceleration/deceleration curve

0

Setting range

1

Acceleration time

Setting range

0.1

-

6500.0s

Deceleration time

Setting range

0.1

-

6500.0s

[b15]: Acceleration/deceleration curve mode

Frequency

Linear

HF

Factory default

Line ar acceleration/deceleration

S curve acceleration/deceleration

Factory default

10.00

Minimum unit

Factory default

0.1s

10.00

Minimum unit

0

0.1s

HF

Frequency

S-curve

Time

Time

Acc time

Dec time Acc time Dec time

[b15] also determines the jogging acceleration/deceleration curve mode.

[b16] Acceleration time

If internal PLC control is disabled ([b00] 3), [b16] sets the time for frequency increasing from 0.00 Hz to HF.

If internal PLC control is enabled ([b00]=3) and speed 0 is activated,

[b16] sets the time for frequency increasing from 0.00 Hz to the frequency given by [b01].

[B17] Deceleration time

If internal PLC control is disabled ([b00] 3), [b17] sets the time for frequency decreasing from HF to 0.00 Hz.

If internal PLC control is enabled ([b00]=3) and speed 0 is activated,

[b17] sets the time for frequency decreasing from the frequency given by [b01] to 0.00 Hz.

Rexroth

Bosch Group

83




Output frequency

(1)

Internal PLC control is disabled

([b00] 3)

Highest frequency

Running frequency

Output frequency

Acceleration action time

Deceleration action time

Time

Acceleration time

Deceleration time

(2)

Internal PLC control is enabled

([b00] = 3)

Multi-speed frequency command

b18

Time

Acceleration time

Deceleration time


Setting range

0.0

-

10.0s

Factory default

Minimum unit

1.0

0.1s

The time given by [b18] is the duration from slowing down to stop to starting to accelerate in the reverse direction. The function should be set based on load inertia and deceleration time.

If forward and reverse rotation signals are input simultaneously, the motor will decelerate to stop. When the forward and reverse rotation dead zone time is 0.0s, only forward rotation is allowed.

Output frequency

Dead zone time

Time

Forward

O ON

Time

Reverse

O OFF

O ON

O OFF

Time


84

Rexroth

Bosch Group

Parameter Settings 11-21 b19


Automatic torque increase

Setting range

Factory default

OFF

1 - 10 %

OFF

“OFF” is to prohibit automatic torque increasing, and other values is the percentage to the voltage increasing at 0 output frequency and rated current. It is used to improve the torque characteristics of the motor running at a low frequency. The function can automatically adjust the output voltage of the converter, based on the load current, to increase torque at low frequency and avoid over excitation when the motor has no load.

In operation, the converter automatically determines the percentage of voltage increasing based on output frequency and load current.

During commissioning, [b19] should be gradually increased. An excessively large value may lead to excessive motor current or activation of “n o-trip function ”.

Output voltage

100

100 load

b20

[b19]

0% load

0 BF HF

Output frequency

Electronic t hermal relay

Setting range

Factory default

50

-

110 %

OFF

100

Electronic thermal relay setting value (%) = rated motor current rated converter current

100%

If only one motor is connected to one converter, no overload relay is necessary, and the function should be set based on the characteristics of the motor.

If multiple motors are driven or the rated current of the motor is lower than the setting value of electronic overheat protection, the protection for motors is not sufficient. Provide a thermal relay for each motor in this case.

Rexroth

Bosch Group

85




Time

Inverse time lag characteristics of overload protection are shown in the diagram.

G series: 200 % of rated current for 1 second; 150 % of rated current for

60 seconds.

P series: 120 % of rated current for 60 seconds; 105 % of rated current for

60 minutes.

Time

100% 100%

50% 50%

b21 b22

One minute

Output current (%)

One minute

Output current (%)

75 110

G series

150 60 105

P series

120


Setting range

Lower frequency - LF

Setting range

LF - HF

0.00 - UF

Factory default

Minimum unit

Factory default

Minimum unit

50.00

0.01 Hz

0. 50

0.01 Hz

Upper frequency (UF) is the highest allowable frequency when the converter works stably.

Lower frequency (LF) is the lowest allowable frequency when the converter works stably.

Output frequency

HF

UF

Forward rotation

LF

-HF

-LF

Reverse rotation

-UF

-HF

HF

Frequency command


86

Rexroth

Bosch Group


Rexroth Frequency Converter Fe b23 b24

LF mode

Setting range

Hysteresis frequency width

Setting range

0

1

0.10

-

HF

Factory default

Stop

Run

Factory default

Minimum unit

0

1.00

0.01 Hz

When the frequency command is lower than the set value of LF, the converter has two work modes:

If [b23]=0, the output frequency directly lowers down to 0.00 Hz; it is necessary to set hysteresis frequency width, to avoid possible frequent starting and stopping of the converter at frequencies around the LF.

If [b23] = 1, the converter works under the LF.

(1) [b23]=0

Output frequency

Lower

frequency

Frequency command

Magnetic hysteresis frequency

(2) [b23]=1

Output frequency

Lower

frequency

Frequency command

Rexroth

Bosch Group

87



11-24 Parameter Settings b25 b26 b27 b28 b29 b30

Gain of given channel

Setting range

0.00

-

9.99

Analog input channel filtering time constant

Setting range

0.0

-

10.0s

Minimum curve setting

Setting range

0.0

-

100.0 %

Frequency corresponding to minimum curve setting

Setting range

0.00 - 650.00 Hz

Maximum curve setting

Setting range

0.0

-

100.0 %


Setting range

0.00 - 650.00 Hz

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

1.00

0.01

0.5

0.1s

0.0

0.00

0.01 Hz

100.0

50.00

0.01 Hz

When VRC, +I, pulse frequency or operating panel potentiometer input is selected to give open loop frequency, the relationship between commanded value and set frequencies is illustrated below:

Frequency command Filtering [b26]

Gain [b25]

Calibration

[b27], [b28],

[b29], [b30]

Frequency setting

If analogue signals (0 - 5 V, 0 - 10 V, 4 - 20 mA, or operating panel

potentiometer 0 - 5 V) and pulse frequency are used to set the

frequency command value, the output frequency may be freely set by

changing [b25], [b27], [b28], [b29] and [b30].

[b26] defines the first order lag time constant, for first order lag filtering of analog input. The larger the time constant, more interference signals will be suppressed, but the lower the response will be. [b26] is also the filtering time constant of FB channel.

For command value of frequency after filtering and gain processing, their relationship with the frequency setting is determined by the curve defined with [b27], [b28], [b29] and [b30]. See the diagram below for details.

Frequency setting

[b30]

[b28]

[b27]

Analog input

[b29]


88

Rexroth

Bosch Group



Slip frequency compensation

Setting range

0.00

-

5.00 Hz

Factory default

Minimum unit

0.00

0.01 Hz

When the frequency converter is used to drive an asynchronous motor, the load and slip will be increased. The parameter is used to set the compensation frequency to reduce slip, allowing the motor to run under the rated current with a speed closer to the synchronous speed. The slip frequency compensation can be determined based on the loads.

Note:

Too large slip frequency compensation will cause the motor speed to exceed the synchronous speed. In this case:

Upper frequency = output frequency + K (slip compensation [b31])

K depends on the load current and is less than or equal 1.

Rated converter current

150%

100%

50%

After slip compensation

Motor speed

0

Note:

If slip frequency compensation is used, turn off drooping control of [H37] by

setting [H37]=0.00.

Starting frequency

Setting range

Starting holding time

Setting range

0.00

0.0

-

-

60.00 Hz

10.0s

Factory default

Minimum unit

Factory default

Minimum unit

0.50

0.01 Hz

0.0

0.1s

HF

[b32] starting frequency can be used to optimally adjust the starting torque in combination with torque compensation; however, a too large value may lead to a current trip.

[b33] refers to the duration of running at the starting frequency. If the running frequency is lower than the starting frequency, the motor will run at the starting frequency. After the starting holding time ends, the running frequency will be reached according to the deceleration time, to address the starting of systems with different inertia loads.

Output frequency

Stop

Starting

frequency

Rexroth

Bosch Group

Starting holding time

Time

89


Rexroth Frequency Converter Fe b34


Stopping mode selection

Setting range

3

4

1

2

Factory default

0

0

OFF

X1

X2

X3

ON

The motor may be stopped in two modes: deceleration to stop and coasting to stop.

[B34]=0: Deceleration to stop is selected while coasting to stop is turned off.

[B34]=1-3: Coasting to stop is achieved by closing external terminals

X1, X2 or X3, while deceleration to stop applies for other stopping commands.

[B34]=4: Coasting to stop is selected.

If the parameter [b34] is set to be 1-3 and if the selected terminal is closed, coasting to stop will be immediately activated and F.r.on is immediately displayed. If the external terminal is disconnected, the output will increase from 0.00 Hz to the set frequency. If a stop signal is given and the selected terminal is disconnected, the motor decelerates to stop.

If X1, X2 or X3 has already been defined by another function, [b34] will not show related value to avoid repeated definition for the same terminal.

Output frequency

Running signal

[b34]=4

Output frequency

Time

Running signal

-


Time

90

Rexroth

Bosch Group


Rexroth Frequency Converter Fe b36 b37 b38 b35

Jogging mode selection

Setting range

2

3

0

1

Jogging frequency

Setting range

0.00 - HF

Jogging acceleration time

Setting range 0.1 - 6500.0s

Jogging deceleration time

Setting range 0.1

-

6500.0s

Factory default

OFF

X1

X2

X3

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

0

0.00

0.01 Hz

0.1

0.1s

0.1

0.1s

[b35]=0: J ogg ing is disabled.

[b35]=1-3: For selection of terminals X1 - X3 as the input terminal for j ogg ing. The terminal is closed to be enabled. J ogg ing commands will only be executed when both j ogging

signal and running signal are valid.

No j ogg ing is allowed during programmable program running.

J ogg ing acceleration time [b37] is the time for increasing from 0.00 Hz to HF, and jogging deceleration time [b38] is time for decreasing from

HF to 0.00 Hz.

After the j ogg ing command is removed, if the jogging frequency is higher than the set frequency, the set frequency will be reached according to the jogging deceleration time.

After the jogging command is removed, if the jogging frequency is lower than the set frequency, the set frequency will be reached according to the normal acceleration time.

Rexroth

Bosch Group

91




Three common j

ogg

ing modes are illustrated below:

Frequency setting

Jogging frequency

Jogging acceleration

Normal acceleration

Normal acceleration

Time

Running signal

Jogging signal

Use j ogg ing to have faster frequency increasing

Highest frequency

Jogg ing frequency

Jogg ing acceleration time

Jogg ing deceleration time

Time

Running signal

Jogg ing signal

Jogg ing at running frequency of 0.00 Hz

Frequency

Running frequency

Jogging frequency

Jogg ing deceleration response time

Normal Acc time

Time

Running signal

Jogg ing signal

Jogg ing frequency lower than running frequency


92

Rexroth

Bosch Group


Rexroth Frequency Converter Fe b39

Function

Code b03 b04 b11 b21 b30

E11

E13

P33


Setting range

0

1

2

3

Factory default

4

0

All parameters are readable and rewritable.

All parameters are read-only except [b01] and [b39]

Initialization to factory defaults at 50 Hz

Initialization to factory defaults at 60 Hz

Clear all fault records

Note: Hold key for 2 seconds to change [b39] from 1 to 2, 3 or 4.

When [b39]=3 and initialization to factory default at 60 Hz is activated, related parameters are listed below.

Function


Base frequency - B

F

Middle frequency 2 - M

F2






Parameter range and eescription

50.00 - 650.00 Hz

20.00-HF

BF-HF

LF-HF

0.00 - 650.00 Hz

0.00 - 650.00 Hz

0.00 - 650.00 Hz

0.00 - HF

Factory default at 60 Hz

60.00

60.00

60.00

60.00

60.00

60.00

30.00

60.00

b40


Setting range

380.0 V - 480.0 V

Factory default

Minimum unit

380.0

0.1 V

P arameter [b40] has to be set according to the power supply voltage.

b41


0

Setting range

1

2

3

Factory default 1

Not saved when power is off or the converter is stopped

Not saved when power is off; saved when the converter is stopped

Saved when power is off; not saved when the converter is stopped

Saved when power is off or the converter is stopped

If [b00]=0-2 and [b02]=0 and if [b41]=1 or 2 or 3 the current frequency will be saved in [b01] before the system power is switched off or the converter is stopped, and will be restored from [b01] automatically when the system power is switched on again.

Rexroth

Bosch Group

93


Rexroth Frequency Converter Fe 11-30 Parameter Settings b 42 b 43 b44


Setting range


Setting range

Changing rate of

Up/Down

Setting range

Factory default

0

0

No output

1

Output DC voltage as per [b43] as holding torque

2 Output DC voltage as per V/F curve

Factory default

5.0

0.0 - 20.0 %BV

0.01

0.01 - 99.99 Hz / s

The changing rate of the output frequency can be adjusted by the external control terminals or the button

Up/Down

on the panel.


94

Rexroth

Bosch Group



Notes

on Extended Function Group (group E)

E00

E01

E02

E03

Skip frequency 1

Setting range

Skip frequency2

Setting range

0.00 - HF

0.00 - HF

Skip frequency3

Setting range 0.00 - HF

Skip frequency range

Setting range

0.00 - 10.00 Hz

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

0.00

0.01 Hz

0.00

0.01 Hz

0.00

0.01 Hz

0.00

0.01 Hz

Th e function is used to avoid mechanical vibration (noise) and resonance of loads.

Three skip frequencies may be set within the range of 0.00 Hz - HF.

If no skip frequency is used, set the skip frequency parameters to be

0.00 Hz.

The function is invalid during acceleration and deceleration (the function is only available for steady state output).

The function is available for the frequency giving channels selected by

[b02].

Frequency output

[E02]

[E01]

[E00]

Frequency command

[E03]

[E03]

Actual forbidden output frequency range

Forbidden output frequency

Rexroth

Bosch Group

95




E04

E05

E06

E07

FM1 selection

Setting range

FM1 gain setting

Setting range

FM2 selection

Setting range

FM2 gain setting

Setting range

Factory default

0

1

2

3

Factory default

0.50 - 1.20

Factory default

0

1

2

3

Factory setting

0.5 - 1.20

0

Output frequency

Output voltage

Output current

PI feedback signal

1.00

1

Output frequency

Output voltage

Output current

PI feedback signal

1.00

control panel control panel

FM1 FM2

1 2 3

JP4

GND

20 mA 10 V

1 2 3

JP3

GND

A DC ammeter (0 to 20 mA) or a DC voltmeter (0 to 10 V) may be connected between FM1/FM2 and GND terminal to monitor the frequency, output voltage or output current of the converter.

When Jp3 is in position 2-3, the output of FM2 is 0 to 10 V; connect a voltmeter or frequency meter with a full range of 10 V and a resistance of larger than 10 k .

When JP4 is in position 1-2, the output of FM1 is 0 to 20mA; connect an ammeter or frequency meter with a full range of 20 mA.

[E04]=0: Frequency is output; when the highest frequency is reached, the FM1 terminal outputs 20 mA or 10 V;

[E04]=1: Voltage is output; when the AC 500 V is reached, the FM1 terminal outputs 20 mA or 10 V;

[E04]=2: Current is output; when the output is 2 times the rated current, the FM1 terminal outputs 20 mA or 10 V;

[E04]=3: PI feedback signal.

[E05] is used to adjust the gain of FM1.

The output and gain of FM2 are selected by [E06] and [E07] respectively.


96

Rexroth

Bosch Group



E08

E09

FM channel mode

Setting range

Pulse output selection

Setting range

Factory default

0

1

2

3

Factory default

0

1

2

0

FM1 outputs 0 - 20 mA or 0 - 10 V








2

Output frequency

Output voltage

Output current

DO pulse frequency output range: 0

-

[E10].

[E09] =0 Frequency is outputted; when the highest frequency is reached, the DO terminal outputs [E10] kHz.

[E09] =1 Voltage is outputted; when 500 V is reached, the DO terminal outputs [E10] kHz.

[E09] =2 Current is outputted; when rated current is reached, the DO terminal outputs ([E10]/2) kHz.

Rexroth

Bosch Group

97




E10

E11

E12

E13

E14

E15

Maximum output pulse frequency

Setting range

0.1 - 50.0 kHz


Setting range

0.00 - 650.00 Hz


Setting range

0.00 - 650.00 Hz


Setting range

0.00 - 650.00 Hz


Setting range

0.00 - 650.00 Hz


Setting range

0.00 - 650.00 Hz

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

10.00

0.01 kHz

50.00

0.01 Hz

1.00

0.01 Hz

25.00

0.01 Hz

1.00

0.01 Hz

2.00

0.01 Hz

After the output frequency exceeds the frequency set by [E11], the digital output “f requency level detection ” active until the output frequency is lower than set in [E11] minus [E12].

After the output frequency exceeds the frequency set by [E13], the digital output “f requency level detection signal 2 (FDT2 )” becomes active until the output frequency is lower than set in [E13] minus [E14].

Output frequency

Frequency level detection

FDT1/2 Lagging frequency

Frequency level detection signal

FDT1/2

Output frequency

Time

Time

Frequency setting


Time

Frequency arrival signal (FAR)

Time

When the output frequency is within the set frequency [E15], the digital output frequency arrival signal (FAR) is active.


98

Rexroth

Bosch Group



E16

Open collector output

OUT1

Setting range

E17

E18

Open collector output

OUT2

Relay Ry output selection

Setting range

14

15

16

17

10

11

12

13

6

7

8

9

4

5

2

3

0

1

22

23

24

25

18

19

20

21

Running

Frequency level detection signal 1 ( FDT1)

Frequency level detection signal 2 ( FDT2)

Frequency arrival signal ( FAR)

Reserved

Under voltage

Over load

Reserved

Zero speed(lower than starting frequency)

E-Stop

Lower voltage

No trip action

Fault

Programable program running

Programable program run

Run for one stage

Over current stall

Over voltage stall

In forward rotation command indication

In reverse rotation command indication

Zero speed (incl. stop)

Being braked

Accelerating

Decelerating

Fan action

Reserved

Factory default

Factory default

Factory default

6

0

12

Open collector output terminal wiring examples

control panel control panel

Rexroth

Bosch Group

a b

Note 1:

Open collector output terminals OUT1 and OUT2 may use the internal +24 V power supply of the converter, and the wiring is illustrated in diagram a.

Note 2:

Open collector output terminals OUT1 and OUT2 may also use the external power supply, and the wiring is illustrated in diagram b.

99




Relay output Ry output wiring example

Multifunction indication output terminals

AC 250 V / 3 A

DC 30 V / 3 A

(N.O)

Ta

Fault indication

BZ

(N.C)

Tc Power indication

LT

Tb

AC/DC

Power supply

Detailed notes on [E16], [E17] and [E18] settings:

0: Running

When the converter has output frequency, OUT or Ry activates.

1: Frequency level detection signal 1 (FDT1)

When the output frequency of the converter exceeds [E11], OUT or Ry activates until the output frequency is lower than [E11] minus [E12].

2: Frequency level detection signal 2 (FDT2)

When the output frequency of the converter exceeds [E13], OUT or Ry activates until the output frequency is lower than [E13] minus [E14].

3: Frequency arrival signal (FAR)

When the output frequency is within the set frequency ±[E 15], OUT or

Ry activates.

4: Reserved.

5: Under voltage

When the converter detects that the input voltage is too low (P.OFF),

OUT or Ry activates.

6: Overload

When the converter detects an overload, OUT or Ry activates.

7: Reserved.

8: Zero speed (lower than starting frequency)

When the output frequency of the converter is lower than the set frequency of starting [b32], OUT or Ry activates.

9: E-Stop

When an external abnormal command is sent to E-Stop and [E32]=0 and [E34]=1, OUT or Ry activates.

When the converter detects that the DC bus voltage is lower than 90 % of the rated voltage, OUT or Ry activates.

11: No trip action

When the converter has no trip control action, OUT or Ry activates.


100

Rexroth

Bosch Group

1



12: Fault

When the converter detects fault, OUT or Ry activates.

13: Programmable program running

When the Internal PLC control is being automatically run ([b00]=3),


14: Programmable program run

When the Internal PLC control has been automatically run ([b00]=3) for all stages, OUT or Ry activates.

15: Run for one stage

When the Internal PLC control is being automatically run ([b00]=3) for all stages, OUT or Ry activates for 0.5 second for every stage.

16: Over current stall

When the converter is in the state of stall over current protection or acceleration stall over current protection, OUT or Ry activates, the related parameters are [E19] and [E20].

17: Over voltage stall

When the converter is in the state of stall over voltage protection, OUT or Ry activates, the related parameter is [H34].

18: In forward rotation command indication

When the converter is rotating forward, OUT or Ry activates.

19: In reverse rotation command indication

When the converter is rotating reverse, OUT or Ry activates.

20: Zero speed (incl. stop)

When the output frequency of the converter is lower than the set frequency of starting [b32] or when the frequency converter is stopped,


21: Being braked

When the converter is in the state of DC braking, OUT or Ry activates.

22: Accelerating

When the output frequency of the converter is increasing, OUT or Ry activates.

23: Decelerating

When the output frequency of the converter is decreasing, OUT or Ry activates.

When the cooling fan of the converter is working, OUT or Ry activates.

25: Reserved.

Rexroth

Bosch Group

101



E19

Stall over current protection level during running

50 % - 200 % of rated current

Setting range

OFF

Factory default OFF

The stallover current protection level during running may be set between 50 % and 200 % of rated converter current. If the setting is

OFF, the stall over current protection is turned off.

The diagram below shows that during running at the set frequency, the output frequency is automatically decreased once the current exceeds

[E19], to reduce the output current below the stall over current level.

Output frequency

Time

Output current

[E19]

Time

E20

Stall over current protection level during acceleration

50 % - 200 % of rated current

Setting range

OFF

Factory default OFF

The stall over current protection level [E20] during acceleration may be set between 50 % and 200 % of rated converter current. If the setting is

OFF, the stall over current protection during acceleration is turned off.

As shown in the diagram below, the frequency increase will be stopped when the output current is larger than the stall over current protection level [E20] during the acceleration, the acceleration will be resumed once the current is lower than [E20], to avoid over current due to stall. This function will lead to a longer acceleration time than programmed.

Output frequency

Time

Output current

[E20]

Time


102

Rexroth

Bosch Group



E21

E22

E23

Note:

The stall over current protection function may only be used when the no trip control function is turned off ([H33]=OFF). If no trip control is used

([H33]=ON), set [E19]=OFF and [E20]=OFF.

Setting range

Display factor A

Setting range

Display factor B

Setting range

The first use of display factor A and display factor B is to convert the output frequency of converter to a physical quantity and display it on the digital operating panel.

In group d of the digital operating panel, “oUtF”=output frequency *A+B,

“SEtF”= set frequency *A+B

If [E22] and [E23] are as default,

“o

Ut

F” a n d “S

Et

F” d isplay the actual output frequency and set frequency.

The second use of display factor A and display factor B is to calibrate the given and the feedback quantity value, when the motor is controlled with the PI closed loop function.

Display factor A [E22] = Maximum analog given or feedback value (e.g.:

5 V) corresponding to the physical engineering application.

Display factor B [E23] = Minimum analog given or feedback value (e.g.:

0 V) corresponding to the physical engineering application.

Engineering value

Factory default

0

1

Display output frequency

Display set frequency

2 Display output current

3

4

Display output voltage

Display DC bus voltage

5

Display input signal

6

Display radiator temperature

Factory default

1.0

-99.9 - 6000.0

Factory default

0.0

-99.9 - 6000.0

0

[E22]A

[E23]B

0%

Rexroth

Bosch Group

HF(100%)

Analog signal of frequency and PI control giving

103



E24


The PI adjustment function of the converter detects the sensor feedback of the control subject and compares it with the given value. If deviation exists, use the PI adjustment to reduce the deviation up to 0.

This function is suitable for control of flow, pressure, temperature, speed of rotation, etc.

Given value

P drive unit control subject

I feedback

HF

0%

Output frequency

D ire

Inve ct ac tio n rs e a cti on

PI output

100%

PI adjustment selection

Setting range

0

1

2

Factory default

No PI

Direct action

Inverse action

0

[E22]A

[E23]B

0%

Direct action or inverse action may be selected for PI adjustment output, therefore PI adjustment output can increase or decrease motor speed.

Display engineering value

Feedback value

100%

Feedback value of given value

100%

0%

0 V

4 mA

Dir ec t ac tio n

In ve rs e a cti on

Feedback input

5 V

20 mA


104

Rexroth

Bosch Group



E26

E27

E28

E25

Setting range

Proportional gain

Setting range

Integration time constant

Setting range

Sampling period

Setting range

0

1

2

3

4

5

Factory default

0

Control terminal FB direct action (voltage input 0 - 5 V)

Control terminal FB Inverse action (voltage input 5 - 0 V)

Control terminal +I direct action(current input 4 - 20 mA)

Control terminal +I inverse action (current input 20 - 4 mA)

Single phase pulse feedback

Orthogonal pulse feedback

Factory default

0.01 - 99.99 times

Factory default

0.1 - 60.0s

Factory default

0.1 - 60.0s

10.00

1.0

0.1

Note:

If [E25]=4 or if [E25]=5, the upper limit of input pulse frequency range is 200 kHz.

[E25]=0, 1 control panel

FB

GND

0-5V feedback

[E25]=2, 3

C control panel

+I

GND

4-20mA feedback

[E25]=4 control panel

PGP

1 2 3

A-

JP2

COM

Single phase pulse feedback

[E25]=5 control panel PGP

A-

B-

1 2 3

JP2

COM

Orthogonal pulse feedback

Note:

Orthogonal pulse encoder has two modes. The diagrams above correspond to the open collector output type (JP2 in position 1-2). The diagram below shows the encoder PG as differential output type (JP2 in position 2-3). In this case make the wiring as shown below.

Rexroth

Bosch Group

105




[E25]=5 differential output type encoder Va

0V

A+

A-

B+

Bcontrol panel

PGP

COM

A+

A-

1 2 3

JP2

B+

B-

Setting range of proportional gain [E26]: 0.01 - 99.99 times

A larger proportional gain means faster response; however, a too large proportional gain may cause oscillation. A smaller proportional gain means slower response.

Setting range of integration time constant [E27]: 0.1 - 60.0s

A larger integration time constant means slower response, and the reaction to external disturbance is slowed, with better stability. A smaller integration time constant means faster response; however, a too small integration time constant may cause oscillation.

Proportional adjustment is based on deviation. Generally, PI adjustment is used to eliminate steady state deviation in a closed loop system. For

PI adjustment, if the integration time constant is too large, the response will be slow for fast changing deviation. P adjustment alone may be used for load systems with integrating elements.

Simple method of PI parameter adjustment:

[E26] (P) Increase the value if no oscillation occurs.

[E27] (I) Decrease the value if no oscillation occurs.

[E28] is the sampling period of closed loop adjustment, with a range of

0.1 to 60.0s, and depends on the time constant (inertia) of control subjects.


106

Rexroth

Bosch Group



E29

E30

PI adjustment upper factor

Setting range

PI adjustment lower factor

Setting range

Factory default

1 - 100/OFF

Factory default

1 - 100

OFF

0

[E29] is used to set the PI adjustment upper factor of closed loop system;

[E30] is used to set the PI adjustment lower factor of closed loop system.

During PI adjustment, as shown in the diagram, when the feedback quantity is larger than the feedback upper limit (time t1), PI is deactivated and the output frequency is decreased to the lower frequency ([b23]=1) or 0.00 Hz ([b23]=0) according to the deceleration time; when the feedback quantity is smaller than the feedback lower limit (time t2), PI is reactivated.

Feedback upper limit = [E22] [E29]/100)

Feedback lower limit = [E22] ([E30]/100)

Pressure

Feedback upper limit

Set value

Feedback lower limit

E31

t1 t2

Time

PI adjustment upper and lower limit frequency

Maximum input pulse frequency

Setting range 1.0 kHz - 200.0 kHz

Factory default

Minimum unit

20.0

0.1 kHz

When [b02]=11, the function code gives the external input pulse frequency ( 200.0 kHz) corresponding to [b30].

When [b02] 11, and [E24] 0, [E25]=4 or 5 (under PI control), the function code gives the feedback pulse frequency corresponding to the maximum set engineering quantity.

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E32

E33

E34


Setting range

0

1

Stop modes in the case of external abnormality

Setting range

0

1

Stop alarm modes in the case of external abnormality

Setting range

0

1

Factory default

0

Stopping due to connected E-Stop/SC

Stopping due to disconnected E-Stop/SC

Factory default

0

Coasting to stop

Deceleration to stop

1

Factory default

No alarm output

Alarm output

[E33]=0: Coasting to stop. Alarm output is allowed.

[E34]=0: No alarm output. While E-Stop input is activated, it can be used in combination with “b rake ” and other mechanical drive devices.

“E.-S t ” indication will disappear after a short time.

[E34]=1: Alarm output confirms stopping with external abnormal command.

“E.-

St

”

indication remains, until fault retry or fault reset with

Stop key, before the converter is put into service again. OUT/Ry may output alarm signal by selecting [E16], [E17] or [E18]=9.

[E33]=1: Deceleration to stop. Alarm output is not allowed.

“E.

-St

”

will not be displayed. The alarm output is not allowed and invalid even if [E34]=1.

IMPORTANT:

Without additional measures the “E -Stop ” command does not provide an “E mergency Stop ” . There is neither an electrical isolation between motor and frequency converter nor a

“s ervice switch

” or a

“re pair switch ”. An “E mergency Stop ” r equires an electrical isolation, e.g. by means of a central mains contactor!

E35

E36

Low voltage protection mode

Setting range

Setting range

0

1

1

2

Factory default

0

Factory default

2

Coasting to stop

Deceleration to stop

Resume with previous speed

0

No alarm output

Alarm output

Low voltage protection is a countermeasure against a fault where the power supply voltage is 10 % lower than the rated voltage, in this case the motor will act according to [E35].

Under voltage protection means that when the power supply voltage is

20 % lower than the rated voltage, the converter immediately blocks output to make the motor coast to stop and displays P.oFF.

If [E36]=1, the alarm state remains until the power supply voltage increases to 90 % of the rated voltage.

OUT1, OUT2 or Ry may output alarm signal by selecting [E16], [E17] or

[E18]=5.


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E37

E38

Converter automatically starts after powering on

Setting range

Factory default

0

1

0

Forbidden

Allowed

When the running control of digital operating panel is used ([b00]=0 or

3), and no stop signal exists, in the case of [E37]=1, the converter will automatically start without Run key being pressed down after powering on; in the case of [E37]=0, the converter only starts after Run key is pressed down.

When another source of running commands is selected, in the case of

[E37] 1, the converter will automatically start after powering on, if a running command (e.g. connected SF/SC) exists; in the case of

[E37]=0, the converter will remain static, even if a running command exists. To start the converter, cancel and reissue the running command

(e.g. disconnecting and reconnecting SF/SC).


Setting range

Factory default

0

0

1

Forward/reverse mode

Run/stop, forward/reverse mode

2 Key control holding mode.

[E38] terminal function is only activated when [b00]=1 or 2 or 4.

In the following the function of [E38] is explained, assuming the NPN/PNP switch in position 3 (internal NPN)

SC

SF/SC connected: Forward rotation forward/stop

SF/SC and SR/SC connected or disconnected simultaneously: Stop

SR

R reverse/stop

R reverse/forward

SF/SC disconnected: Stop

SF

SR/SC connected: Reverse rotation

SR/SC disconnected: Forward rotation

SR

R run/stop

[E38]=2: Key control holding mode f forward

[E39] is used to select X1, X2 or X3

SF

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X1-X3

X1-X3/SC disconnected: Stop

If the reverse key is pressed when the converter is rotating forward, the motor will decelerate to zero to stop before reversing its rotation to the set frequency.

109




E39


0

Setting range

1

2

3

OFF

X1 is a self-holding stop terminal

Factory default



0

If [E38]=2, terminal X selected with [E39] and SF and SR key input have self-holding function.

[E39]=0: Self-holding not activated.

E40

E41

E42


0

Factory default

Input phase loss protection disabled

Setting range

1

Input phase loss protection enabled

1

If [E40]=0, the protection is disabled; if [E40]=1, the protection will act as the converter stops output and the motor coasts to stop.

Important note: The function is invalid for Frequency Converter Fe up to 7.5 kW.


0

Factory default

Output phase loss protection disabled

Setting range

1

Output phase loss protection enabled

1

If [E41]=0, the protection is disabled; if [E41]=1, the protection will act as the converter stops output and the motor coasts to stop.

Fault retry options

0

Setting range

7

8

5

6

3

4

1

2

9

10

11

12

13

14

Factory default

Fault retry disabled

Retry from over current at constant speed

Retry from over current during acceleration

Retry from over current during deceleration

Retry from over voltage at constant speed

Retry from over voltage during acceleration

Retry from over voltage during deceleration

Retry from overload

Retry from overheat

Retry from drive protection

Retry from EMI

Retry from input phase loss

Retry from output phase loss

Retry from stop after response to internal abnormality command

Retry from any fault

0


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E43

E44

E45

E46

E47

E48

Waiting time for fault retry

Setting range

Number of fault retries

2.0 - 60.0s

Setting range

0 - 3

Current fault record

Last fault record



0: No fault record

1: O.C.-1, over current at constant speed

2: O.C.-2, over current during acceleration

3: O.C.-3, over current during deceleration

4: O.E.-1, over voltage at constant speed

5: O.E.-2, over voltage during acceleration

6: O.E.-3, over voltage during deceleration

7: O.L., Overload;

8: O.H., overheat

9: d.r., drive protection;

10: CPU-, EMI

11: IPH.L., input phase loss

12: oPH.L., output phase loss

13: E.-St., stopping by external abnormality command

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Factory default

Factory default

Factory default

10.0

0.1s

0

1

0

0

0

0

[E43] is the waiting time for the converter to automatically resume running after a fault, while [E42] has been activated ([E42] 0).

[E44] is the allowed number of attempts to resume running after powering on of converter.

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111 DOK-RCON01-FE*********-IB05-EN-P



Notes on Programmable Control Function Group (group P)

This function group will be used in the case of internal PLC control running and multi-speed running with external terminals.

P00

PLC working mode

Setting range

Factory default

Stop after one cycle

Cycle operation

Running at the last frequency after one cycle

0

0

1

2

[P00] setting is only activated when [b00]=3, that means when internal PLC control has been activated.


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P19

P24

P29

P34

P01

P04

P09

P14

P18

P23

P28

P33

P03

P08

P13


Setting range 0.00 Hz - HF











Speed

Step7 frequency setting


Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

5.00

0.01 Hz

10.00

0.01 Hz

20.00

0.01 Hz

30.00

0.01 Hz

40.00

0.01 Hz

50.00

0.01 Hz

50.00

0.01 Hz

These are settings of the running frequency for speeds 1 to 7.

The frequency command for speed 0 depends on two different multispeed modes:

If [b00]=2 (multi-speed external terminal control), the source for speed

0 is given by [b02].

If [b00]=3 (internal PLC control), speed 0 is directly given by [b01].

The acceleration and the deceleration time of speed 0 are still determined by [b16] and [b17].


Setting range


Setting range


Setting range


Setting range

Factory default

SF: Forward, SR: Reverse

Factory default


Factory default


Factory default


SF

SF

SF

SF


Setting range


Setting range


Setting range


Setting range

Factory default


Factory default


Factory default


Factory default


Speeds 0-7 running direction is activated when [b00]=3

(internal PLC control).

SF

SF

SF

SF

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P25

P30

P35

P02

P05

P10

P15

P20

P26

P31

P36

P06

P11

P16

P21


Setting range

Setting range

Setting range

Setting range

Setting range

Setting range

Setting range

Setting range

Factory default

OFF/1-65000s

Factory default

OFF/1-65000s

Factory default

OFF/1-65000s

Factory default

OFF/1-65000s

Factory default

OFF/1-65000s

Factory default

OFF/1-65000s

Factory default

OFF/1-65000s

Factory default

OFF/1-65000s

OFF

1s

OFF

1s

OFF

1s

OFF

1s

OFF

1s

OFF

1s

OFF

1s

OFF

1s

Speeds 0-7 holding time is activated when [b00]=3

(internal PLC control).

Speeds 0-7 holding time is the time for running after reaching the set speed. OFF indicates the motor will not run at the corresponding speed.


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

10.0

0.1s

10.0

0.1s

10.0

0.1s

10.0

0.1s

10.0

0.1s

10.0

0.1s

10.0

0.1s

Speed 1-7 acceleration time:

If [b00]=2, (multi-speed external terminal control), it is the time from

0.00 Hz to HF.

If [b00]=3, (internal PLC control), it is the time from the former speed to the current speed.


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P27

P32

P37

P07

P12

P17

P22


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s


Setting range

0.1 - 6500.0s

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

Factory default

Minimum unit

10.0

0.1s

10.0

0.1s

10.0

0.1s

10.0

0.1s

10.0

0.1s

10.0

0.1s

10.0

0.1s

Speed 1-7 deceleration time:

If [b00]=2 (multi-speed external terminal control), it is the time from HF to

0.00 Hz.

If [b00]=3, (internal PLC control), it is the time from the former speed to the current speed.

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Example of internal PLC control ([b00]=3):

The converter is required to run according to the curve shown in the diagram,

[P00]=0 should be set. The speeds include speed 1, 3 and 4. The running parameters are given in the table below. For speeds without internal PLC control, the holding time is set to be OFF, i.e.

[P02]=[P10]=[P25]=[P30]=[P35]=OFF.

The deceleration time of each speed phase is decided by [b17].

Forward rotation frequency (Hz)

[P13]=10

[P03]=5

[P06]

[P16]

[P05]

[P15]

[P17]

End

Time

[P18]=10

2.0s

1.0s

0.5s

2.0s

3.0s

[P21]

3.0s

[P20]

3.0s

[P22]

2.0s

Note:

The diagram does not show the effect of the forward and reverse rotation

dead zone time. Please refer to the following table for speeds 1, 3 and 4 with

internal PLC control:

P16

P17

P18

P19

P20

P21

P22

Function code Parameter set value

P03

P04

5.00

SF: Forward

P05

P06

P13

P14

P15

1.0

2.0

10.00

SF: Forward

2.0

-s s

Hz

-s

Unit

Hz

0.5

3.0

10.00

SR: Reverse

3.0

3.0

2.0

s s s s s

Hz

--


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Example of Multi-

speed under external terminal control ( [b00] 2)

X3, X2 and X1 binary combination speed table (X closed indicates 1)

Speed

Frequency setting

X3-SC

X2-SC

X1-SC

0

0

0

[b02]

0

0

0

1

[P03]

1

0

1

2

[P08]

0

0

1

3

[P13]

1

1

0

4

[P18]

0

1

0

5

[P23]

1

1

1

6

[P28]

0

1

1

7

[P33]

1

[E38]=0

C control panel

SF

X3

X2

X1

SC

The following examples are explained according to the NPN/ PNP switch in position 3 (internal NPN)

Example 1: 8-speed forward rotation cycle operation.

[P33]

[P28]

[P23]

[P18]

[P13]

[P08]

[P03]

[B02]

SF

X3

X2

X1

Frequency

[b17]

Time

[E38]=1

C control panel

SF

SR

X2

X1

SC

Example 2: 2-speed forward/reverse rotation cyclic operation.

[P08]

0

Frequency

Time

[P13]

SF

X2

X1(SR)

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Notes on Advanced Function Group (group H)

H00

PWM frequency

Setting range

1 - 15 kHz (range depends on frequency converter rated power)

Factory default

Minimum unit

Depending on model

1 kHz

The function is used to set the PWM frequency output.

Note:

the setting range depends on frequency converter rated power. See the table below.

[H00]: Setting range and factory default

Frequency converter power range

0.75 - 7.5 kW

11 - 22 kW

30 - 45 kW

55 - 110 kW

PWM frequency setting range

1 - 15 kHz

1 - 8 kHz

1 - 6 kHz

1 - 4 kHz

Factory default

6 kHz

6 kHz

3 kHz

2 kHz

Note:

1) adjustable in 1 kHz steps

2) The PWM frequency at output frequency below 4 kHz is always

limited to 4 kHz to protect the converter.

H01

Automatic adjustment of PWM frequency

Setting range

Factory default

OFF/ON

ON

When the function is enabled, the frequency converter can automatically adjust PWM frequency based on machine temperature.


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H02

Delay for restarting after transient stopping

Setting range

Factory default

OFF

0.1 - 20.0s

Minimum unit

OFF

0.1s

Restarting after a transient stopping allows the motor to restart smoothly by estimating the rotating speed of the motor.

If there is a run command signal when powering on after a transient stop, the motor may be instantaneously stopped before restarting.

The delay time may be between 0.1 to 20.0 seconds.

Th e function is disabled, if the parameter is set to be OFF.

[E35] should be set to 2 (for running at the current speed) to enable restarting after transient stopping due to low voltage protection mode.

Power supply

Running command

Motor speed

Output frequency

H05

H06

H07

H03

H04

Delay time Deceleration resynchronization

Reserved

DC braking time

Setting range

OFF

0.1 - 10.0s


Factory default

Minimum unit

Factory default

Setting range

DC braking voltage

0.00 - 60.00 Hz Minimum unit

Factory default

Setting range 1 - 15 % of rated voltage

DC braking holding options Factory default

Setting range

2

3

0

1

4

OFF

X1

X2

X3

ON

OFF

0.1s

3.00

0.01 Hz

10

0

DC braking allows the frequency converter to achieve fast and stable stopping, it is defined by [H04]-[H07].

If [H04]=OFF, DC braking is disabled during deceleration to stop, then

[H05], [H06] and [H07] settings has no meaning.

If [H07]=0, no DC braking voltage will be applied after the motor is stopped, dc.on is displayed during DC braking.

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If [H07]=1-3, DC braking voltage will be applied when X1-X3 are closed under stopping state, dc.on is displayed during DC braking. If any of

X1-X3 is occupied by other functions, no related indication will be shown.

If [H07]=4, DC braking voltage remains under stopping state, but dc.on is not displayed. If a run signal is applied during DC braking, DC braking will be interrupted and running will start.

Output frequency

[H05]


Time

Output frequency

[H06]

Indicates DC braking voltage

(1 - 15 % )

[H05]

DC braking

initial frequency

Time

Operation signal

[H04]

[H07]=0 diagram

Output frequency oFF

[H06] indicates applied

DC braking voltage

(1 - 15 %)

[H05] DC braking initial frequency

Time

Running signal

X1-SC DC braking signal

[H07]=1 diagram

Output frequency

[H05] DC braking initial frequency

Running signal

[H07]=4 diagram


[H06] indicates applied

DC braking voltage

Time

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H08

H09

H10

Communication protocol selection

Setting range

Local address

Setting range

Baud rate selection

Setting range

2

3

0

1

4

5

Factory default

0

1

Factory setting

0

ModBus

PROFIBUS

1

ModBus: 1 - 247 PROFIBUS: 1 - 126

Factory default

1200 bps

2400 bps

4800 bps

9600 bps

19200 bps

38400 bps

3

If [H08 ]=0, [H09] defines the local address for ModBus serial communication, and one external computer may be connected to a maximum of 247 frequency converters. If [H08]=1, [H09] defines the local address for PROFIBUS communication, and one external computer or control device may be connected to a maximum of 126 frequency converters.

ModBus (PROFIBUS)

External computer

H11

H12

H13

Fe

# 1

(# 1)

Fe

# 2

(# 2)

Fe

# 24 7 ModBus

(# 126)

(PROFIBUS)

H10] defines the baud rate of communication.

Important: The baud rate [H10] must be identical to the rate of the external computer.

In case of PROFIBUS communication, the baud rate of the converter must be identical to the PROFIBUS communication interface.

Data format

Factory default

0

0 N, 8, 2 (1 start bit, 8 data bits, 2 stop bits, without check)

Setting range

1

2

E, 8, 1 (1 start bit, 8 data bits, 1 stop bit, even)

O, 8, 1 (1 start bit, 8 data bits, 1 stop bit, odd)

Communication disruption action

Factory default 0

Setting range

Communication disruption detection time

Setting range

0

1

Factory default

Stop

Keep running

0.0

0: (ineffective); 0.1 - 60.0s

[If the frequency converter does not receive valid massages from the external control system within the in [H13] defined time, the converter assumes a communication disruption and reacts according to parameter

[H12].

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H14

H15

H16

H17

H18

H19

H20

H21

H22

H23

H24

H25

H26

H27

H28

H29

PZD3 Settings

PZD4 Settings

PZD5 Settings

PZD6 Settings

PZD7 Settings

PZD8 Settings

PZD9 Settings

PZD10 Settings

Setting range

5

6

3

4

7

0

1

2

Output frequency

Frequency setting

Output current

Output voltage

Bus voltage

Switch value input signal

Module temperature

PI control feedback value

The parameters [H14] to [H21] can be used to set the register values for converter state feedback.

Factory default

0

1

0

Auto control

No control

0

1

2

3

4

5

6

7

[H22]=0: The fan keeps rotating while the converter is working.

The fan automatically starts internal temperature detection 3 minutes after the converter stopped and then decides whether to continue or to stop based on the module temperature.

[H22]=1: No control. The fan starts when the converter is powered on.

Energy saving mode

Setting range

Setting range

0.0 - 5.0s

Voltage gain for energy saving under external terminal control

Factory default

2

3

0

1

4

Factory default

Minimum unit

0

Disabled

X1

X2

X3

Automatic energy saving

2.0

0.1s

Factory default

80

Setting range

Energy saving initial frequency

Setting range

Automatic energy saving control gain

50 - 100 %

0.00 - 650.00 Hz

Setting range

Automatic energy saving time constant

0.0 - 10.0

Setting range

0.0 - 10.00

Automatic energy saving rated percentage slip

Setting range

0.1 - 50.0 %

Factory default

Factory default

Factory default

Factory default

0.00

0.5

1.00

5.0

Energy saving control is beneficial especially in circumstances where light loads are encountered.


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Running command

Energy saving

command

X terminal designated by [H23]=1, 2 or 3

Output frequency

F ref

[H26]

Output voltage

[H24]

Energy saving voltage gain [H25] of voltage X determined by V/F curve

[H23]=1, 2 or 3: X1, X2 or X3 as the input terminal for energy saving command

If the energy saving command is activated and if the output frequency is larger than the starting frequency for energy saving set by [H26], the output voltage of the converter will decrease from the previous V/F curve value to the previous V/F curve value multiplied with the energy saving gain [H25]. The output voltage decreasing time and resumption time are set by [H24].

[H23]=4: Automatic energy saving

In contrast to the energy saving with external terminals, the automatic energy saving method will search the motor voltage with the highest degree of energy saving (for frequencies bigger than set by parameter

[H26]).

For automatic energy saving parameter [H27] defines the voltage range for every adjustment; [H28] defines the time interval between two voltage adjustments and can be changed based on the motor capacity and the application to achieve fast and stable control for energy saving.

[H29] is the maximum allowable decrease of speed due to voltage decrease for automatic energy saving.

When the motor load increases, the voltage of the motor resumes from the energy saving mode to the V/F curve value according to [H24].

H30

Auto matic current limitation level

Setting range

Factory default 150

[H30] defines the threshold current of the automatic current limitation.

The set value is a percentage of the rated converter current.

The automatic current limitation function is used to limit the load current up to the in parameter [H30] set value. This way a tripping of the frequency converter can be avoided. The function is useful for loads with large inertia or in case of big load changes.

If [H30]=OFF, the function is disabled.

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H31

Current regulator proportion factor

Setting range

Factory default

0.001 - 1.000

0.060

The higher the set value of [H31] the faster the current suppression will be; but if [H31] is set too high this may result in operation of anti-trip control.

H32

Current regulator integrating time constant

Setting range

Factory default

0.001 - 10.00

0.200

Larger [H32] means less accuracy of current suppression (compared with current threshold). And vice versa, however, a too small value may lead to incorrect operation of anti-trip control.

H33

Automatic current limitation at constant speed

Setting range

Factory default

OFF/ON

ON

[H33]= ON; automatic current limitation is enabled at constant speed.

[H33]= OFF; automatic current limitation is disabled at constant speed.

Parameter [H33] does not affect the automatic current limitation during acceleration and deceleration.

H34

Stall over voltage selection

Setting range

400 V model: 710 - 800 V/OFF

Factory default

Minimum unit

OFF

1 V

Stall over voltage protection detects the DC bus voltage during the deceleration of the frequency converter and compares the voltage with the stall over voltage point set by [H34].

If the voltage exceeds the stall over voltage point, the output frequency of the frequency converter stops to decrease and deceleration will only be resumed after the detected DC bus voltage is lower than the stall over voltage point, as shown in the diagram.

DC voltage

[H34]

Time

Time

Note:

if [H34]=OFF, stall overvoltage protection is disabled.


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H35

Software over voltage protection point

Setting range

790 - 820 V

Factory default

810

When the DC bus voltage of the main circuit of the frequency converter raises to the over voltage point or software over voltage protection point, over voltage fault will be reported and the frequency converter will immediately stop output and running.

H36

Deceleration braking activation voltage threshold

Setting range

600 - 785 V

Factory default 770

During deceleration of the frequency converter, the frequency converter will activate dynamic braking if the DC bus voltage exceeds the deceleration braking activation voltage threshold.

The function is valid for models with built-in braking transistors (15 kW and below).

H37

Drooping control

Setting range

0.00 - 10.00 Hz

Factory default

Minimum unit

0.00

0.01 Hz

The function is suitable for circumstances where multiple frequency converters are used to drive the same load.

The function allows uniform distribution of power among multiple frequency converters which drive the same load. When a frequency converter takes on a heavy load, the converter will automatically reduce the output frequency to relieve part of the load according to the parameter value. The parameter may be adjusted from small to large values during commissioning. The relation between load and output frequency is shown in the diagram below:

Torque

Rated torque

Without drooping control

With drooping control

Speed

0

Synchronous speed

Note:

If drooping control is used, turn off slip frequency compensation by setting

[H31]=0.00 Hz.

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H38

H39

H40

Motor poles Factory default

4

Setting range

2 - 14 (It is only allowed to input even numbers like 2, 4, 6 …1 4.)

Rated power of the motor Factory default Dependent on model

Setting range

0.4 - 999.9 kW

Rated stator current

Setting range

0.1 - 999.9 kA

Minimum unit

Factory default

Minimum unit

0.1 kW

Dependent on model

0.1 A

Set the parameters of the controlled motor according to its nameplate to ensure that the rated motor and the rated converter power match.

Generally, the motor power is allowed to be one power level higher or up to two power levels lower than that of the frequency converter. For example, a motor from 30 kW up to 55 kW is allowed to be used with a 45 kW frequency converter. Otherwise the control performance cannot be ensured.

H41

H42

H43

H44

H45

No-load current

Setting range

Rotor resistance

Setting range

0.1 - 999.9 A

Stator resistance

Setting range

0.00 - 50.00 %

Leakage inductance

Setting range

0.00 - 50.00 %

0.00 - 50.00 %

Mutual inductance

Setting range

0.0 - 2000.0 %

Factory default

Minimum unit

Factory default

Factory default

Factory default

Factory default

Minimum unit

Depending on model

0.1 A

Depending on model

Depending on model

Depending on model

Depending on model

0.1

Details of above motor parameters are shown in the diagram below:

I1

R1

X11

I0

I2

R2

X21

Rm

U1

1-S

S

R2

Xm

R1, X11, R2, X21, Xm and I0 in the diagram represent stator resistance, stator leakage inductance, rotor resistance, rotor leakage inductance, mutual inductance and no-load current.

[H43] is the sum of the stator and the rotor leakage inductance. [H42]-

[H45] are all percentages to the motor parameters and the formula is as follows:

R

100%

V

/

(

3 I

)

V: Rated voltage / I: Rated motor current

100%

/

(

3 I

)

V: Rated voltage / I: Rated motor current


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H46

Set [H41] directly and set the values obtained from above formula in

[H42]-[H45] if all motor parameters are known.

If auto-tuning of motor parameters is used, values in [H41]-[H45] will be automatically set after the auto-tuning.

Rated slip frequency

Setting range

0.00 - 20.00 Hz

Factory default

Minimum unit

0.00

0.01 Hz

The rated slip frequency of the motor can be calculated with the help of the rated motor speed on the nameplate.

Rated slip frequency = rated frequency([b04])

(synchronous speed - rated speed) synchronous speed synchronous speed = rated frequency 120 motor poles ([H38])

H47

Auto-tuning parameters

Setting range

Factory default

0: No auto-tuning of parameters

1: Auto-tuning when the motor is static

2: Auto-tuning when the motor is running.

After auto-tuning, [H47] is automatically set to be 0.

DANGER

0

Before auto-tuning, you must correctly input the nameplate parameters of the connected motor ([H38]-[H40])

The function automatically detects and sets motor parameters.

[H47]=0, No auto-tuning of parameters;

[H47]=1, Auto-tuning when the motor is static;

[H47]=2, Auto-tuning when the motor is running.

Motor load has to be removed before using auto-tuning function [H47]=2!

Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage!

Ensure safety because the motor shaft will rotate.

After auto-tuning, [H47] is automatically set to be 0.

Auto-tuning steps:

(1) Set the base frequency ([b04]) and the base voltage ([b05]) according to the motor characteristics.

(2) Set the nameplate parameters of the connected motor ([H38]-[H40]).

(3) Set the acceleration time ([b16]) and the deceleration time

([b17]).Before setting [H47]=2, disengage the motor shaft from the load and check carefully to ensure safety!

(4) Set [H47] to 1 or 2, press the Set key and press Run to start the auto-tuning;

(5) The auto-tuning is complete when the display of the operating panel is flashing.

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Notes:

When [H47] is set to be 2, increase the acceleration/deceleration time appropriately, if over current or over voltage occurs during auto-tuning.

When [H47] is set to be 2 to conduct auto-tuning when the motor is running, disengage the motor shaft from the load. Do not conduct autotuning when the motor is running with a load!

Ensure the motor is stopped before starting auto-tuning, or else autotuning will not work properly.

In circumstances in which auto-tuning is not used, properly input the parameters on the motor nameplate ([H38]-[H40]). If accurate motor parameters are known, properly input [H38]-[H45].

“d

. Fr r” will be displayed If auto-tuning fails .

H48

H49

Total working hours

Setting range

Password input

0 - 65535 hours

Factory default

Minimum unit

Factory default

0

1 hour

0

[H49] allows access to manufacturer function codes ([H50]-[H63]).


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Notes on Monitoring Function Group (group d )

Function

Monitored items

Abbreviation

outF

SEtF outA outV dCV t inPt

Description

displays converter output frequency (Hz), motor speed and linear speed displays converter set frequency (Hz), motor speed or PI target value displays converter output current displays output command voltage if PI control is disabled; displays feedback quantity if PI control is enabled displays DC bus voltage displays input signals

Signal enabled no signal

X1

X2

X3

SR

SF

RST

E-Stop displays the temperature of power module and heat sink ( )

Notes

:

[b00], [b34], [b35], [E39], [H07] and [H23] are related to external terminals.

Consider if any of the external terminals X1, X2 and X3 have already been used by a function, they cannot be used by another function.

To select a terminal which has already been used, the previous function has to be disabled before the definition of a new function.

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12-1 Fault Indication

12 Fault Indication

Faults may cause the converter to stop.

12.1 Fault Types

The frequency converter can record the reasons of the last 4 faults and can display them after resetting from faults.

Fault Code

Description

Over current at constant speed

Cause

Excessively reduced acceleration/deceleration time

Load short circuit or sudden changes in load

Low grid voltage

A special motor or a motor larger than the maximum allowable capacity

Too short acceleration time

Solution

Increase acceleration/deceleration time

Check the load

Check power supply

Use a converter with suitable power

Over current during acceleration

Improper V/F curve

The converter power is too low

Increase acceleration time

Enable automatic torque increasing or manualLY adjust V/F curve settings

Select a converter with higher power

Increase deceleration time Over current during deceleration

Too short deceleration time

Large load inertia torque or potential load

The converter power is too low

Too high input voltage of power supply

Add a appropriate dynamic braking unit

Select a converter with higher power

Keep the input voltage of power supply within the specified range

Over voltage at constant speed

Over voltage during acceleration

Over voltage during deceleration

Excessively reduced acceleration/deceleration time Increase acceleration/deceleration time

Abnormality in load

Check the load

Abnormality in input voltage of power supply

Check power supply

Abnormality in load

Check the load

Too large moment of inertia of load

Increase the deceleration time to suit the load inertia, or purchase a dynamic braking unit

Too large load, too short acceleration/deceleration time or cycle

Adjust the load, acceleration/deceleration time or cycle; or increase the converter capacity

Motor overload

Improper V/F characteristic curve settings

Improper setting of electronic thermal relay

Adjust V/F curve settings

Converter overheat

Drive protection

Fan failure

Too high ambient temperature

Ventilation outlet obstructed

Damaged power component

Incorrect operation of drive circuit protection

Set proper setting of electronic thermal relay

Check if fan works normally

Lower the ambient temperature

Clear dust and foreign matters at ventilation outlet

Seek technical support

Remove interference and seek technical support

EMI

Phase loss at input side

Phase loss at output side

CPU incorrect operation due to external interference Remove nearby interference or other EMI

Phase loss of the converter's 3-phase input power supply

Open wire or phase loss of converter's 3-phase output power supply (severe asymmetry of the 3 phase's loads)

Check 3-phase input power supply or seek technical support

Check converter's 3-phase wiring

(or symmetry of loads)


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Fault Indication 12-2


Fault Code

Description Cause

Abnormal power supply voltage

Motor fails to start

Motor can not run at different speeds

Motor stalls during acceleration

External wiring between control SF or SR is disconnected

Improper parameter setting

The highest frequency is too low

Improper frequency setting mode

Too short acceleration time

Too large inertia of motor and load

Improper V/F curve

Abnormal heating of motor

Continuous running at low speed

Too large load

Solution

Check power supply

Check external wiring between control SF or SR

Check parameter setting

Check the highest frequency

Confirm frequency setting

Increase acceleration time

Adjust acceleration time

Adjust V/F curve settings

Use a special motor if it is necessary to run at low speed for a long time

Check load

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12-3 Fault Indication

12.2 List of Fault Protection Actions

What

Main circuit under voltage

Main circuit over current

Main circuit over voltage

Motor overload

Converter over heating

Drive protection

EMI

Phase loss protection

Under voltage trip

Over current limit (stall current)

Over voltage limit (stall voltage)

Stopping upon abnormality

Fault Code on Display

P.oFF

Description

Description

This function code will be displayed when the main circuit voltage is less than 80 % of the rated value.

O.C.-1

O.C.-2

O.C.-3

This function code will be displayed when the output current exceeds the maximum allowed current. The output will then be shut off and the frequency converter will stop.

O.E.-1

O.E.-2

O.E.-3

O.L.

This function code will be displayed when the main circuit

DC voltage exceeds 800 V through deceleration of the motor. The output will then be shut off and the frequency converter will stop.

This function code will be displayed when the set load exceeds the specified characteristic of the output. The frequency converter will then stop according to the anti-time curve.

The characteristic of the output can be set according to the motor type.

O.H.

d.r.

CPU-

IPH.L

oPH.L

E.-St

This function code will be displayed when the heat sink temperature is about 85 °C . The frequency converter will then stop.

This function code will be displayed when there is a bridge fault in the main circuit. The frequency converter will then stop.

This function code will be displayed when the CPU or the output protection circuit is under EMI. If there are strong magnetic field disturbing factors, the frequency converter will stop.

The converter immediately stops output and running in case of input/output phase loss protection of the converter.

This happens in operation when the power supply is lower than the set value due to power off or declining voltage. The output will then be shut off and the frequency converter will stop.

During acceleration or running, once over current occurs, the frequency converter will regulate its output frequency to decrease the current under current stall level.

If the output frequency declines rapidly, the regenerated energy from motor will increase the DC voltage. The frequency converter will then auto-regulate frequency to avoid DC voltage of the main circuit exceeding the specified value.

This function code will be displayed when the input terminal

E-Stop/SC is connected and [E32]=0, [E33]=0 and [E34]=1.

The frequency converter will then stop.


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Technical Data13 -1


13 Technical Data

13.1 Fe General Technical Data

Input

Output

Functions

Power supply voltage

Supply frequency

Rated motor output

Short circuit current rating

(UL) (SCCR) (480 V Maximum)

Rated voltage

Output frequency

Overload capability

Control mode

Modulation type

Speed regulation range

Start-up torque

Frequency resolution

V/F characteristic curve

Ramps

Direct-current brake

3 AC 380 to 480 V (-15 % / +10 %) (TN-Net)

50 to 60 Hz (±5 %)

0.75 to 110 kW

5000 A rms

Corresponding to input voltage

0 to 650 Hz

G se ries: 200 % of rated current for 1s; 150 % of rated current for 60s

P series: 120 % of rated c urrent for 60s; 105 % of rated current for 60min

V/F

Magnetic flux PWM modulation

1:100

Maximum start-up torque 150 % at 5 Hz

(torque and slip compensation activated)

Digital

Analog

0.01 Hz

Maximum frequency x 0.1 %

Freely definable

Linear, S-curve

Start frequency

Braking time

0 to 60 Hz

0.1 to 10s

Integrated PLC, operating panel Integrated controller

Status messages via multi-function output signal

Automatic energy saving function

In/above/below frequency range, operation, etc.

Load-dependent adaptation of V/F characteristic curve

Automatic PWM frequency adaptation Load-dependent adaptation of PWM frequency

Customization functions

Fast current restriction

Automatic voltage regulation (AVR)

Running command channel

Frequency setting

Fast current restriction during running to prevent trip due to frequent over current

Excessively high supply voltage is automatically reduced to rated motor voltage

Given by operating panel, control terminal and serial port

Set by digital operating panel, analog voltage, analog current and serial port, which can be switched at any time

Operating panel

Protection

Optional parts

Environment

Auxiliary frequency setting Flexible frequency trimming and frequency synthesis

Analog output terminal

LED display

Analog signal output, 0 or 4 to 20 mA / 0 or 2 to 10 V, to output physical quantities, such as output frequency

Displaying of various parameters, including set frequency, output frequency, output voltage, output current, etc.

Input phase loss protection (models = 11 kW), output phase loss protection, output short circuit protection, grounding protection, over current protection, over voltage protection, under voltage protection, overheat protection, overload protection

Braking resistor, remote controller, remote communication cable, bus adapter

Location

Power reduction/Max. installation height

Ambient temperature

Relative humidity

Indoor use, without corrosive gas or liquid or dust

Up to 1000 m above sea level: none;

1000 …40 00 m above sea level: 1 % / 100 m

-10 °

C to 4

0 °C (with out condensation and frost);

Derating between 40 °C and 50 °C

< 90 % RH (without condensation)

Allowed pollution degree 2 (EN 50178)

Shocking

Degrees of protection

< 5.9 m/s (0.6 g)

IP20

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Rexroth Frequency Converter Fe 13-2 Technical Data

Derating of electrical data

Derating and ambient temperature

Where installation conditions differ, the following performance data are reduced in accordance with the diagram:

Frequency converter: continuous power output continuous current output

Use outside of the indicated installation conditions is not allowed, even if the performance data are additionally reduced.

As the ambient temperature increases, the capacity utilization of the devices is reduced according to the figure below.

f

Ta

T a_work

{{ {{

T a_work_red

Ambient temperature in f load factor

Ta

T ambient temperature range for operation with nominal data a work

T a work red

ambient temperature range for operation with reduced nominal data

Derating and mains voltage

Reduced overcurrent based on mains voltage

The Fe frequency converters are thermally dimensioned for the rated currents.

This rated current is available with the specified rated voltage. With deviating voltages in the permissible range, please note the following:

Umains Urated: With mains voltages below the rated voltage, no higher currents may be withdrawn to ensure that the dissipated power remains current.

Umains Urated: With mains voltages greater than the rated voltage, a reduction of the permissible output permanent currents takes place to compensate for the increased switching losses.


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Derating vs. U mains

At mains voltage 380 V: 1 % power derating every 4 V

Derating of the output current depending on the pulse frequency

This illustration shows the current reduction based on the pulse frequency for the different frequency converters. In case of higher pulse frequency, the current is reduced insofar that the power dissipation in power section remains more or less constant.

For converters with 0.75 to 7.5 kW, the current reduction starts at 8 kHz; with 11 to 22 kW at 6 kHz; with 30 to 45 kW at 4 kHz; with 55 to 110 kW at 2 kHz.

2 4 6 8 10 12 14

I/I

N

100%

95%

90%

85%

80%

55 - 110 kW 30 - 45 kW 11 - 22 kW 0.75 - 7.5 kW

100%

95%

90%

85%

80%

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1

3

5

I: Permissible overcurrent

I : Rated current

N

Derating output current vs. fs

135

7

9

f pulse

11 13

Pulse frequency [kHz]

15



13-4 Technical Data

13.2 Electrical Parameters

G series

P series

Fe

Power [kW]

3-phase

400V

3-phase

400V

400 V Series

Model Unit

FECG02 1-

0K75-3P400-

A-SP-MODB-

01V01

Power kW

0.75

Rated input current

A

Weight kg

3.4

Capacity kVA

Rated output

A current

1.9

2.5

3.0

Model

Unit

FECx02 1-

15K0-3P400-

A-BN-MODB-

01V01

Power kW

15

Rated input current

A

42

Capacity kVA

25

Rated output current

A

Weight kg

33

10.9

Model

Unit

FECx02 1-

75K0-3P400-

A-BN-MODB-

01V01

Power kW

Rated input current

A

75

157

Capacity

Rated output current kVA

A

116

152

Weight kg

50.9

FECG02 1-

1K50-3P400-

A-SP-MODB-

01V01

1.5

6

140

183

52.5

FECG02 1-

2K20-3P400-

A-SP-MODB-

01V01

2.2

8

170

223

96.5

FECG02 1-

4K00-3P400-

A-SP-MODB-

01V01

4

13

3

4

3.0

FECx02 1-

18K5-3P400-

A-BN-MODB-

01V01

18.5

43

29

39

16.2

FECx02 1-

90K0-3P400-

A-BN-MODB-

01V01

90

187

4

5.5

3.2

FECx02 1-

22K0-3P400-

A-BN-MODB-

01V01

22

51

34

68

46

44 60

16.9

FECx02 1-

110K-3P400-

A-BN-MODB-

01V01

110

21.5

226

7.6

10

3.2

FECx02 1-

30K0-3P400-

A-BN-MODB-

01V01

30

FECx02 1-

5K50-3P400-

A-SP-MODB-

01V01

5.5

17

9.9

83

55

75

22.0

13

3.5

FECx02 1-

37K0-3P400-

A-BN-MODB-

01V01

37

21

13

FECx02 1-

7K50-3P400-

A-SP-MODB-

01V01

7.5

101

68

95

33.2

17

3.5

FECx02 1-

45K0-3P400-

A-BN-MODB-

01V01

45

FECx02 1-

11K0-3P400-

A-BN-MODB-

01V01

11

30

55

117

85

110

33.8

18

24

10.7

FECx02 1-

55K0-3P400-

A-BN-MODB-

01V01

Note 1:

x is a substitute for G or P series.

Note 2:

The data is based on the supply voltage of 3 × 380 VAC.


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13.3 Electromagnetic Compatibility (EMC)

13.3.1 EMC Requirements

13.3.1.1 General information

The electromagnetic compatibility (EMC) or electromagnetic interference

(EMI) includes the following requirements:

Sufficient noise immunity of an electric installation or an electric device against external electric, magnetic or electromagnetic interference via lines or through air.

Sufficiently low noise emission of electric, magnetic or electromagnetic noise of an electric installation or an electric device to other surrounding devices via lines or through air.

13.3.1.2 Noise immunity in the drive system

Basic structure for noise immunity

The figure below illustrates the interference for definition of noise immunity requirements in the drive system.

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Minimum noise immunity values

No.

Place of effect

Enclosure port

Power port

Power interface

Phe- nomenon

ESD

RF field

Burst

Surge

Standard

IEC 61000-4-2

IEC 61000-4-3

Conditions

Coupling

CD, AD

Via antenna on EUT

Test values according to standard EN61800-3

4 kV CD; 8 kV AD, if CD not possible

10 V / m

IEC 61000-4-4 mains connection

I 100 A: CDN;

I = 100 A: clamp

2 kV / 2.5 kHz

(CN or CDN);

4 kV / 2.5 kHz (clamp)

IEC 61000-4-5 only mains connection;

I 63 A, light load test

IEC 61000-4-6 length 3 m clamp line-line 1 kV line-earth 2 kV

10 V, 0.15 - 80 MHz

Perform- ance level

B

A

B

B

A

Burst IEC 61000-4-4 length 3 m clamp

2 kV / 5 kHz

B

Signal interface

Burst IEC 61000-4-4 length 3 m

1 kV / 5 kHz

IEC 61000-4-6 length 3 m clamp or CDN 10 V, 0.15 - 80 MHz

B

A

Ports of process; measurement control lines

Burst IEC 61000-4-4 length 3 m clamp

2 kV / 5 kHz

IEC 61000-4-6 length 3 m clamp or CDN

10 V, 0.15 - 80 MHz

Note:

CD: contact discharge

AD: air discharge

CDN: coupling and decoupling network

CN: coupling network

B

A

Evaluation criterion

B

C

Evaluation criterion

A

Explanation (abbreviated form from EN 1800-3)

deviations within allowed range automatic recovery after interference

Switched off without automatic recovery. Device remains undamaged.


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13.3.1.3 Noise emission of the drive system

Causes of noise emission

Controlled variable-speed drives contain converters containing snappy semiconductors. The advantage of modifying the speed with high precision is achieved by means of pulse width modulation of the converter voltage.

This can generate sinusoidal currents with variable amplitude and frequency in the motor.

The steep voltage rise, the high clock rate and the resulting harmonics cause unwanted by physically unavoidable emission of interference voltage and interference fields (wide band interference). The interference mainly is asymmetric interference against ground.

The propagation of this interference strongly depends on: configuration of the connected drives number of the connected drives conditions of mounting site of installation radiation conditions wiring and installation

If the interference gets from the device to the connected lines in unfiltered form, these lines can radiate the interference into the air (antenna effect).

This applies to power lines, too.

Limit values for line-based disturbances

According to IEC EN 61800-3 or CISPR 11 (corresponds to EN 55011), the limit values in the table below are distinguished. For this documentation both standards are combined in the limit value classes A2.1 to B1.

IEC / EN61800-3 CISPR 11

IEC / EN 61800-3 nd

Category C4 2 environment nd

Category C3 2 environment nd

Category C3 2 environment st

Category C2 1 environment; restricted distribution st

Category C1 1 environment; unrestricted distribution

None

Class A; group 2

I 100 A

Class A; group 2

I 100 A

Class A; group 1

Class B; group 1

Explanation

In this documentation

Curves of limit value characteristic

One of the following 3 requirements must have been fulfilled: Mains connection current 400 A, IT mains or required dynamic drive behavior not reached by means of EMC filter. Adjust limit values to use and operation on site. User has to carry out and provide evidence of EMC planning.

limit value in industrial areas to be complied with for applications operated at supply mains with no minal currents 100 A

None

A2.1

-

1.1

1.2

limit value in industrial areas to be complied with for applications operated at supply mains with no minal currents 100 A

Limit value in residential area or at facilities at low-voltage mains supplying buildings in residential areas. To be comply with for applications with restricted distribution.

A2.2

A1

2.1

2.2

3.1

3.2

limit value in residential areas to be complied with for applications with unrestricted distribution

B1

4.1

4.2

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Limit values for line-based disturbances (IEC 61800-3); limit characteristic through frequency range

1.1

Category C3: 2 environment, QSP, I 100 A (class A, group 2, I 100 A) nd

1.2

Category C3: 2 environment, AV, I 100 A (class A, group 2, I 100 A) nd

2.1

Category C3: 2 environment, QSP, I 100 A (class A, group 2, I 100 A) nd

2.2

Category C3: 2 environment, AV, I 100 A (class A, group 2, I 100 A) st st

3.1

Category C2: 1 environment, restricted distribution, QSP (1 environment, nd even if source of interference in 2 environment) (class A, group 1) st st

3.2

Category C2: 1 environment, restricted distribution, AV (1 environment, nd even if source of interference in 2 environment) (class A, group 1)

4.1

Category C1: 1 environment, unrestricted distribution, QSP (1 environm- nd ent , even if source of interference in 2 environment) (class B, group 1) st st

4.2

Category C1: 1 environment, unrestricted distribution, AV (1 environment, nd even if source of interference in 2 environment) (class B, group 1) st nd

Notes

(1) Limit value for 1 environment is also relevant, if source of interference of 2 st environment affects 1 environment.

(2) Designation s “class” and “group” acc ording to IEC CISPR 11.

QSP: measuring method quasi peak measurement;

AV: measuring method arithmetic averaging


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Second Environment,

Industrial Area

First Environment

Nominal Current of

Supply Mains

Unrestricted Distribution

Restricted Distribution

Facilities not directly connected to a low-voltage mains to supply buildings in residential areas.

If the limit values in an industrial area separated from public supply by a transformer station only have to be complied with at the property boundary or in the neighboring low-voltage mains, the filter might not be necessary. In the vicinity such as measuring sensors, measuring lines or measuring devices, it is normally required to use the interference suppression filter.

Increasing the noise immunity of a sensitive device can often be the economically better solution compared to measures of interference suppression at the drive system of installation.

Environment containing residential areas and facilities directly connected, without interstage transformer, to a low-voltage mains supplying buildings in residential areas.

Medium-sized manufacturing plants and industrial establishments can be connected to the public low-voltage mains together with residential buildings. In this case there is a high risk for radio and television reception if there are not any measures for radio interference suppression taken. Therefore, the indicated measures are generally recommended.

The nominal current of the supply mains ( 100 A or 100 A) is specified by the local power supply company at the connection point of the mains. For industrial companies, for example, such connection points are the interconnecting stations from the power supply company.

Channel of distribution for which placing on the market is independent of the EMC expert knowledge of the customer or user of electric drives.

Channel of distribution for which the placing on the market is restricted to traders, customers or users who individually or together have technical expert knowledge of EMC for the use of electric drives.

Since it is impossible to obtain the lower limit values for residential areas with all applications by means of usual measures (like in the case of large and electrically not closed installations, longer motor cables or a large number of drives), the following note included in EN 61800-3 has to be observed

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Components of the drive system Rexroth Fe are products of category C3 (with restricted distribution) according to IEC 61800-

3. They are not provided for use in a public low-voltage mains supplying residential areas. If they are used in such a mains, high-frequency interference is to be expected. This can require additional measures of radio interference suppression.

See the following chapters for the limit classes (as per categories C1,

C2, C3, C4 according to EN 61800-3) which can be reached for the

Frequency Converter Fe.


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13.3.2 Ensuring the EMC requirements

Standards and laws

EMC Properties of

Components

Applicability for End

Product

On the European level there are the EU Directives. In the EU states these Directives are transformed into laws valid on a national level. The relevant directive for EMC is EU Directive 89/336/EWG which was transformed on the national level in Germany into the law EMVG (“Law concerning electromagnetic compatibility of devices”) of 1992-11-09.

Drive and control components by Rexroth are designed and built, in accordance with the present state-of-the-art of standardization, according to legal regulations of the EU Directive EMC 89/336/EEC and the German law.

The compliance with EMC standards was tested by means of a typical arrangement with a test setup conforming to standard with the indicated mains filters. The limit values according to product standard

EN 61800-3 have been complied with.

Apart from the internal test at the factory, a conformity test was carried out for individual drive systems in an accredited laboratory of a CEresponsible authority.

Measurements of the drive system with an arrangement typical for the system are not in all cases applicable to the status in a machine or installation. Noise immunity and noise emission strongly depend on: configuration of the connected drives number of the connected drives conditions of mounting site of installation radiation conditions wiring and installation

In addition, the required measures depend on the requirements of electric safety technology and economic efficiency in the application.

In order to prevent interference as far as possible, notes on mounting and installation are contained in the application manuals of the components and in this documentation.

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Cases to Distinguish for

Declaration of EMC

Conformity

For validity of the harmonized standards, we distinguish the following cases:

Case 1: Delivery of the drive system.

According to the regulations, the product standard EN 61800-3 is complied with for Rexroth drive systems. The drive system is listed in the declaration of EMC conformity. This fulfills the legal requirements according to EMC directive.

Case 2: Acceptance test of a machine or installation with the installed drive systems.

The product standard for the respective type of machine/installation, if existing, applies to the acceptance test of the machine or installation. In the last years, some new product standards were created at present.

These new product standards contain references to the product standard EN 61800-3 for drives or specify higher-level requirements demanding increased filter and installation efforts. When the machine manufacturer wants to put the machine/installation into circulation, the product standard relevant to his machine/installation has to be complied with for his end produc t “machine/installation”. Th e authorities and test laboratories responsible for EMC normally refer to this product standard.

This documentation specifies the EMC properties which can be achieved, in a machine or installation, with a drive system consisting of the standard components.

It is also specifies the conditions under which the indicated EMC properties can be achieved.


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13.3.3 EMC measures for design and installation

13.3.3.1 Rules for design of installations with drive controllers in compliance with EMC

The following rules are the basics for designing and installing drives in compliance 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 possible surface area to establish a good electrical connection. This, too applies to the mounting of the mains filter. If required, use serrated washers which cut through the paint surface. Connect the cabinet door to the control cabinet using the shortest possible grounding straps.

Line Routing

Interference Suppression

Elements

Avoid coupling routes between lines with high potential of noise and noise-free lines; therefore, signal, mains and motor lines and power cables have to be routed separately from another. Minimum distance:

10 cm. Provide separating sheets between power and signal lines.

Ground separating sheets several times.

The lines with high potential of noise include:

Lines at the mains connection (incl. synchronization connection)

Lines at the motor connection

Lines at the DC bus connection

Generally, interference injections are reduced by routing cables close to grounded sheet steel plates. For this reason, cables and wires should not be routed freely in the cabinet, but close to the cabinet housing or mounting panels. Separate the incoming and outgoing cables of the radio interference suppression filter.

Provide the following components in the control cabinet with interference suppression combinations:

Contractors

Relays

Solenoid values

Electromechanical operating hours counters

Connect these combinations directly at each coil.

Twisted Wires Twist unshielded wires belonging to the same circuit (feeder and return cable) or keep the surface between feeder and return cable as small as possible. Wires that are not used have to be grounded at both ends.

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Lines of Measuring

Systems

Digital Signal Lines

Analog Signal Lines

Connection of Mains

Choke

Installation of Motor

Power Cable

Lines of measuring systems must be shielded. Connect the shield to ground at both ends and over the largest possible surface area. The shield may not be interrupted, e.g. using intermediate terminals.

Ground the shields of digital signal lines at both ends (transformer

and

receiver) over the largest possible surface area and with low impedance. This avoids low frequency interference current (in the mains frequency range) on the shield.

Ground the shields of digital signal lines at one end (transformer

or

receiver) over the largest possible surface area and with low impedance. This avoids low frequency interference current (in the mains frequency range) on the shield.

Keep connection lines of the mains choke at the drive controller as short as possible and twist them.

Use shield motor power cable or run motor power cables in a shielded duct;

Use the shortest possible motor power cable;

Ground shield of motor power cable at both ends over the largest possible surface area to establish a good electrical connection;

Run motor lines in shielded form inside the control cabinet;

Do not use any steel-shielded lines;

The shield of the motor power cable must not be interrupted by mounted components, such as output chokes, sine filter or motor filters.


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13.3.3.2 EMC-optimal installation in facility and control cabinet

General information

For EMC-optimal installation, a special separation of the interference-free area

(mains connection) and the interference-susceptible area (drive components) is recommended, as shown in the figures below.

For EMC-optimal installation in the control cabinet, use a separate control cabinet panel for the drive components.

Division into areas (zones)

Exemplary arrangements in the control cabinet: See section

Control Cabinet

Mounting According to Interference Areas Exemplary Arrangements

We distinguish three areas:

1. Interference-free area of control cabinet

(area A):

This includes:

Supply feeder, input terminals, fuse, main switch, mains side of mains filter for drives and corresponding connecting lines;

Control voltage or auxiliary voltage connection with power supply unit, fuse and other parts unless connection is run via the mains filter of the

AC drives;

All components that are not electrically connected with the drive system.

2. Interference-susceptible area

(area B):

Mains connections between drive system and mains filter for drives, mains contactor;

Interface lines of drive controller

3.

Strongly interference-susceptible area

(area C):

Motor power cables including single cores

Never run lines of one of these areas in parallel with lines of another area so that there is not any unwanted interference injection from one area to the other and that the filter is jumped with regard to high frequency. Use the shortest possible connecting lines.

Recommendation for complex systems: Install drive components in one cabinet and the control units in a second, separate cabinet.

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 bottom via short equipment grounding conductors with a

2 cross section of at least 6 mm or, even better, via grounding straps with the same cross section. Make sure connection points have good contract.

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Control Cabinet Mounting According to Interference Areas Exemplary Arrangements

DR1

E1

…E5

K1

M

L

Z1, Z2

Mains choke (optional)

Equipment grounding conductor or the components

External mains contactor

Motor blower

Shield connection points for cables


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Technical Data13 -17 Rexroth Frequency Converter Fe

Design and installation in area A interference-free area of control cabinet

Arrangement of the

Components in the

Control Cabinet

Comply with a distance of at least 200 mm (distance d1 in the figure):

Between components and electrical elements (switches, pushbuttons, fuses, terminal connectors) in the interference-free area A and the components in the two other areas B and C

Comply with a distance of at least 400 mm (distance d4 in the figure):

Between magnetic components (such as transformers, mains chokes and DC bus chokes that are directly connected to the power connections of the drive system) and the interference-free components and lines between mains and filter including the mains filter in area A

If these distances are not kept, the magnetic leakage fields are injected to the interference-free components and lines connected to the mains and the limit values at the mains connection are exceeded in spite of the installed filter.

Cable Routing of the

Interference-free

Lines to the Mains

Connection

Comply with a distance of at least 200 mm (distance d1 and d3 in the figure):

Between supply feeder or lines between filter and exit point from the control cabinet in area A and the lines in area B and C

If this is impossible, there are two alternatives:

1. Install lines in shielded form and connect the shield at several points

(at least at the begging and at the end of the line) to the mounting plate or the control cabinet housing over a large surface area.

2. Separate lines from the other interference-susceptible lines in areas

B and C by means of a grounded distance plate vertically attached to the mounting plate.

Install the shortest possible lines within the control cabinet and install them directly on the grounded metal surface of the mounting plate or of the control cabinet housing.

Mains supply lines from areas B and C must not be connected to the mains without a filter.

Routing and Connecting a Neutral Conductor (N)

In case you do not observe the information on cable routing given in this section, the effect of the mains filter is totally or partly neutralized.

This will cause the noise level of the interference emission to be higher within the range of 150 kHz to 40 kHz and the limit values at the connection points of the machine or installation will thereby be exceeded.

If a neutral conductor is used together with a three-phase connection, it must not be installed unfiltered in zones B and C, in order to keep interference off the mains.

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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 interferencesusceptible lines, must be filtered:

In drive system with

only infeeding supply units

, via the available three phase filter of the drive system

When switching power off, make sure the blower is not switched off.

Only operate allowed loads at the mains filter of the drive system!

Loads at Mains Filter of

Drive System

Shielding Mains Supply

Lines in Control Cabinet

Mains Filters for AC

Drives

Grounding

If there is a high degree of interference injection to the mains supply line within the control cabinet, although you have observed the above instructions (to be found out by EMC measurement according to standard), proceed as follows:

Only use shielded lines in area A

Connect shields to the mounting plate at the beginning and the end of the line by means of clips

The same procedure may be required for long cables of more than 2 m between the point of power supply connection of the control cabinet and the filter within the control cabinet.

Ideally, mount the mains filter on the parting line between area A and B. make sure the ground connection between filter housing and housing of the drive controllers has good electrically conductive properties.

If

single-phase

loads are connected on the load side of the filter, their current may be a maximum of 10 % of the three-phase operating current. A highly imbalanced load of the filter would deteriorate its interference suppression capacity.

If the mains voltage is more than 480 V, connect the filter to the output side of the transformer and not to the supply side of the transformer.

In the case of bad ground connections in the installation, the distance between the lines to the grounding points E1, E2 in area A and the other grounding points of the drive system should be at least d4=400 mm, in order to minimize interference injection from ground and ground cables to the power input lines.

See also

13.3.3.2 Division into Areas (Zones)

.


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Point of Connection for

Environment Grounding

Conductor at Machine,

Installation, Control

Cabinet

The equipment grounding conductor of the power cable of the machine, installation or control cabinet has to be permanently connected at point

2

PE and have a cross section of at least 10 mm or to be complemented by a second equipment grounding conductor via separate terminal connectors (according to EN50178/ 1997, section

5.3.2.1

). If the cross section of the outer conductor is bigger, the cross section of the equipment grounding conductor must be accordingly bigger.

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Design and installation in area B - interference - susceptible area of control cabinet

Arranging Components

and Lines

Control Voltage or

Auxiliary Voltage

Connection

Line Routing

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.

Alternative: Shield modules, components and lines in area B by distance plates mounted vertically on the mounting plate from modules and lines in area A or use shield lines.

Only connect power supply units for auxiliary or control voltage connections in the drive system to the mains via a mains filter. See

13.3.3.2 Division Into Areas (Zones)

Install the shortest possible lines between drive controller and filter.

Only in exceptional cases should you connect power supply unit and fusing for the control voltage connection to phase and neutral conductor. In this case, mount and install these components in area A far away from area B and C of the drive system.

Run the connection between control voltage connection of the drive system and power supply unit used through area B over the shortest distance.

Run the lines along grounded metal surfaces, in order to minimize radiation of interference fields to area A (transmitting antenna effect).


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Design and installation in area C - strongly interference - susceptible area of control cabinet

Influence of the Motor

Power Cable

Routing the Motor Power

Cables and Motor

Encoder Cables

Area C mainly concerns the motor power cables, especially at the connection point at the drive controller.

The longer the motor cable, the greater its leakage capacitors. To comply with a certain EMC limit value, the allowed leakage capacitance of the mains filter is limited.

Run the shortest possible motor power cables.

Route the motor power cables and motor encoder cables along grounded metal surfaces, both inside the control cabinet and outside of it, in order to minimize radiation of interference fields. If possible, route the motor power cables and motor encoder cables in metal-grounded cable ducts.

Rout the motor power cables and motor encoder cables with a distance of at least

d5=100

mm to interference-free lines, as well as to signal cables and signal lines

(alternative separated by a grounded distance plate) in separate cable ducts, if possible

Routing the Motor Power

Cables and Mains

Connection Lines

For converters (drive controllers with individual mains connection), route motor power cables and (unfiltered) mains connection lines

parallel for a maximum distance of 300 mm

route motor power cables and power supply cables in opposite directions and preferably in separate

cable ducts.

Ideally, the outlet of the motor power cables at the control cabinet should be provided in a distance of at least

d3=200 mm

from the

(filtered) power supply cable.

in

. After that distance,

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13.3.3.3 Ground connections

Housing and Mounting

Plate

By means of appropriate ground connections, it is possible to avoid the emission of interference, because interference is discharged to ground on the shortest possible way.

Ground connections of the metal housings of EMC-critical components

(such as filters, devices of the drive system, connection points of the cable shields, devices with microprocessor and switching power supply units) have to be well contacted over a large surface area. This also applies to all screw connections between mounting plate and control cabinet wall and to the mounting of a ground bus to the mounting plate.

The best solution is to use a zinc-coated mounting plate. Compared to a lacquered plate, the connections in this area have a good long-time stability.

Connection Elements For lacquered mounting plates, always use screw connections with tooth lock washers and zinc-coated, tinned screws as connection elements. At the connection points, remove the lacquer so that there is safe electrical contact over a large surface area. You achieve contact over a large surface area by means of bare connection surfaces or several connection screws. For screw 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.

Bare zinc-coated or tinned metal surfaces have

good electroconductive properties.

Anodized, yellow chromatized, black gunmetal finish or lacquered metal surfaces have

bad electroconductive properties.

Ground Wires and Shield

Connections

For connecting ground wires and shield connections, it is not the cross section but the size of contact surface that is important, as the highfrequency interference currents mainly flow on the surface of the conductor.

Always connect cable shields, especially shields of the motor power cables, to ground potential over a large surface area.


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13.3.3.4 Installing signal lines and signal cables

Line Routing

Shielding

For measures to prevent interference, see the Project Planning

Manuals of respective device. In addition, we recommend the following measures:

Route signal and control lines separately from the power cables with a minimum distance of d5=100 mm (see

13.3.3.2 Division

Into Areas (Zones)

) or with a grounded separating sheet. The optimum way is to route them in separate cable ducts. If possible, lead signal lines into the control cabinet at one point only.

If signal lines are crossing power cables, route them in an angle of

90° in ord er to avoid interference injection.

Ground spare cables, that are not used and have been connected, at least at both ends so that they do not have any antenna effect.

Avoid unnecessary line lengths.

Run cables as close as possible to grounded metal surfaces

(reference potential). The ideal solution are closed, grounded cable ducts or metal pipes which, however, is only obligatory for high requirements (sensitive instrument leads).

Avoid suspended lines or lines routed along synthetic carries, because they are functioning like reception antennas (noise immunity) and like transmitting antennas (emission of interference).

Exceptional cases are flexible cable tracks over short distances of a maximum of 5 m.

Connect the cable shield immediately at the devices in the shortest and most direct possible way and over the largest possible surface area.

Connect the shield of analog signal lines at one end over a large surface area, normally in the control cabinet at the analog device. Make sure the connection to ground/housing is short and over a large surface area.

Connect the shield of digital signal lines at both ends over a large surface area and in short form. In the case of potential differences between beginning and end of the line, run an additional bonding conductor in parallel. This prevents compensating current from flowing

2 via the shield. The guide value for the cross section is 10 mm .

You absolutely have to equip separate connections with connectors with grounded metal housing.

In the case of non-shielded lines belongs to the same circuit, twist feeder and return cable.

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13.3.3.5 General measures of radio interference suppression for relays, 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 semiconductors, appropriate interference suppression has to be provided for them:

By arranging free-wheeling diodes in the case of d.c. operation

In the case of a.c. operation, by arranging usual RC interference suppression elements depending on the contactor type, immediately at the inductance

Only the interference suppression element arranged immediately at the inductance does serve this purpose. Otherwise, the emitted noise level is too high which can affect the function of the electronic system and of the drive.

If possible, mechanical switches and contacts should only be realized as snap contacts. Contact pressure and contact material must be suited for the corresponding switching currents.

Slow-action contacts should be replaced by snap switches or by solid-state switches, because slow-action contacts strongly bounce and are in an undefined switching status for a long time which emits electromagnetic waves in the case of inductive loads. These waves are an especially critical aspect in the case of manometric or temperature switches.


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13.4 Selection Matrix for the EMC Accessories

For this topic, please contact us via the following email address: [email protected]

Please send your enquiry in English.

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Rexroth Frequency Converter Fe 14-1 Accessories

14 Accessories

14.1 EMC Filter

EMC filters are used to reduce radio interference and mains pollution.

14.1.1 Technical Data



14.2 Mains Chokes

Mains chokes are used to reduce harmonics in the mains current.





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Accessories 14-2


14.3 Braking Unit

14.3.1 General precautions

The FELB braking unit is used to dissipate the energy produced by the motor during a braking process, resulting in an increased braking capability and faster deceleration of the load without overvoltage trips. In order to avoid personal injury or machine damage please read the manual carefully before installation or operation of the FELB brake unit.

14.3.2 Technical specifications

The applicable voltage class

Braking unit model FELB

AC power supply 380 V - 15 %...480 V+10 % 50/60 Hz 5 %

FELB02.1N-30K0-NN0NE-A-560-NNNN FELB02.1N-45K0-NN0NE-A-560-NNNN

50 75 Peak current (A)

Rated current (A)

Maximum hysteresis

Synchronous signal

15

Braking Start-up Voltage

DC 630 / DC 660 / DC 690 / DC 730 / DC 760 V 16 V

About 16 V

25

Coupled input, coupled output, up to 3 braking units at most can be set to operate in parallel

Power supply

DC BUS voltage range

DC 460 - 800 V

Pro-

Overheat of heat sink tection Failure output

It is active when the temperature exceeds +85 .

RELAY junction 0.6 A 125 VAC / 2 A 30 VDC (T1, T2)

Power ON

Braking ON voltage 10 V on the PCB AC main lead terminal flows in, the red POWER indicator light on

When braking unit works, the green BRAKING indicator light on

14.3.3 Braking unit dimensions, weight and installation environment

FELB Weight

Type

FELB02.1N-30K0

FELB02.1N-45K0

Weight

2.5 kg

2.5 kg

Environment requirement:

Keep it away from corrosive gases, liquids and dust.

Humidity should be within 20 %RH 90 %RH.

Temperature should be -10 - +40 .

Rigid mounting, without excessive vibration.

Installation Space: Reserve enough air space around the braking unit to ensure proper ventilation. Recommend minimum mounting distances to other devices top/bottom 150 mm, left/right 50 mm of the braking unit.

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14.3.4 Instructions for safety wiring

When the frequency converter is connected with a DC reactor, for the wiring of the braking unit input terminal +(P), please refer to the manual of the frequency converter.

Do not connect braking unit input terminal -(N ) to the neutral point of the power supply.

Confirm the polarities of the braking unit input terminals +(P) and -(N), otherwise the braking unit will break down immediately at the startup phase of the braking process.

Flammable objects, gases or liquids must be avoided in the application field where the braking unit or the braking resistor is installed. They should be installed in a metal box with cooling fans and good ventilation.

Do not change any wiring or inner setting of the braking unit while the power is on.

To prevent personal injury, do not touch any terminal or any component on PCB in the braking unit.

At the beginning of the wiring phase, please isolate the main circuit and control circuit wires to avoid unnecessary interference and fault operations.

The wiring distance between the braking unit and the frequency converter should be not more than 5 M (16.4 ft). The wiring distance between braking unit and braking resistor should be not more than 10

M (32.8 ft).

Name of terminal

Input power supply

Braking resistor

Multiple units in parallel

Failure output

( Diagram of wiring distance)

Wirings on each terminal of braking units

Signs of terminal

N, P

P1, PB

Input

Output

T1, T2

Line width

2

[mm / AWG]

4.0 - 6.0 / 10 - 12

4.0 -6.0 / 10 - 12

IN+, IN-

OUT+, OUT-

0.75 - 1.0 / 18 - 20

0.75 - 1.0 / 18 - 20

(Diagram of terminals)

Screw specification

M4

M4

M4

M4

M4


160

Torque

[Nm]

1.8

1.8

1.8

1.8

1.8

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14.3.5 Basic wiring diagram

In order to avoid brake unit damage or break down in case of overload or fault conditions please consult the following wiring diagram. The brake unit

FELB fault switch should be connected to E-Stop of the REXROTH Fe unit.

The temperature switch of the braking resistor should be in series with the line contactor coil circuit.

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14.3.6 The settings of the braking unit

14-5 Accessories

The settings diagram of braking unit

Selections of braking voltage: the 400 V class braking unit has 5 operating voltages (630 V, 660 V, 690 V, 730 V, 760 V), and power supply of the braking unit is from +(P), -(N) of the frequency converter.

This setting will influence the level of the operating voltage of the braking unit, which is an important procedure. Please switch the jumpers to the needed operating voltage position; the factory default value of JP1 is 690 V.

The table of recommended start-up braking voltage

The input voltage of the power supply to the frequency converter

Braking start-up voltage

380V

660V

400V

690V

415V

730V

440V

760V

Master/Slave settings: The braking unit set JP2 on “MASTER” as factory setting. Master braking unit will sele ct “MASTER” and slave unit will sel ect “SLAVE” w hen two or more braking units are applied in parallel.

The selections of fault output: the temperature failure output of the braking unit is T1-T2; operating temperature is +85 . T1-T2 is set normally open as factory default; if normally closed is required in practical, it can be achieved by setting JP3, and to make 1-2 short circuit.

As the chart below shows, the first braking unit is set as "MASTER"; all others have to be set as "SLAVE"s when multiple units are applied in parallel.

In this way, the system wiring is completed.


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14.3.7 Definition for braking usage ED%

As the indication of following diagram, braking usage ED% is the ratio of the braking time and the braking period, usually represented by percentage.

When ED% is selected, the resistance and the power of braking resistor must be taken into consideration so that enough time can be ensured for the braking unit and the braking resistor to release the heat generated in the braking process.

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14.3.8 Selection of braking units and braking resistors

For the selection of the braking unit and braking resistor refer to

chapter 14.4

in this manual.

Notes:

In the table in the manual, the recommended resistance of the braking resistor is 100 % braking torque, selected according to necessity. If the actual needed torque is not 100 %, the resistance of the braking resistor in the table should be adjusted in proportionality, i.e. how much the braking torque increases based on 100 %, the resistance of the braking resistor should decrease by the same amount, vice versa.

When selecting braking resistor Rb, make sure the current Ic which flows through the resistor less than the current output ability of the braking unit. The current Ic through the braking resistor can be calculated by formula Ic = Ud / Rb, in which Ud is the braking operating voltage of braking unit.

After the adjustment of the resistance of braking resistor, the power of braking resistor should be also adjusted appropriately. The power can be calculated by formula Pmax = Ud2 / Rb. According to the actual working condition, the braking rate ED% can be selected to reduce the power of braking resistor reasonably for intermittent braking load. The power of braking resistor can be calculated by formula PR =

K × Pmax

× ED%, in which k is the derating coefficient of braking resistor. The selection of the braking torque should be in general smaller than 150 % of the rated motor torque, or consulting the technical support for more information.


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14.3.9 Fault analysis and countermeasures

When there is abnormality with the braking unit, the thermal protection of the braking unit will be active. A failure signal (via terminal T1, T2) will be sent by the braking unit to the frequency converter. The abnormality of the braking unit may result in the failure and warning of the frequency converter

(depending on the setting of the frequency converter). Make sure to find the cause of failure and run it after the failure is removed.

Item Fault conditions

1

The POWER light of braking unit off

2

3

4

Failure cause

Wrong connection

The BRAKING light of braking unit always on

Over voltage warning with the frequency converter

Breakdown of of braking unit IGBT

Open circuit with braking resistor

Wrong connected wires

Inadequate capacity of braking resistor and braking unit

Inappropriate braking unit voltage selection

Over braking ratio

Thermal protection device of braking unit acts resulted by overheated radiator Environmental temperature >40

Countermeasures

Check out if MASTER is selected and check wire connection

Replace braking unit

Check out braking resistor and its wirings

Check out wires

Check out design and calculate again

Set again

Check out design and calculate again

Reduce entironmental temperature with cooling fans

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14.4 Braking Resistor

Braking resistors with different power ratings are available to dissipate braking energy when the frequency converter is in generator mode.

The adjacent tables list the optimal combination of frequency converter, braking unit and braking resistor and the number of components required to operate one frequency converter with respect to a given moderating ratio OT.

ON time

(

OT

) =

Braking time

´ 100 %

Cycle time

Selection reference of OT = 10 %

Braking resistors

FECG02. 1-0K75-3P400

FECG02. 1-2K20-3P400

15

18.5

22

30

37

45

55

75

90

110

FECx02. 1-15K0-3P400

FECx02. 1-18K5-3P400

FECx02. 1-22K0-3P400

FECx02. 1-30K0-3P400

FECx02. 1-37K0-3P400

FECx02. 1-45K0-3P400

FECx02. 1-55K0-3P400

FECx02. 1-75K0-3P400

FECx02. 1-90K0-3P400

FECx02. 1-110K-3P400

Internal

FELB02 1N-30K0

FELB02 1N-30K0

FELB02 1N-30K0

FELB02 1N-45K0

FELB02 1N-45K0

FELB02 1N-30K0

FELB02 1N-45K0

FELB02 1N-45K0

FELB02 1N-45K0

Note:


1

1

1

2

1

1

2

3

3

-

-

-

-

-

-

-

-

FELR01.1N-0080-N750R-D-560-NNNN

FELR01.1N-0260-N250R-D-560-NNNN

FELR01.1N-1K56-N040R-D-560-NNNN


FELR01.1N-04K8-N27R2-D-560-NNNN








750 /80W

400 /260W

250 /260W

150 /390W

100 /520W

75 /780W

50 /1040W

40 /1560W

32 /4.8kW

27.2

/4.8kW

20 /6.0kW

16 /9.6kW

13.6

/9.6kW

20 /6.0kW

13.6

/9.6kW

20 /6.0kW

20 /6.0kW

1

1

1

1

1

1

2

2

3

3


166

Rexroth

Bosch Group



Braking units

Braking resistors Braking resistors

FECG02. 1-0K75-3P400

FECG02. 1-2K20-3P400

30

37

45

55

75

90

110

15

18.5

22

FECx02. 1-15K0-3P400

FECx02. 1-18K5-3P400

FECx02. 1-22K0-3P400

FECx02. 1-30K0-3P400

FECx02. 1-37K0-3P400

FECx02. 1-45K0-3P400

FECx02. 1-55K0-3P400

FECx02. 1-75K0-3P400

FECx02. 1-90K0-3P400

FECx02. 1-110K-3P400

Internal

FELB02 1N-30K0

FELB02 1N-30K0

FELB02 1N-45K0

FELB02 1N-45K0

FELB02 1N-45K0

FELB02 1N-30K0

FELB02 1N-45K0

FELB02 1N-45K0

FELB02 1N-45K0

Note:


1

1

2

2

3

3

3

1

1

-

-

-

-

-

-

-

-

FELR01.1N-0150-N700R-D-560-NNNN

FELR01.1N-0520-N350R-D-560-NNNN

FELR01.1N-0520-N230R-D-560-NNNN

FELR01.1N-0780-N140R-D-560-NNNN





FELR01.1N-10K0-N028R-A-560-NNNN









700 /150W

350 /520W

230 /520W

140 /780W

90 /1040W

70 /1560W

47 /2.0kW

68 /1.5kW

28 /10.0kW

22 /10.0kW

17 /12.5kW

32 /10.0kW

24 /10.0kW

18 /12.5kW

20 /12.5kW

20 /12.5kW

20 /12.5kW

1

2

2

2

3

3

3

2

1

1

Rexroth

Bosch Group

167



30

37

45

55

75

90


Motor power

(kW)

FECG02. 1-0K75-3P400

FECG02. 1-1K50-3P400

FECG02. 1-2K20-3P400

15

18.5

22

FECG02. 1-4K00-3P400

FECx02. 1-5K50-3P400

FECx02. 1-7K50-3P400

FECx02. 1-11K0-3P400

FECx02. 1-15K0-3P400

FECx02. 1-18K5-3P400

FECx02. 1-22K0-3P400

FECx02. 1-30K0-3P400

Internal

FELB02 1N-45K0

FELB02 1N-45K0

FELB02 1N-30K0

FECx02. 1-37K0-3P400

FECx02. 1-45K0-3P400

FECx02. 1-55K0-3P400

FECx02. 1-75K0-3P400

FECx02. 1-90K0-3P400

FELB02 1N-45K0

FELB02 1N-45K0

FELB02 1N-45K0

FELB02 1N-45K0

FELB02 1N-45K0

Note:


2

2

2

3

1

1

4

4

-

-

-

-

-

-

-

-

FELR01.1N-0500-N550R-D-560-NNNN

FELR01.1N-0800-N275R-D-560-NNNN









FELR01.1N-10K0-N27R2-A-560-NNNN






550

110

/500W

275 /800W

180 /1.2kW

/2.0kW

150 /1.5kW

55 /4.5kW

40 /6.0kW

27 /8.0kW

22 /10.0kW

18 /12.5kW

27.2

/10.0kW 2

22

18

22

/10.0kW

/12.5kW

/12.5kW

2

2

3

22 /10.0kW

22 /10.0kW

4

4

1

1

1

1

1

1

1

1

1

2


168

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Drawing of braking resistor in aluminium housing

H

B h

T

H h

T

B

Rexroth

Bosch Group

169



Braking resistor in aluminium housing dimensions

Braking resistor typecode

FELR01.1N-0520-N100R-D-560-NNNN

Impedance

[ ]

Power

[W]

Pic-

100

520

Dimensions[mm] h B T

335 317 60 30

Wiring

2.5

Terminal

[mm]

Cable length

[mm]

Weight

[kg]

-

500 1.03

Type

Aluminium housing

FELR01.1N-0390-N150R-D-560-NNNN

FELR01.1N-0520-N230R-D-560-NNNN

150

230

390

520

265

335

247

317

60

60

30

30

2.5

2.5

-

-

500 0.80

Aluminium housing

500 1.03

Aluminium housing

FELR01.1N-0260-N250R-D-560-NNNN 250 260 215 197 60 30 2.5

-

500 0.62

Aluminium housing

FELR01.1N-0520-N350R-D-560-NNNN

FELR01.1N-0260-N400R-D-560-NNNN

FELR01.1N-0500-N550R-D-560-NNNN

FELR01.1N-0150-N700R-D-560-NNNN

FELR01.1N-0080-N750R-D-560-NNNN

350

400

550

700

750

520

260

500

150

80

A

335 317

215 197

60

60

30

30

2.5

2.5

335 317 60 30

215 197

140 123

40

40

20

20

2.5

2.5

2.5

-

-

-

-

-

500

500

1.03

Aluminium housing

0.62

Aluminium housing

500

500

500

1.03

Aluminium housing

0.32

Aluminium housing

0.20

Aluminium housing




40

47

50

1560

2.0k

1040

485 470 50 107 2.5

M6

550

400

532

384

50 107

50 107

4.0

2.5

M6

M6

-

-

4.35

Aluminium housing

4.90

Aluminium housing

-

4.35

Aluminium housing



FELR01.1N-0780-N075R-D-560-NNNN

68

70

75

1.5K

1560

780

485

485

470

470

50 107 2.5 M6

50 107 2.5

M6

400 382 61 59 2.5

M6

-

-

3.60

Aluminium housing

2.20

Aluminium housing

FELR01.1N-1K04-N090R-D-560-NNNN 90 1040

B

400 384 50 107 2.5

M6

-

-

4.35

Aluminium housing

3.60

Aluminium housing

FELR01.1N-02K0-N110R-D-560-NNNN 110 2.0K

550 532 50 107 4.0

M6

-

2.20

Aluminium housing

FELR01.1N-0780-N140R-D-560-NNNN 140 780

FELR01.1N-01K5-N150R-D-560-NNNN 150 1.5K

FELR01.1N-01K2-N180R-D-560-NNNN 180 1.2K

FELR01.1N-0800-N275R-D-560-NNNN 275 800

400 382 61 59 2.5

M6

-

4.35

Aluminium housing

485 470 50 107 2.5 M6

-

4.90

Aluminium housing

450 434 50 107 2.5 M6

-

4.00

Aluminium housing

400 382 61 59 2.5 M6

-

2.20

Aluminium housing


170

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Drawing of braking resistor box

H

B


W b

T t T

H h

Rexroth

Bosch Group

171



Braking resistor box dimensions

Braking resistor typecode


Impeda nce [ ]

Power

[kW]

Dimensions[mm]

B H t T h b

13.6

9.6

410 685 145 170

Wiring

2

[mm ]

642 340

6.0

Terminal

[mm]

Weight

[kg]

Type

M6 18.5 Resistor box



16

17

9.6

12.5

410 685 145 170 642 340 6.0

410 685 145 170 642 340 6.0

M6

M6

18.5

20.5

Resistor box

Resistor box















18

20

20

22

22

24

27

27.2

27.2

28

32

32

40

55

12.5

12.5

6.0

10.0

12.5

10.0

4.8

10.0

410

410

340

410

340

685 145 170 642 340 6.0

685 145 170 642 340 6.0

600 145 170 580 291

4.0

410 685 145 170 642 340 6.0

410 685 145 170 642 340 6.0

685 145 170 642 340 6.0

8.0

410 685 145 170 642 340

6.0

10.0

410

685 145

170

642

340 6.0

600 145 170 580 291 4.0

410 685 145 170 642 340 6.0

10.0

410 685 145 170 642 340 6.0

4.8

340 600 145 170 580 291

4.0

340 600 145 170 580 291 4.0 6.0

4.5

340 600 145 170 580 291 4.0

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

20.5

20.5

14.0

Resistor box

18.5 Resistor box

20.5 Resistor box

18.5 Resistor box

16.5 Resistor box

18.5 Resistor box

12.0 Resistor box

18.5 Resistor box

18.5 Resistor box

12.0

14.0

12.0

Resistor box

Resistor box

Resistor box

Resistor box

Resistor box


172

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Connection of braking resistors

Fe (0.75-15 kW) DBR

(+)

PB

Power

Fuse MC

L1

L2

L3

U

V

W

M

~

Fe (18.5-110 kW)

Power

Fuse MC

L1

L2

L3

(+) (-)

U

V

W

M

~

WARNING

Energy regenerated when a 3-phase AC motor is decelerated (the frequency is reduced) is recovered and fed into the frequency converter. To prevent overvoltage of the frequency converter, an external braking resistor may be used. A power transistor discharges the DC bus voltage energy (braking voltage threshold at approx. 770 VDC) to the braking resistor, and the energy is lost as heat. The external braking resistor is connected as shown above:

Note 1:

If a resistance lower than the recommended value (and no less than the minimum resistance) is used, contact the agent or manufacturer for calculation of resistance power.

Note 2:

Safety and flammability of surrounding conditions shall be considered. Keep any item 10 cm away from the braking resistor.

Note 3:

A braking resistor can not work overload for a long time. 10 times of rated load should not exceed 5 seconds.

Note 4:

There could be smoking for the first use of the braking resistor as its surface uses organic silicon, which is normal and does not affect the performance of the braking resistor.

Fe Frequency Converters from 18.5 to 110 kW need an external braking unit to use the braking resistor.

For installation of the braking unit please refer to chapter

14.3 Braking Unit

.

The braking resistor connector connection at the frequency converter

(Terminals (+) and PB at converters from 0.75 - 15 kW) and the braking resistor connection at the braking unit (Terminals P1 and PB) have no shortcut protection!

Wrong wiring will cause damage to the components!

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173



14.5 dV/dt filter (Motor filter)

dV/dt filters are used to reduce the rise of the output voltage of the frequency converter; to reduce the leakage current of the motor lines; to reduce the interference voltage on the motor lines.




14.6 Communication Interface

14.6.1 PROFIBUS adapter

The PROFIBUS adapter FEAA02.1-MODB-PROFI-NNNN-NN is used to convert the converters serial RS485 interface (ModBus) to the PROFIBUS

DP standard.

Refer to the separate PROFIBUS Adapter User Manual.

14.6.2 RS232 / RS485 adapter

The RS232 / RS485 adapter FEAA01.1-RS485-RS232-NNNN-NN is used to connect the RS485 interface (ModBus) with a PC or another control unit.

14.6.3 Cable for PROFIBUS adapter

The cable FRKB0001/001,0, which is 1 m long, is used to connect the frequency converter to the PROFIBUS adapter.

14.6.4 Cable between frequency converter and RS232 / RS485 adapter

The cable FRKB0002/005,0, which is 5 m long, is used to connect the frequency converter to the RS232 / RS485 adapter.


174

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14.7 Remote Operating Panel

14.7.1 Remote operating panel for control cabinet mounting

The remote operating panel FECC02.1T-R-STD-POTI-NNNN is used to mount the panel at the control cabinet. The user can conveniently operate the frequency converter from the outside of the control cabinet.

Rexroth

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175



14-19 Accessories


176

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14.7.2 Control cabinet operating panel cable

The cable FRKS0001/001,0, which is 1 m long, is used to connect the operating panel for control cabinet mounting with the frequency converter.

The cable FRKS0002/003,0, which is 3 m long, can be also used for the connection of the operating panel. For connection of the FRKS0001 or

FRKS0002 cable, it is necessary to remove the panel at the frequency converter and connect the cable there.

14.7.3 Operating panel with potentiometer for converters from 11 kW.

The standard panel of the frequency converter from 11 kW and bigger has no potentiometer.

There is an optional operating panel with potentiometer for converters from

11kW and bigger available: FECC-02.1T-B-STD-POTI-NNNN.

14.8 Engineering Software

Rexroth ConverterPC4.0 is an engineering software that allows user to commission and parameterize the frequency converters. Parameters are set on the PC and transferred to the converters via serial RS485 (ModBus) interface. Together with the engineering software is the ConverterPC4.0 user manual available.

Rexroth

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177



15-1 Additional Information

15 Additional Information

15.1 Running Settings Diagram

[b00]=0

SF, SR terminals, panel Run, panel Stop

[b02]

[b16]

[b17]

[b00]=1

C ommand from Circuit given by

[E38] panel Stop

[b00]=2


[E38] panel Stop

[b01]

[b16]

[b17]

[b00]=3

SF, SR terminal, panel Run, panel Stop

[b00]=4


[E38] panel Stop

[b00]=5

External computer, panel Stop

External terminals

(incl. external terminal multi

-speed)

Simple

PLC

[b02] decides speed 0 setting

Other speeds given by group

P multifrequency

Multi-speed acceleration/ deceleration time (Group P)

[b01] decides speed 0 setting

Other speeds given by group

P multifrequency

Multi-speed acceleration/ deceleration time (Group P)

Given by panel potentiometer, when X3 is disconnected;

Given by [b02], when X3 is closed.

When [b02]=0-2,

[b02]=5, and other values shall be normally considered

[b16] [b17]

[b02]

[b16]

[b17]

[b00]=6

External computer

[b02]

[b16]

[b17]

PI operation

Frequency setting

Upper frequency

[b21]

Skip frequency

[E00]

[E01]

[E02]

Lower frequency

[b22]

PI control enabling[E24]

Jogging mode selection [b35]

Jogging frequency selection [b36]

Jogg ing acceleration/deceleration time [b37][b38]

DOK-RCON01-FE*********-IB05-EN-P 178

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Additional Information 15-2


15.2 Process Control

Set Value a) Panel potentiometer b) VRC c) +I d) Ae) External machine

[b01]

f) Setting with digital

Operating panel g) Multi-speed 1-7 h) PLC

i) Jogging [b36]

NOTE:

See the Running

Setting Diagram

Proportional gain [E26]

Integration time constant [E27] inverse action

PI output

24

Proportional gain [E26]

Integration time constant [E27]

Ramp function

8

Group P acceleration/ deceleration time

Feedback a) FB

([E25]=0, 1) b) +I

([E25]=2, 3) c) A-

([E25]=4) d) A-, B- (A+, B+)

([E25]=0,1)

15.2.1 Simple application of process control

(1) Automatic constant pressure water control system

Rexroth

Bosch Group

The set value of pressure is set by using [b01] to set the frequency directly.

The pressure feedback from the FB terminal corresponds to a value of

0 V to 5 V.

2

If the pressure feedback relationship is 0V 0.0kg/cm , [E22]=10.0,

[E23]=0.0, [E24]=1 and [E25]=0, while [E26], [E27] and [E28] are set depending on actual conditions.

179



(2) Closed-loop speed control system


15.2.2 conditions and requirements

PGP is connected to the operational power supply of PG, and the set value of speed is set by 0 to 5 V signals from the panel potentiometer.

If the relationship between 0 to 5 V setting and speeds is: 0V 0.0 rpm, and

5 V 1500 rpm, and the pulses per cycle of the feedback encoder are 1024, the feedback pulse frequency that corresponds to 1500 rpm is:

1500 rpm

60s

1000

1024

= 25.6 kHz

DOK-RCON01-FE*********-IB05-EN-P 180

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15.2.3 Parameter setting steps:

A. Set the display factor [E22]=1500.0, [E23]=0.0; b. For single phase pulse input, set [E24]=1 or 2, [E25]=4 and [E31]=25.6 kHz.

c. For orthogonal pulse input, set [E24]=1 or 2, [E25]=5 and [E31]=25.6 kHz.

Notes:

If the calc ulated [E31] is not an integral multiple of 0.1 kHz, to improve the accuracy of steady-state control, the calculated result may be rounded to be an integral multiple of 0.1 kHz. Then [E22] can be derived and the speed corresponding to 5 V can be set. Since 200.0 kHz is the maximum pulse frequency which may be input into Fe series converter, the pulses per cycle of the feedback encoder cannot be higher than , for the control target of 1500 rpm.

1500 rpm

Generally, for a feedback encoder whose pulses per cycle are N, the maximum speed to be controlled is:

[

200.0 kHz 60s

N

]

(rpm)

Example:

If the relationship between 0 to 5 V and the speed is 0 V 0.0 rpm, and

5 V 1600 rpm, and the pulses per cycle of the encoder are 1000, the maximum input pulse frequency is:

[E31] =

1000

1600

60

1000

= 26.667 kHz

To improve the control accuracy, take [E31] 26.7 kHz and

[E22] =

26.7

26.667

1600 = 1602.0

Since 5 V 1602.0 rpm, the voltage which corresponds to 1600 rpm equals

1600

1602

5 V = 4.99 V

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181




15.3 Discharging of Capacitors

15.3.1 Discharging of DC bus capacitors

In the frequency converters, capacitors are used in the DC bus as energy stores.

Energy stores maintain their energy even when the supply voltage has been cut off and have to be discharged before somebody gets in contact with them.

Discharging devices have been integrated in the frequency converters; within the indicated discharging time, these devices discharge the voltage below the allowed 50 V.

Frequency converters have been dimensioned in such a way that after the supply voltage was cut off, the voltage value falls below 50 V within a discharging time of a maximum of 30 minutes.

To shorten the waiting time until voltage has fallen below 50 V, you can take the following measure:

Use the discharging device described below

15.3.2 Discharging device

Operating principle

A contactor is installed to switch a resistor to the terminals L+ and L- of the

DC bus connection to discharge the capacitors. The contactor is activated via a control input which is supplied with appropriate control voltage.

R Discharging resistor

K Contactor contact

Operating Principle of Discharging Device


182

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Bosch Group



Dimensioning

Installation

WARNING

CAUTION

Activation

Rexroth

Bosch Group

The individual components have to be sufficiently dimensioned:

Value of the discharging resistor: 1000 ohm and at least 1000 W;

The discharging resistor and the contactor contact have to withstand the loads of practical operation (for example in the case of frequent use of the discharging device of the occurring continuous power).

The contactor contact has to withstand the occurring direct voltage of a minimum of 1000 V;

The contactor contact has to withstand the occurring discharge current according to the resistance value that is used, i.e. 1 A with

1000 ohm.

Lethal electric shock caused by live parts with more than 50 V!

Before working on live parts: De-energize the installation and secure the power switch against unintentional or unauthorized re-energization.

Wait at least

30 minutes

after switching off the power supply voltages to allow discharging.

Check whether voltages have fallen below 50 V before touching live parts!

Risk of damage by intense heat!

During the discharging process, the discharging resistor generates intense heat. Therefore, place the discharging resistor as far as possible from heatsensitive components.

How to install the discharging device

1.

Preferably install discharging device

before switching on supply voltage of the first time.

If you install discharging device after having switched on supply voltage for the first time, wait 30 minutes to allow discharging. Check whether voltage has fallen below 50 V before touching live parts!

2.

Place discharging resistor as far as possible from heat-sensitive components.

Observe the following order for activating the discharge device:

1.

De-energize installation and secure power switch against unintentional for unauthorized re-energization.

2.

Activate discharging device.

183 DOK-RCON01-FE*********-IB05-EN-P

16-1 Communication Protocols


16 Communication Protocols

The standard RS485 port realizes the communication between the master station and the slave station via ModBus protocol. In addition to that

PROFIBUS adapter is available as an external option to realize PROFIBUS network communication. With the help of a PC, a PLC or an external computer a “

sin

gle master/ multiple slav

e

” n etwork can be realized (setting of frequency control command and running frequency, modification of function code parameters, monitoring of frequency converter running status and failure messages) to address the specific requirements of applications.

For the PROFIBUS communication, please refer to the manual of the

PROFIBUS adapter. For the ModBus communication, please refer to the following parts of this technical documentation.

16.1 ModBus Protocol

16.1.1 Overview

ModBus is a master/slave protocol. Only one device may send commands in the network at a particular time.

The master station manages information exchange by polling the slave stations. Unless being approved by the master station, no station may send information.

In case of an error during data exchange, if no response is received, the master station will query the slave stations absent from the polling.

If a slave station is not able to understand a message from the master station, it will send an exception response to the master station.

Slave stations can not communicate with each other but through the master's software, which reads data from one slave station and send them to another.

There are two types of dialogues between the master station and the slave stations:

The master station sends a request to a slave station and waits for its response.

The master station sends a request to all slave stations and does not wait for their response (broadcasting).


184

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Communication Protocols 16-2


16.1.2 Transmission

The transmission is of RTU (remote terminal unit) mode with frames containing no message header or end mark. A typical RTU fame format is shown below:

Slave address

ModBus function code (1 byte)

Data

CRC16 check

Data are transmitted in binary codes.

If an interval is 3.5 characters or longer, it is taken as the end of the frame.

Therefore, all information in a frame must be transmitted in a continuous data flow. If an interval of 3.5 characters or longer occurs before a complete frame is sent out, the receiving device will consider the information has ended and start processing it, and mistake following bytes for a new frame's address. Similarly, if the interval between a new frame and the previous one is less than 3.5 characters, the receiving device will consider it as a part of the previous frame. Due to confusion of the frames, the CRC check will fail and lead to a communication fault.

Data format and sending sequence of one byte:

1 start bit, 8 data bits; 1 parity check bit or no parity check bit; 1 or 2 stop bits.

CRC (Cyclic redundancy check): CRC16, lower bytes first and higher bytes later.

Slave address:

The address of a frequency converter may be any between 1 and 247.

The address 0 is reserved for broadcasting. Frequency converters will act upon its request but make no acknowledgement.

Every address must be unique in the network.

16.2 Port

The standard RS485 communication port provided by Fe series converter is shown below.

Rexroth

Bosch Group

See the following table for information on the relationship between pins and signals:

2

3

Pin

1

Signal

Void

GND

485-

Pin

4

5

6

Signal

485+

+5V

Void

185 DOK-RCON01-FE*********-IB05-EN-P



16.3 Protocol Functions

16.3.1 Supported functions

The main function of ModBus is to read and write parameters. Different function codes decide different operation requests.

The following table lists the ModBus functions managed by Fe series converters and their limits.

“Re ading

” and

“writi ng

” is

considered from the prospect of the master station.

Function code

Descreption

3=0x03

Read N register parameters

Broadcast

NO

6=0x06 Rewrite a register with information stored even after power off

YES

8=0x08

Loop test

NO

16=0x10

23=0x17

Rewrite N registers with information stored even after power off

YES

Read from and write to N registers

NO

-

-

Maximum value of N

16 characters in maximum



If the device fails to act upon the request, it responds with an error code and exception code. The error code is the function code plus 0x80. The frame format is: Local address + (function code + 80H) + exception code + check lower byte and check higher byte. An example is given below:

Meaning

Start

Data

---

Local address

0x01

RTU

3.5 t

0x01

Error code

Exception code

Frame check

The highest digit of the command code is 1. For example, command code 0x16 is considered as 0x96

Code meaning

0x01: Invalid command code

0x02: Invalid data address

0x03: Illegal data frame (out of limit reading/writing characters or an

incomplete frame)

0x04: Fault in command execution (function code un-rewritable due to

protection/ function code to be modified out of limit/ function code can

not be modified/wrong password)

0x05: CRC error

0x96

0x01

CRC lower byte

---

CRC higher byte

End

--3.5 t

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16.3.2 Function code and communication data description

Function 0x03:

read N words (continuous reading 16 words in maximum)

For example, it is necessary to read 2 words continuously starting from the memory address of 0004 from the slave converter addressed at 01H. The frame is described below:

RTU host command information

START

ADDR

CMD

Higher byte of start address

Lower byte of start address

Higher byte of data counts

Lower byte of data counts

CRC lower byte

CRC higher byte

END

Transmission time for 3.5 bytes

01H

03H

00H

04H

00H

02H

85H

CAH

Transmission time for 3.5 byte

Responses message from RTU slave

START

ADDR

CMD

Number of bytes

Data address 0004H higher byte

Data address 0004H lower byte

Data address 0005H higher byte

Data address 0005H lower byte

CRC lower byte

CRC higher byte

END


01H

03H

04H

04H

00H

00H

00H

43H

07H


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Function 0x06:

Write a word

Example: write 5000 (1388H) to the address 0008H of the slave converter with address 02H. The frame structure is described below:

RTU master command message

START

ADDR

CMD

Write data address higher byte

Write data address lower byte

Data content higher byte

Data content lower byte

CRC lower byte

CRC higher byte

END


02H

06H

00H

08H

13H

88H

05H

6DH


Responses message from RTU slave

START

ADDR

CMD

Write data address higher byte

Write data address lower byte

Data content higher byte

Data content lower byte

CRC lower byte

CRC higher byte

END


02H

06H

00H

08H

13H

88H

05H

6DH


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Function 0x08:

Loop test.

The test function code is 0000H and it is necessary to return the frame as being received. The message sent by the master to the No. 1 slave is as follows:

START

Slave address:

ModBus function code

Test function code higher byte

Test function code lower byte

Test data higher byte

Test data lower byte

CRC (lower byte)

CRC (lower byte)

END


01H

08H

00H

00H

37H

DAH

77H

A0H


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Function 0x10:

Writes N words (16 in maximum)

Example: A converter's slave address is 01H and it is necessary to modify two continuous parameter registers. The start address of the registers is 0109H and the data to be written are 003CH and 0050H.

The messages are given below:

Request from the master:

Message start

Slave address


Higher byte of the start address of register to be written

Lower byte of the start address of register to be written

Higher byte of number of registers

Lower byte of number of registers

Number of bytes of date to be written

Higher byte of datum1

Lower byte of datum1



CRC lower byte

CRC higher byte

Message end


01H

10H

01H

09H

00H

02H

04H

00H

3CH

00H

50H

FEH

65H


Response from the slave :

Message start

Slave address


Higher byte of the start address of register

Lower byte of the start address of register

Higher byte of number of registers

Lower byte of number of registers

CRC lower byte

CRC higher byte

Message end


01H

10H

01H

09H

00H

02H

90H

36H


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Function 0x17:

Read/write N words (16/16 in maximum)

Example: A converter's slave address is 01H. It is necessary to read the contents from 2 continuous parameter registers with the start address at 0100H and write 0064H and 00C8H into 2 continuous parameter registers with the start address at 0109H. The messages are given below:

Request from the master:

Message start

Slave address


Higher byte of the start address of read/write registers

Lower byte of the start address of read/write registers

Higher byte of number of read registers

Lower byte of number of read registers

Higher byte of the start address of write register

Lower byte of the start address of write register

Higher byte of number of registers to be written

Lower byte of number of registers to be written

Number of bytes of data to be written





CRC lower byte

CRC higher byte

Message end


01H

17H

01H

00H

00H

02H

01H

09H

00H

02H

04H

00H

64H

00H

C8H

48H

72H


Response from the slave:

Message start

Slave address


Byte of number of read registers

Higher byte of contents in 0100H

Lower byte of contents in 0100H

Higher byte of contents in 0101H

Lower byte of contents in 0101H

CRC lower byte

CRC higher byte

Message end


01H

17H

04H

00H

05H

00H

00H

E9H

26H


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16.4 Communication Mapping Register Address Distribution

The communication mapping registers of ModBus are in three types:

converter parameter register group converter control register group

converter state feedback register group

Converter parameter register group

Converter parameter registers correspond to the function codes one-to-one.

Reading and writing of related function codes can be achieved through reading and writing of the contents in converter parameter registers via

ModBus communication. The characteristics and scope of reading and writing function codes are in compliance with the user manual of the converter. The address of a converter parameter register consists of one word. The higher byte (8-bit) (0x00-0x03) represents the function code group, and the relationship is shown below; the lower byte (8-bit) represents the function code within the code group (group b: 0-43 / E: 0-48 / P: 0-37 / H: 0-

63).

Function code group

Mappped address

b E

P H

00H 01H 02H 03H

Example:

For the parameter register with address 0x0103, the higher byte 0x01 represents group E, and the lower byte represents the fourth function code of group E, i.e. [E03].

The frequency converter may provide monitoring values, which can be used to query corresponding state feedback registers PZD3 to PZD10, with function codes [H14] to [H21].

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Converter control register group (0x4000, 0x4001)

The address of register for communication control commands is 0x4000

(allows write-only). The converter is controlled through writing related data words into the address. The definition of each bit is shown below:

Control register Address Description Action

Main control communication set frequency

0x4000

0x4001

Bit 0: 0: Invalid; 1: Stopping in the mode as set by function code

Bit 1: Reserved

Bit 2: Reserved

Bit 3: 0: Invalid; 1: Starting converter

Bit 4: Reserved

Bit 5: Reserved

Bit 6: Reserved

Bit 7: 0: Invalid; 1: Reset after fault

Bit 8: 0: Forward jogging invalid; 1: Forward jogging valid

(level signal)

Bit 9: 0: Reverse jogging invalid;1: Reverse jogging (level signal)

Bit 10: Reserved

Bit 11: 0: Invalid; 1: Converter forward rotation

Bit 12: 0: Invalid; 1: Converter reverse rotation

Bit 13: Reserved

Bit 14: Reserved

Bit 15: Reserved

Write only

0 to highest frequency, unit 0.01 Hz

Write only

The address of register for communication set frequency is 0x4001 (allows write-only). If the frequency setting mode [b02] is set to be loaded by external computer, the converter's running frequency can be changed by writing the corresponding data into the address.

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Status

Register

Main status

Fault word

Output frequency

Frequency setting

Output current

Output voltage

Converter state feedback register group

The converter state can be monitored by reading the register(allows readonly). The state is defined as follows:

Address Description

Action

0x5000

0x5001

Bit 0: DC voltage (1: normal; 0: abnormal)

Bit 1: System fault (1: fault; 0: no fault)

Bit 2 and 3: Motor direction (01: reverse; 10: forward)

Bit 4: Running status (1: running; 0: stopped)

Bit 5: Acceleration (1: yes; 0: no)

Bit 6: Deceleration (1: yes; 0: no)

Bit 7: Waiting for fault retry (1: yes; 0: no)

Bit 8: Coasting to stop (1: yes; 0: no)

Bit 9: DC braking (1: yes; 0: no)

Bit 10: Stall over current protection (1: yes; 0: no)

Bit 11: Stall over voltage protection (1: yes; 0: no)

Bit 12: Jogging (1: yes; 0: no)

Bit 13: Restarting after transient stopping (1: yes; 0: no)

Bit 14: Reserved

Bit 15: Reserved

Bit 0: Main circuit under voltage

Bit 1: Over current at constant speed

Bit 2: Over current during acceleration

Bit 3: Over current during deceleration

Bit 4: Over voltage at constant speed

Bit 5: Over voltage during acceleration

Bit 6: Over voltage during deceleration

Bit 7: Motor overload

Bit 8: Converter overheat

Bit 9: Drive protection action

Bit 10: EMC CPU -

Bit 11: Input phase failure

Bit 12: Output phase failure

Bit 13: External fault (E-Stop)

Bit 14: Reserved

Bit 15: Reserved

Read only

Read only

0x5002

Unit 0.01 Hz

0x5003

Unit 0.01 Hz

0x5004

Unit 0.1 A

0x5005

Unit 0.1 V

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Status

Register

Bus voltage

Addressing

0x5006

Switch value input signal

Module temperature

PI control feedback value

PZD1

PZD2

PZD3

PZD4

PZD5

PZD6

PZD7

PZD8

PZD9

PZD10

0x5007

0x5008

0x5009

0x7346

0x7347

0x7348

0x7349

0x734A

0x734B

0x734C

0x734D

0x734E

0x7350

Description

Unit 0.1 V

Bit14-X1; bit13-X2; bit12-X3; bit11-SR; bit10-SF

Unit: 1

Signed fixed-point number Q14

Status word (contents of 0x5000)

Actual running frequency (contents of 0x5002)

Set by [H14]

Set by [H15]

Set by [H16]

Set by [H17]

Set by [H18]

Set by [H19]

Set by [H20]

Set by [H21]

Action

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16.5 ModBus Communication Example

A Fe series converter's slave address is 01H. The frequency setting of the frequency converter has been set to “ex ternal computer frequency settin g” and the source of running commands is “exter nal computer contr ol”. It is required for the motor connected to the frequency converter to run with 50

Hz (forward rotation). The operation can be achieved with function 0x10 of the ModBus protocol. The messages of the requests from the master and responses from the slave are given below:

Example 1: Start 01# converter for forward rotation at frequency of 50.00 Hz

(represented by 5000 internally)

Request

Response

Slave address

0x01

0x01

Function code

0x10

0x10

Start address

0x4000

0x4000

Number of addresses

0x0002

0x0002

Bytes of contents

Data contents CRC code

0x0808

0x04

0x1388

0x4C98

N/A N/A 0x5408

Example 2: Read the output voltage of 01# converter and bus voltage

Request

Response

Slave address

0x01

0x01

Function code

0x03

0x03

Start address

0x5005

N/A

Number of addresses

0x0002

N/A

Bytes of contents Data contents CRC code

N/A N/A

0xC50A

0x04

0x114D

0x175B

0x2113

Example 3: Stop 01# converter according to the stopping mode set with the function code

Request

Response

Slave address

0x01

0x01

Function code

0x06

Start address

0x4000

Number of addresses

N/A

Bytes of contents Data contents CRC code

N/A 0x0001

0x5DCA

0x06 0x4000

N/A

N/A 0x0001

0x5DCA

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16.6 Communication Networking

16.6.1 Networking

The communication network is shown below, with a PC, a PLC or an external computer and various frequency converters, which are connected by shielded twisted pair cables via RS232/485 adapters. The maximum length of 232 network cable connection is 15 meters. Network terminal slaves need external resistance with a recommended value of 120

Shielded twisted pair wire

485

RS232/485

Adapter

232 GND

GND 485+ 485GND

485+ 485-

GND

485+ 485-

PC/PLC

Slave station 1 Slave station 2 Slave station n

Warning!

Cables may only be connected when drive is turned off.

16.6.2 Recommendations on networking

Use shielded twisted pair cable to connect RS485 links.

ModBus cable should be adequately away from power cables (30 cm in minimum).

Avoid crossing of ModBus cables and power cables and use orthogonal crossing if crossing must be used.

The shield layer of cables should be connected to protected ground or to equipment ground if the equipment ground has already been connected to protected ground. Do not directly ground any point of the

RS485 network.

In no circumstance should ground cables constitute a loop.

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17-1 Disposal and Environmental Protection

17 Disposal and Environmental Protection

17.1 Disposal

Packaging Materials

T he packaging materials consist of cardboard and polystyrene. These materials can be easily recycled. For ecological reasons you should not return the empty packages to us.

17.2 Environmental Protection

No Release of Hazardous Substances

Our products do not contain any hazardous substances that they can release in case of appropriate use. Normally there are not any negative effects on the environment to be expected.

Materials contained in the products

Electronic Devices

Electronic devices mainly contain: steel aluminum copper synthetic materials electronic components and modules

Recycling

D ue to their high content of metals most of the product components can be recycled. In order to recycle the metal in the best possible way it is necessary to disassemble the products into individual modules.

The metals contained in the electric and electronic modules can also be recycled by means of specific separation processes.

The synthetic materials remaining after these processes can be thermally recycled.

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Service and Support 18-1

18 Service and Support

Our service helpdesk at our headquarters in Lohr, Germany, will assist you with all kinds of enquiries. Out of helpdesk hours please contact our German service department directly.

Time

1)

Phone

Fax

Helpdesk

Service Hotline Germany

Mo-Fr 7:00 am - 6:00 pm CET

Mo-Fr 6:00 pm - 7 am CET

Sa-Su 0:00 am - 12:00 pm CET

Service Hotline Worldwide

Outwith Germany please contact our sales/service office in your area first.

+49 (0) 9352 40 50 60

+49 (0) 171 333 88 26 or

+49 (0) 172 660 04 06

+49 (0) 9352 40 49 41

-

For hotline numbers refer to the sales office addresses on the Internet.

e-mail [email protected]

-

Internet http://www. boschrexroth. com

You will also find additional notes regarding service, maintenance (e.g. delivery addresses) and training.

1) Central European Time (CET)

Preparing Information

For quick and efficient help please have the following information ready: detailed description of the fault and the circumstances information on the type plate of the affected products, especially type codes and serial numbers

Your phone, fax numbers and e-mail address so we can contact you in case of questions.

For technical support, please use the following email address: [email protected]

.


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19 Index

A

About this documentation, 1

Accessories, 158

Advanced function group (group H), 118

Analog input terminal, 52

Appropriate use, 14

B

Basic function group (group b), 65

Block diagram, 39

Braking resistor, 166

Braking unit, 159

C

Cable and fuse dimensions, 41

CE certification, 19

Commissioning, 61

Communication interface, 174

Communication protocols, 184

Control terminals, 50

Cooling types, 16

D

Delivery and storage, 17

Derating and ambient temperature, 134

Derating and mains voltage, 134

Derating of electrical data, 134

Derating of the output current, 135

Dimensions, 30

Discharging device, 182

Discharging of capacitors, 182

Disposal, 198 dV/dt filter (Motor filter), 174

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19-1 Index

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Index 19-2


E

Electrical parameters, 136

Electromagnetic compatibility (EMC), 137

EMC filter, 158

EMC measures for design and installation, 145

EMC requirements, 137

EMC-optimal installation in facility and control cabinet, 147

Ensuring the EMC requirements, 143

Environmental protection, 198

Extended function group (group E), 95

F

Fault protection actions, 132

Fault types, 130

Fe general technical data, 133

Functions, 15

G

Ground connections, 154

I

Inappropriate use, 14

Installation, 33

Interfaces, 16

Introduction, 1

Introduction to the drive system, 3

L

LED, 54

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M

Main circuit terminals, 49

Mains chokes, 158

Materials contained in the products, 198

Menu structure, 56

ModBus communication example, 196

ModBus protocol, 184

Mounting, 28

N

Noise emission of the drive system, 139

Noise immunity in the drive system, 137

O

Opening instruction, 33

Operating panel, 54

Operating panel operation, 58

P

Parameter fast setting, 62

Parameter settings, 65

Port, 185

Process control, 179

PROFIBUS adapter, 174

Programmable control function group (group P), 112

Properties of the basic device Fe, 15

19-3 Index

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Index 19-4


R

Radio interference suppression, 156

Recycling, 198

Remote operating panel for control cabinet mounting, 175

Restore factory defaults, 64

RS232 / RS485 adapter, 174

Running settings diagram, 178

S

Safety instructions, 4

Service and support, 199

Signal lines and signal cables, 155

Solutions for simple fault, 64

Switch wiring, 50

T

Technical data, 133

Type coding, 19

U

UL certification, 20

W

Wiring, 40

Wiring terminals, 49

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