REXROTH IndraDrive C Series Project Planning Manual
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REXROTH IndraDrive C Series Project Planning Manual

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Industrial
Electric Drives
Hydraulics
and Controls
Rexroth IndraDrive C
Drive Controllers
Power Sections HCS02.1
Project Planning Manual
Linear Motion and
Assembly Technologies
Pneumatics
Service
Mobile
Automation
Hydraulics
R911306138
Edition 02

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Summary of Contents for REXROTH IndraDrive C Series

  • Page 1 Industrial Electric Drives Linear Motion and Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth IndraDrive C R911306138 Drive Controllers Edition 02 Power Sections HCS02.1 Project Planning Manual...
  • Page 2 "Rexroth IndraDrive Drive System" Copyright Bosch Rexroth AG 2004 2005  Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).

  • Page 3: Table Of Contents

    Rexroth IndraDrive C Contents Contents Introduction Documentation..........................1-1 Purpose of Documentation ...................... 1-1 Documentations - Overview ....................1-2 Basic Structure of a Drive Controller .................... 1-3 Power Section.......................... 1-3 Control Section ........................1-4 Drive Controllers - Block Diagram ....................1-4 HCS02.1E-W0012-NNNN .......................
  • Page 4 Contents Rexroth IndraDrive C Type Code ..........................4-1 Type Plates ........................... 4-2 Type Plate Arrangement......................4-2 Type Plate Power Section (Example)..................4-2 Type Plate Control Section...................... 4-2 Scope of Delivery.......................... 4-3 Mechanical Data Dimensions ........................... 5-1 HCS02.1E-W0012 ........................5-1 HCS02.1E-W0028 ........................5-2 HCS02.1E-W0054 and HCS02.1E-W0070 ................
  • Page 5 Rexroth IndraDrive C Contents Touch Guard Cutouts............................7-1 Mounting ............................7-2 Disposal and Environmental Protection Disposal ............................8-1 Products........................... 8-1 Packaging Materials ........................ 8-1 Environmental Protection......................8-1 No Release of Hazardous Substances ................... 8-1 Materials Contained in the Products ..................8-1 Recycling ..........................
  • Page 6 Contents Rexroth IndraDrive C DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 7: Introduction

    "Rexroth IndraDrive Drive System" (DOK-INDRV*- SYSTEM*****-PRxx-EN-P; part no. R911309636) into account. For complete project planning of a Rexroth IndraDrive drive system you need, in any case, the Project Planning Manual "Rexroth IndraDrive Drive System" (DOK-INDRV*-SYSTEM*****-PRxx-EN-P; part no. R911309636). This Project Planning Manual, among other things, contains: •...

  • Page 8: Documentations - Overview

    Introduction Rexroth IndraDrive C Documentations - Overview For project planning a drive system following documentations are available: Title Type of Documentation Document Typecode Rexroth IndraDrive Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P Drive System Rexroth IndraDrive Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P Drive Controllers Control Sections...

  • Page 9: Basic Structure Of A Drive Controller

    Rexroth IndraDrive C Introduction Basic Structure of a Drive Controller hcs_lt_rt.fh7 Power section Control section Fig. 1-2: Basic structure The drive controller consists of two essential parts: • Power section • Control section Power Section The following are connected to the power section: •...

  • Page 10: Control Section

    Introduction Rexroth IndraDrive C Control Section The control section is a separate section which is inserted into the power section. The drive controller is supplied ex works complete with control section The control section must only be replaced by a trained person.

  • Page 11: Hcs02.1E-W0012-Nnnv

    Rexroth IndraDrive C Introduction HCS02.1E-W0012-NNNV Softstart line input with optional braking resistor DC bus converter bridge circuit integrated circuit capacitance bridge circuit rectifier control with output to charging voltage the motor current limit supply hcs_block_12v.FH7 Fig. 1-4: HCS02.1E-W0012-NNNV - Block diagram HCS02.1E-W0028-NNNN...

  • Page 12: Hcs02.1E-W0028-Nnnv

    Introduction Rexroth IndraDrive C HCS02.1E-W0028-NNNV Softstart line input with optional braking resistor DC bus converter DC bus bridge circuit integrated circuit capacitance bridge circuit connection rectifier control with output to charging voltage the motor current limit supply hcs_block_28v.FH7 Fig. 1-6: HCS02.1E-W0028-NNNV - Block diagram HCS02.1E-W0054/70-NNNN...

  • Page 13: Hcs02.1E-W0054/70-Nnnv

    Rexroth IndraDrive C Introduction HCS02.1E-W0054/70-NNNV optional external braking resistor R Softstart line input with optional braking resistor DC bus converter DC bus bridge circuit integrated circuit capacitance bridge circuit connection rectifier control with output to charging voltage the motor current limit supply hcs_block_54_70v.FH7...

  • Page 14: General Information

    This protects the electronic components (permitted in accordance with EN 60204-1). During their routine check test, Rexroth drive components are tested for high voltage and insulation in accordance with EN 50178.

  • Page 15: Important Directions For Use

    The user alone carries all responsibility of the risks. Before using Rexroth products, make sure that all the pre-requisites for an appropriate use of the products are satisfied: • Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use.

  • Page 16: Areas Of Use And Application

    Important Directions for Use Rexroth IndraDrive C Areas of Use and Application Drive controllers made by Rexroth are designed to control electrical motors and monitor their operation. Control and monitoring of the motors may require additional sensors and actors. Note: The drive controllers may only be used with the accessories and parts specified in this document.

  • Page 17: Safety Instructions For Electric Drives And Controls

    Rexroth IndraDrive C Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls Introduction Read these instructions before the initial startup of the equipment in order to eliminate the risk of bodily harm or material damage. Follow these safety instructions at all times.

  • Page 18: Hazards By Improper Use

    Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C Hazards by Improper Use High voltage and high discharge current! Danger to life or severe bodily harm by electric shock! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by...

  • Page 19: General Information

    Rexroth IndraDrive C Safety Instructions for Electric Drives and Controls General Information • 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.
  • Page 20 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C • Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the documentation "EMC in Drive and Control Systems".

  • Page 21: Protection Against Contact With Electrical Parts

    Rexroth IndraDrive C Safety Instructions for Electric Drives and Controls Protection Against Contact with Electrical Parts Note: This section refers to equipment and drive components with voltages above 50 Volts. Touching live parts with voltages of 50 Volts and more with bare hands or conductive tools or touching ungrounded housings can be dangerous and cause electric shock.

  • Page 22: Protection Against Electric Shock By Protective Low Voltage (Pelv)

    Protection Against Electric Shock by Protective Low Voltage (PELV) All connections and terminals with voltages between 0 and 50 Volts on Rexroth products are protective low voltages designed in accordance with international standards on electrical safety. High electrical voltage due to wrong...

  • Page 23: Protection Against Dangerous Movements

    Rexroth IndraDrive C Safety Instructions for Electric Drives and Controls Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of the connected motors. Some common examples are: • improper or wrong wiring of cable connections • incorrect operation of the equipment components •...
  • Page 24 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ensure personal safety by means of qualified and ⇒ tested higher-level monitoring devices or measures DANGER integrated in the installation.

  • Page 25: Protection Against Magnetic And Electromagnetic Fields During Operation And Mounting

    Rexroth IndraDrive C Safety Instructions for Electric Drives and Controls ⇒ 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 ⇒...

  • Page 26: Protection Against Contact With Hot Parts

    3-10 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C Protection Against Contact with Hot Parts Housing surfaces could be extremely hot! Danger of injury! Danger of burns! ⇒ Do not touch housing surfaces near sources of heat! Danger of burns!

  • Page 27: 3.11 Battery Safety

    3-11 Rexroth IndraDrive C Safety Instructions for Electric Drives and Controls 3.11 Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or material damage. Risk of injury by incorrect handling! ⇒ Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and cauterization).
  • Page 28 3-12 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C Notes DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 29: Identification

    Rexroth IndraDrive C Identification Identification Device Types Type Code Note: The following figure illustrates the basic structure of the type code. Your sales representative will help with the current status of available versions. Abbrev. Column 1 2 3 4 6 7 8 9...

  • Page 30: Type Plates

    Identification Rexroth IndraDrive C Type Plates Type Plate Arrangement hcs_lt_rt_typenschildert.fh7 Power section type plate Control section type plate Fig. 4-2: Type plate arrangement Type Plate Power Section (Example) Device type HCS02.1E-W0012-A-03- NNNN R911298371 Made in Germany FD:04W12 Part number SN: HCS021-00123...

  • Page 31: Scope Of Delivery

    Rexroth IndraDrive C Identification Scope of Delivery as standard optional Power section Control section Touch guard Accessories HAS02.1 Connectors X3, X5, X6, X13 Further accessories Connector X9 (HCS02.1E-W0054 and HCS02.1E-W0070 only) Accessories HAS01.1 Fig. 4-4: Scope of delivery DOK-INDRV*-HCS02.1****-PR02-EN-P...
  • Page 32 Identification Rexroth IndraDrive C Notes DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 33: Mechanical Data

    Rexroth IndraDrive C Mechanical Data Mechanical Data Dimensions HCS02.1E-W0012 minimum mounting clearance (when using accessories HAS02.1); plus space for cables minimum mounting clearance; plus space for cables Fig. 5-1: Dimensional drawing HCS02.1E-W0012 DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 34: Hcs02.1E-W0028

    Mechanical Data Rexroth IndraDrive C HCS02.1E-W0028 minimum mounting clearance (when using accessories HAS02.1); plus space for cables minimum mounting clearance; plus space for cables Fig. 5-2: Dimensional drawing HCS02.1E-W0028 DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 35: Hcs02.1E-W0054 And Hcs02.1E-W0070

    Rexroth IndraDrive C Mechanical Data HCS02.1E-W0054 and HCS02.1E-W0070 minimum mounting clearance (when using accessories HAS02.1); plus space for cables minimum mounting clearance; plus space for cables Fig. 5-3: Dimensional drawing HCS02.1E-W0054 and HCS02.1E-W0070 DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 36: Weight

    Mechanical Data Rexroth IndraDrive C Weight Drive controller Weight [kg] HCS02.1E-W0012 HCS02.1E-W0028 HCS02.1E-W0054 HCS02.1E-W0070 Fig. 5-4: Weight of drive controllers (without control section and accessories) The weight of devices with integrated 24V power supply (-NNNV) is 0.2 kg higher. Note: Weight of control section: 0.42 kg.

  • Page 37: Temperatures Above The Top Of The Device

    Rexroth IndraDrive C Mechanical Data Temperatures Above the Top of the Device The drive controllers have a high efficiency. Outlet temperatures higher than the ambient temperature are nevertheless produced at the top of the devices, among other things due to the converted energies. High outlet temperatures are particularly produced in the case of insufficient cooling or when the cooling air current (blower failure) fails.

  • Page 38: Outlet Temperatures In Normal Operation

    Mechanical Data Rexroth IndraDrive C Outlet Temperatures in Normal Operation The diagrams below (see next page) show the temperature rise of the air from air intake at the bottom of the device to air outlet at the top of the device, depending on the average continuous power at the breaking resistor.
  • Page 39 Rexroth IndraDrive C Mechanical Data HCS02.1E-W0012 T [K] ∆ T @ d~0mm ∆ T @ d~40mm ∆ T @ d~80mm ∆ T @ d~120mm ∆ average continuous power of braking resistor distance from the top of the device Fig. 5-7: HCS02.1E-W0012 HCS02.1E-W0028...
  • Page 40 Mechanical Data Rexroth IndraDrive C HCS02.1E-W0054 T [K] ∆ T @ d~0mm ∆ T @ d~40mm ∆ T @ d~80mm ∆ T @ d~120mm ∆ average continuous power of braking resistor distance from the top of the device Fig. 5-9: HCS02.1E-W0054 HCS02.1E-W0070...

  • Page 41: Electrical Data

    Rexroth IndraDrive C Electrical Data Electrical Data Note: The current and power data below apply when the allowed motor cable length is complied. Power Section– Mains Supply Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E- W0012 W0028 W0054 W0070 operating mode on the...

  • Page 42: Power Section - Dc Bus

    Electrical Data Rexroth IndraDrive C Power Section – DC Bus Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E- W0012 W0028 W0054 W0070 DC bus voltage (range) (unloaded) uncontrolled * 1.41 internal DC bus capacity 0.135 0.270 0.405 0.675 max. allowed external DC bus...

  • Page 43: Power Section - Dc Bus Power

    Rexroth IndraDrive C Electrical Data Power Section – DC Bus Power Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E- W0012 W0028 W0054 W0070 Profile DC bus power DC_peak overload operation overload capacity: DC_base DC_peak base DC bus peak power DC_peak_1 = 3 x AC 400 V, at Ta<40 °C;...
  • Page 44 Electrical Data Rexroth IndraDrive C Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E- W0012 W0028 W0054 W0070 DC bus power DC_base_5 = 3 x AC 400 V, at Ta<40 °C; t=60 s; T=10 min without mains choke with mains choke 13.3 Abb.

  • Page 45: Allowed Dc Bus Continuous Power With Three-Phase Mains Connection

    Rexroth IndraDrive C Electrical Data Allowed DC Bus Continuous Power with Three-Phase Mains Connection The diagram below illustrates the characteristic of the allowed DC bus continuous power over the mains connection voltage range. Using HNL mains chokes increases the allowed DC bus continuous power for W0054 and W0070 devices, because this reduces the load of the DC bus capacitors in the drive controllers.

  • Page 46: Allowed Dc Bus Continuous Power With Single-Phase Mains Connection

    Electrical Data Rexroth IndraDrive C Allowed DC Bus Continuous Power with Single-Phase Mains Connection For operation with single-phase mains supply, DC bus continuous powers according to the diagrams below are allowed. Note: Single-phase mains connection via the connections L1 and L2...

  • Page 47: Mains Connection Power And Dc Bus Continuous Power

    Rexroth IndraDrive C Electrical Data Mains Connection Power and DC Bus Continuous Power The diagrams below illustrate the interrelation between mains connection power (S ) and DC bus continuous power (P ) with and without the DCcont use of mains chokes.
  • Page 48 Electrical Data Rexroth IndraDrive C HCS02.1-E-W0054 @3AC400V [kVA] without choke with choke [kW] DC cont Fig. 6-8: HCS02.1E-W0054 HCS02.1-E-W0070 @3AC400V without choke [kVA] with choke 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10, 11, 12, 13, 14, [kW] DC cont Fig.

  • Page 49: Power Section - Braking Resistor

    Rexroth IndraDrive C Electrical Data Power Section – Braking Resistor Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E- W0012 W0028 W0054 W0070 nominal braking resistor DC(Bleeder) (internal) max. regenerative power R,MAX braking resistor threshold see Functional Description of firmware DC (R_DC On)

  • Page 50: Power Section - Inverter

    6-10 Electrical Data Rexroth IndraDrive C Power Section – Inverter Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E- W0012 W0028 W0054 W0070 output voltage fundamental component with open-loop U/f ctrl * 0.95 of voltage with closed-loop oper. * 0.9 output frequency range...

  • Page 51: Power Section - Examples Of Allowed Load Profiles

    6-11 Rexroth IndraDrive C Electrical Data Power Section - Examples of Allowed Load Profiles The capacity of the drive controllers is described below with examples of load profiles. Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E- W0012 W0028 W0054 W0070 output current profile for...
  • Page 52 6-12 Electrical Data Rexroth IndraDrive C Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E- W0012 W0028 W0054 W0070 maximum output current 13.4 22.9 30.9 out_peak_5 (4 kHz) t=60s; T=10min; K=1.2 22.2 22.9 out_peak_5 (8 kHz) 14.3 15.1 out_peak_5 (12 kHz) 11.6 11.2...

  • Page 53: Power Section - Cooling, Power Dissipation, Insulation Resistance, Sound Pressure

    6-13 Rexroth IndraDrive C Electrical Data Power Section – Cooling, Power Dissipation, Insulation Resistance, Sound Pressure Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E- W0012 W0028 W0054 W0070 cooling power section forced forced forced forced volumetric capacity of the m³/h approx. 24 approx.
  • Page 54 6-14 Electrical Data Rexroth IndraDrive C The current-depending power dissipation of the power sections illustrated in the following diagrams is composed of • the losses of the mains-supply rectifier • the switching losses of the inverter HCS02.1E-W0012 8 kHz 4 kHz...
  • Page 55 6-15 Rexroth IndraDrive C Electrical Data HCS02.1E-W0028 Pv vs Iout for HCS02.1-W0028 8 kHz 4 kHz 12 kHz 10 kHz 16 kHz P V4kHz i out_4kHz P V8kHz i out_8kHz P V10kHz i out_10kHz P V12kHz i out_12kHz P V16kHz i out_16kHz...
  • Page 56 6-16 Electrical Data Rexroth IndraDrive C HCS02.1E-W0054 Pv vs Iout for HCS02.1-W0054 16 kHz 12 kHz 10 kHz 8 kHz 4 kHz P V4kHz i out_4kHz P V8kHz i out_8kHz P V10kHz i out_10kHz P V12kHz i out_12kHz P V16kHz i out_16kHz...
  • Page 57 6-17 Rexroth IndraDrive C Electrical Data HCS02.1E-W0070 Pv vs Iout for HCS02.1-W0070 16 kHz 12 kHz 8 kHz 4 kHz 10 kHz P V4kHz i out_4kHz P V8kHz i out_8kHz P V10kHz i out_10kHz P V12kHz i out_12kHz P V16kHz i out_16kHz...

  • Page 58: Control Voltage

    6-18 Electrical Data Rexroth IndraDrive C Control Voltage Devices without Internal Control Voltage Supply (HCS02.1E-W00xx- NNNN) Note: data below apply control sections. The data are referring to an ambient temperature of 25 °C. Designation Symbol Unit Value • 24 ±20%...

  • Page 59: Devices With Internal Control Voltage Supply Generation From Dc Bus (Hcs02.1E-W00Xx-Nnnv)

    6-19 Rexroth IndraDrive C Electrical Data Devices with Internal Control Voltage Supply Generation from DC bus (HCS02.1E-W00xx-NNNV) The internally generated control voltage is used for stand-alone supply of the drive controller or buffering in case the external 24V supply fails. It is not used for supplying motor holding brakes.
  • Page 60 6-20 Electrical Data Rexroth IndraDrive C Block diagram of control voltage generation from the DC bus: int. SMPS 24 V (optional) hcs_block_steuerspg.fh7 brake circuit power section control section int. SMPS: internal switching-mode power supply DC bus Fig. 6-20: Block diagram of internal control voltage generation Note: The external 24V supply takes place via connection X13.

  • Page 61: Connections

    6-21 Rexroth IndraDrive C Electrical Data Connections Complete Connection Diagram shield connection bus connection OUT X1:Out bus connection IN X1:In control voltage X13:1 0V X13:2 0V X13:3 +24V X13:4 +24V DC bus mains connection motor connection MotTemp+ motor temperature monitoring...

  • Page 62: Connections At Hcs02.1E-W0012

    6-22 Electrical Data Rexroth IndraDrive C Note: Apart from the connections listed below, it is necessary to wire the Bb contact at the control section for signaling the readiness for operation of the drive controller (see Project Planning Manual for Control Section).
  • Page 63 6-23 Rexroth IndraDrive C Electrical Data Bottom hcs0028_x3_x5_x6.fh7 Fig. 6-23: HCS02.1E-W0012 power section connections (bottom) Description of connections: Connection Page X3, Mains connection 6-28 X5, Motor connection 6-30 X6, Motor temperature monitoring, motor holding brake 6-32 XS2, Shield connection (motor cable) 6-42 DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 64: Connections At Hcs02.1E-W0028, -W0054, -W0070

    6-24 Electrical Data Rexroth IndraDrive C Connections at HCS02.1E-W0028, -W0054, -W0070 Front X1 out X1 in hcs0028_front.fh7 Fig. 6-24: HCS02.1E-W0028, -W0054, -W0070 power section connections (front) Description of connections: Connection Page X1, Module bus 6-27 X13, Control voltage 6-36 XS1, Shield connection (control wires)
  • Page 65 6-25 Rexroth IndraDrive C Electrical Data Bottom (HCS02.1E-W0028) hcs0028_x3_x5_x6.fh7 Fig. 6-25: HC02.1E-W0028 power section connections (bottom) Description of connections: Connection Page X3, Mains connection 6-28 X5, Motor connection 6-30 X6, Motor temperature monitoring, motor holding brake 6-32 XS2, Shield connection (motor cable) 6-42 DOK-INDRV*-HCS02.1****-PR02-EN-P...
  • Page 66 6-26 Electrical Data Rexroth IndraDrive C Bottom (HCS02.1E-W0054, -W0070) hcs0054_x3_x5_x6_x9.fh7 Fig. 6-26: HC02.1E-W0054, -W0070 power section connections (bottom) Description of connections: Connection Page X3, Mains connection 6-28 X5, Motor connection 6-30 X6, Motor temperature monitoring, motor holding brake 6-32 X9, External braking resistor...

  • Page 67: X1, Module Bus

    6-27 Rexroth IndraDrive C Electrical Data X1, Module Bus The module bus permits data exchange between the drive controllers. Graphic Representation X1 out X1 in X1f2.FH7 Fig. 6-27: Design Type Number of Type of design poles Flat line connector Connector on device...

  • Page 68: X3, Mains Connection

    6-28 Electrical Data Rexroth IndraDrive C X3, Mains Connection High electrical voltage! Danger to life, severe bodily harm by electric shock! ⇒ Always operate the drive controller with plugged on connector! DANGER Design HCS02.1E- Type Number of Type of design...
  • Page 69 6-29 Rexroth IndraDrive C Electrical Data Damage to the drive controller ⇒ Strain relief for the motor power cable must be provided within the control cabinet, or you can use optionally available connection accessory CAUTION HAS02.1. Note: Observe the following for use within the scope of C-UL: •...

  • Page 70: X5, Motor Connection

    6-30 Electrical Data Rexroth IndraDrive C X5, Motor Connection High electrical voltage! Danger to life, severe bodily harm by electric shock! ⇒ Always operate the drive controller with plugged on connector! DANGER Design HCS02.1E- Type Number of Type of design...
  • Page 71 6-31 Rexroth IndraDrive C Electrical Data For the connection between drive controller and motor, use Rexroth motor Connection of the Motor Power Cable power cables (see documentation "Rexroth Connection Cables; Selection Data", DOK-CONNEC-CABLE*STAND-AUxx-EN-P). Damage to the drive controller! ⇒ Strain relief cannot be provided for the motor power cable at the drive controller.

  • Page 72: X6, Motor Temperature Monitoring And Motor Holding Brake

    6-32 Electrical Data Rexroth IndraDrive C X6, Motor Temperature Monitoring and Motor Holding Brake The drive controller is supplied with 24V for the motor holding brake via connection X13. High electrical voltage! Danger to life, severe bodily harm by electric shock! Always operate the drive controller with plugged on ⇒...
  • Page 73 6-33 Rexroth IndraDrive C Electrical Data A1 A2 A3 shield for motor cable AC motor holding brake PTC / NTC / KTY84 (depends on motor type) x6_kabel_anschluss.FH7 Fig. 6-40: Motor cable, temperature monitor and holding brake connection Maximum permitted braking current: •...
  • Page 74 6-34 Electrical Data Rexroth IndraDrive C Dangerous movements! Danger to personnel from falling or slipping axes! The standard motor holding brake provided or an ⇒ external motor holding brake controlled directly by DANGER the drive controller are not sufficient on their own to guarantee the safety of personnel! ⇒...

  • Page 75: X9, Connection Of Braking Resistor

    6-35 Rexroth IndraDrive C Electrical Data X9, Connection of Braking Resistor Lethal electric shock caused by live parts with more than 50 V! ⇒ Exclusively operate the drive controller with plugged on connector! DANGER Design HCS02.1E- Type Number of poles...

  • Page 76: X13, Control Voltage (+24 V, 0 V)

    6-36 Electrical Data Rexroth IndraDrive C X13, Control Voltage (+24 V, 0 V) The external 24V supply is applied via connection X13 for • the power section of the drive controller • brake control via X6 and • the control section of the drive controller With regard to control voltage supply, the HCS02.1 drive controllers are...
  • Page 77 6-37 Rexroth IndraDrive C Electrical Data Design Type Number of poles Type of design Spring power Pins on connector Fig. 6-46: Design Connection Cross Section Cross section Cross section Cross section single-wire multi-wire in AWG [mm²] [mm²] 0.14-1.5 0.14-1.5 28-16 Fig.
  • Page 78 6-38 Electrical Data Rexroth IndraDrive C The control voltage supply is routed to the connection X13 from above (see following figure). 1: lines to control voltage supply Fig. 6-51: Control voltage supply at X13 DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 79: Dc Bus (L+, L-)

    If drive controllers are stacked in the control cabinet, the connections for the DC buses between the drive controllers have to be correctly made. There is CAUTION otherwise a risk of voltage arcing (See project planning manual "Rexroth IndraDrive Drive System", DOK-INDRV*-SYSTEM*****-PRxx-EN-P.) DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 80: Connection Point Of Equipment Grounding Conductor And Equipment Grounding Connections

    6-40 Electrical Data Rexroth IndraDrive C Connection Point of Equipment Grounding Conductor and Equipment Grounding Connections Dangerous contact voltage at device housing! Lethal electric shock! ⇒ Connect the drive controller via connection X3 (mains) to the equipment grounding system. DANGER...

  • Page 81: Xs1, Shield Connection (Control Wires)

    6-41 Rexroth IndraDrive C Electrical Data XS1, Shield Connection (Control Wires) hcs_xs1.fh7 Fig. 6-52: Shield connection XS1 Connection for shields of wires connected to the control section. Note: Always connect shield of cables with a large metal-to-metal contact surface to the shield connection.

  • Page 82: Xs2, Shield Connection (Motor Cable)

    6-42 Electrical Data Rexroth IndraDrive C XS2, Shield Connection (Motor Cable) hcs0054_XS2.fh7 hcs0028_XS2.fh7 Fig. 6-53: XS2 is used for mounting the accessory HAS02.1 for shield connection of the motor cable (See Project Planning Manual "Rexroth IndraDrive Drive System", DOK-INDRV*-SYSTEM*****-PRxx-EN-P.) DOK-INDRV*-HCS02.1****-PR02-EN-P...

  • Page 83: Touch Guard

    Rexroth IndraDrive C Touch Guard Touch Guard Lethal electric shock caused by live parts with more than 50 V! ⇒ The appropriate touch guard must be mounted for each drive controller following connection work. WARNING Never mount a damaged touch guard.

  • Page 84: Mounting

    Touch Guard Rexroth IndraDrive C Mounting hcs_beruehrschutz.fh7 Fig. 7-2: Touch guard The touch guard must always be mounted following connection work. Note: Risk damage touch guard! The maximum tightening torque for the fixing screw for the touch guard is 2.8 Nm.

  • Page 85: Disposal And Environmental Protection

    Rexroth IndraDrive C Disposal and Environmental Protection Disposal and Environmental Protection Disposal Products Our products can be returned to us free of charge for disposal. It is a precondition, however, that the products are free of oil, grease or other dirt.

  • Page 86: Recycling

    Disposal and Environmental Protection Rexroth IndraDrive C Recycling Due to their high content of metal 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.

  • Page 87: Service & Support

    Rexroth IndraDrive C Service & Support Service & Support Helpdesk Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries.

  • Page 88: Kundenbetreuungsstellen - Sales & Service Facilities

    Service & Support Rexroth IndraDrive C Kundenbetreuungsstellen - Sales & Service Facilities Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen! from abroad: don’t dial (0) after country code! Vertriebsgebiet Mitte Germany Centre S E R V I C E A U T O M A T I O N...
  • Page 89 - Italien Netherlands - Niederlande/Holland Netherlands – Niederlande/Holland Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth Services B.V. Bosch Rexroth B.V. Via del Progresso, 16 (Zona Ind.) Via Isonzo, 61 Technical Services Kruisbroeksestraat 1 35020 Padova 40033 Casalecchio di Reno (Bo) Kruisbroeksestraat 1 (P.O.
  • Page 90 Service & Support Rexroth IndraDrive C Europa (Ost) - Europe (East) vom Ausland: (0) nach Landeskennziffer weglassen from abroad: don’t dial (0) after country code Czech Republic - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland – Polen DEL a.s.
  • Page 91 Australia - Australien Australia - Australien China China AIMS - Australian Industrial Bosch Rexroth Pty. Ltd. Shanghai Bosch Rexroth Shanghai Bosch Rexroth Machinery Services Pty. Ltd. No. 7, Endeavour Way Hydraulics & Automation Ltd. Hydraulics & Automation Ltd. 28 Westside Drive...
  • Page 92 Canada West - Kanada West Mexico Mexico Bosch Rexroth Canada Corporation Bosch Rexroth Canada Corporation Bosch Rexroth Mexico S.A. de C.V. Bosch Rexroth S.A. de C.V. Burlington Division 5345 Goring St. Calle Neptuno 72 Calle Argentina No 3913 3426 Mainway Drive Burnaby, British Columbia Unidad Ind.

  • Page 93: Index

    10-1 Rexroth IndraDrive C Index Index Appropriate use 2-1 Battery safety 3-11 Bb contact 1-4 Block diagrams 1-4 Brake supply 6-36 Braking resistor connection 6-35 Cables motor 6-31 Connection braking resistor 6-35 control voltage 6-36 DC bus 6-39 diagram 6-21 HCS02.1E-W0012 6-22...
  • Page 94 10-2 Index Rexroth IndraDrive C Ground connection of housing 6-40 HAS02.1 XS2 6-42 Hazards by Improper Use 3-2 HCS02.1 4-1 Holding brake 6-36 Housing ground connection 6-40 Improper use hazards 3-2 Inappropriate use 2-2 Consequences, Discharge of liability 2-1 IndraDrive...
  • Page 95 10-3 Rexroth IndraDrive C Index Technical data electrical 6-1 mechanical 5-1 Temperatures above top of device 5-5 Touch guard 7-1 Type code HCS02.1 4-1 Type plates 4-2 directions for use 2-1 hazards by improper use 3-2 inappropriate 2-2 Warning symbols 3-1...
  • Page 96 10-4 Index Rexroth IndraDrive C DOK-INDRV*-HCS02.1****-PR02-EN-P...
  • Page 98 Bosch Rexroth AG Electric Drives and Controls Postfach 13 57 97803 Lohr, Deutschland Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Deutschland Tel. +49 (0)93 52-40-50 60 Fax +49 (0)93 52-40-49 4 1 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany R911306138 DOK-INDRV*-HCS02.1****-PR02-EN-P...

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