Bosch Rexroth IndraDrive Project Planning Manual

Bosch Rexroth IndraDrive Project Planning Manual

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Industrial
Electric Drives
Hydraulics
and Controls
Rexroth IndraDrive
Additional Components
Project Planning Manual
Linear Motion and
Assembly Technologies
Pneumatics
Service
Mobile
Automation
Hydraulics
R911306140
Edition 02

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Summary of Contents for Bosch Rexroth IndraDrive

  • Page 1 Industrial Electric Drives Linear Motion and Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth IndraDrive R911306140 Additional Components Edition 02 Project Planning Manual...
  • Page 2 DOK-INDRV*-ADDCOMP****-PR02-EN-P 03.05 motor filter HMF01.1 added 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 Contents Contents Introduction Documentation..........................1-1 About this Documentation ....................... 1-1 Documentations - Overview ....................1-2 General Information on How to Install ..................1-3 Important Directions for Use Appropriate Use..........................2-1 Introduction ..........................2-1 Areas of Use and Application ....................2-2 Inappropriate Use .........................
  • Page 4 Contents Rexroth IndraDrive Type Code HNF01.1........................ 5-8 Data HNF01.1.......................... 5-9 Dimensional Drawings HNF01.1 ................... 5-10 Mains Filter (-Combination) HNK01.1..................5-12 Type Code HNK01.1 ......................5-12 Type Plate HNK01.1......................5-13 Mechanical Data HNK01.1 ....................5-14 Technical Data HNK01.1 ....................... 5-18 Arrangement of Components ....................5-19 Mains Choke Identification..........................
  • Page 5 Rexroth IndraDrive Contents Diagnostic LEDs and Reset-Pushbutton ..................8-15 Braking Resistors HLR01.1 General Information ........................9-1 Identification..........................9-3 Type Code HLR01.1........................ 9-3 Type Plate HLR01.1 ........................ 9-4 Technical Characteristics of the Standard Braking Resistors HLR01.1 ........9-4 Mechanical Data of the Standard Braking Resistors HLR01.1............. 9-5 Dimensioned Drawings......................
  • Page 6 Contents Rexroth IndraDrive DOK-INDRV*-ADDCOMP****-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

    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 CSx Rexroth IndraDrive M Project Planning Manual DOK-INDRV*-HMS+HMD****-PRxx-EN-P Drive Controllers Power Sections HMx Project Planning Manual DOK-INDRV*-HCS02.1****-PRxx-EN-P Rexroth IndraDrive C Drive Controllers Power Sections HCS02.1...
  • Page 9: General Information On How To Install

    Rexroth IndraDrive Introduction General Information on How to Install Damage can be caused to the drive controller or circuit boards if electrostatic charging present in people and/or tools is discharged across them. Therefore, please note the following information: Electrostatic charges can cause damage to...
  • Page 10 Introduction Rexroth IndraDrive Notes DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 11: Important Directions For Use

    Rexroth IndraDrive Important Directions for Use Important Directions for Use Appropriate Use Introduction Rexroth products represent state-of-the-art developments 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.
  • Page 12: Areas Of Use And Application

    Important Directions for Use Rexroth IndraDrive 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 13: Safety Instructions For Electric Drives And Controls

    Rexroth IndraDrive 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 14: Hazards By Improper Use

    Safety Instructions for Electric Drives and Controls Rexroth IndraDrive 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 15: General Information

    Rexroth IndraDrive 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 16 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive • 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 17: Protection Against Contact With Electrical Parts

    Rexroth IndraDrive 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 18: Protection Against Electric Shock By Protective Low Voltage (Pelv)

    Safety Instructions for Electric Drives and Controls Rexroth IndraDrive To be observed with electrical drive and filter components: High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! ⇒ Connect the electrical equipment, the housings of all...
  • Page 19: Protection Against Dangerous Movements

    Rexroth IndraDrive 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 20 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive 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. Unintended machine motion is possible if monitoring devices are disabled, bypassed or not activated.
  • Page 21: Protection Against Magnetic And Electromagnetic Fields During Operation And Mounting

    Rexroth IndraDrive 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 22: Protection Against Contact With Hot Parts

    3-10 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive 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 23: 3.11 Battery Safety

    3-11 Rexroth IndraDrive 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 24 3-12 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive Notes DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 25: Transformers

    Rexroth IndraDrive Transformers Transformers Transformers are only needed if the systems voltage exceeds the rated voltage of the drive controller. For grounded power supply lines, the line voltage is matched to the rated Grounded power supply lines voltage of the units using autotransformers which are suited to one specific output voltage range.
  • Page 26: Autotransformers

    Transformers Rexroth IndraDrive Autotransformers Type Code Abbrev. Column Object Product Nominal power only only only Construction (Design) Nominal input voltage (Phase-Phase) Nominal output voltage (Phase-Phase) Special design Standard reference Standard Title Edition Note: Fig. 4-1: Type code DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 27: Selection

    Rexroth IndraDrive Transformers Selection Select an autotransformer suited to both the line voltage and the power requirements of the system. Proceed with the selection as follows: ⇒ Determine the rating group using the required rated line voltage range in the diagram "Classification of the three-phase alternating current autotransformers and then locate the transformer ratio "i".
  • Page 28: Technical Data

    Transformers Rexroth IndraDrive Technical Data Æ Fig. 4-3: Technical data DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 29: Mains Filter Nfd / Nfe

    Rexroth IndraDrive Mains Filter Mains Filter Mains Filter NFD / NFE Type Code NFE / NFD NFE01.1 Abbrev. Column Product group NFE ..= NFE Line 1 ....= 01 Design 1 .
  • Page 30 Mains Filter Rexroth IndraDrive NFE02.1 Abbrev. Column Product group NFE ..= NFE Line 2 ....= 02 Design 1 .
  • Page 31 Rexroth IndraDrive Mains Filter NFD03.1 Abbrev. Column Product group Line Design Nominal voltage Rated current Illustration example: Fig. 5-3: Type code NFD03.1 DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 32: Technical Data Nfe / Nfd

    Mains Filter Rexroth IndraDrive Technical Data NFE / NFD Maximum Nominal No. of Type of mains Terminals (3) Power Weight Type connecting mains phases filter dissi- voltage of current pation mains approx Netz 50..60 Hz flexibel starr in V in A mm²...
  • Page 33: Dimensions Nfe / Nfd

    Rexroth IndraDrive Mains Filter Dimensions NFE / NFD Mains filter type NFD 03.1-480-007 NFD 03.1-480-016 NFD 03.1-480-030 NFD 03.1-480-055 NFD 03.1-480-075 NFD 03.1-480-130 NFD 03.1-480-180 NFE 02.1-230-008 0,75 NFE 01.1-250-006 see figure = maximum tightening torque of the ground stud in Nm = maximum tightening torque of the terminal connector in Nm Fig.
  • Page 34 Mains Filter Rexroth IndraDrive NFD03.1 LOAD LINE Fig. 5-7: AC filter NFD03.1 for drives Tolerance limits for NFD03.1: • Dimensions B, C, D, K are maximum values. They can be reduced up to 15 mm. • The ground studs M can also stand vertically, seen from the front side, instead of horizontally.
  • Page 35 Rexroth IndraDrive Mains Filter NFE02.1 LINE / NETZ LOAD / LAST MB5054F1.FH7 NFE02.1-230-008 (with 3 terminal connectors) Fig. 5-8: Single-phase filter NFE02.1 for drives NFE01.1 29.5 Mb5011f1.fh7 Fig. 5-9: Single-phase filter NFE01.1-250-006 for interference suppression of the power supply unit NTM...
  • Page 36: Mains Filter Hnf01.1

    Mains Filter Rexroth IndraDrive Mains Filter HNF01.1 Type Code HNF01.1 Abbrev. Column Product Line Design EMC area per DIN EN 61800-3 Applications Supply system Nominal current Degree of protection Mains connecting voltage Other design Standard reference Standard Title Edition Fig. 5-10:...
  • Page 37: Data Hnf01.1

    < 2 < 2 < 2,2 < 2,2 output (load side) allowed THD (Total see Project Planning Manual "Rexroth IndraDrive Drive System" Harmonic Distortion) Reduction of allowed operating data due to see Project Planning Manual "Rexroth IndraDrive Drive System" harmonic content Input supply voltage 3 x AC 380...480V ±10%, 50/60Hz ±2%...
  • Page 38: Dimensional Drawings Hnf01.1

    5-10 Mains Filter Rexroth IndraDrive Dimensional Drawings HNF01.1 Drilling Pattern Mains filter K [mm] L [mm] M [mm] N [mm] P [mm] R [mm] HNF01.1A-F240-E0051-A-480-NNNN HNF01.1A-M900-E0051-A-480-NNNN HNF01.1A-F240-E0125-A-480-NNNN 12,5 HNF01.1A-M900-E0125-A-480-NNNN HNF01.1A-F240-E0202-A-480-NNNN 12,5 HNF01.1A-M900-E0202-A-480-NNNN HNF01.1A-F240-R0026-A-480-NNNN HNF01.1A-M900-R0026-A-480-NNNN HNF01.1A-F240-R0065-A-480-NNNN HNF01.1A-M900-R0065-A-480-NNNN HNF01.1A-F240-R0094-A-480-NNNN 12,5 HNF01.1A-M900-R0094-A-480-NNNN Fig. 5-12:...
  • Page 39 5-11 Rexroth IndraDrive Mains Filter Dímensions Mains filter A [mm] B [mm] C [mm] D [mm] E [mm] F [mm] G [mm] H [mm] M6x20 HNF01.1A-F240-R0026-A-480-NNNN 8.6 Nm HNF01.1A-F240-E0051-A-480-NNNN M6x16 HNF01.1A-M900-E0051-A-480-NNNN 2.3 Nm M6x20 HNF01.1A-M900-R0026-A-480-NNNN 8.6 Nm HNF01.1A-F240-R0065-A-480-NNNN M6x16 HNF01.1A-M900-R0065-A-480-NNNN 4.8 Nm...
  • Page 40: Mains Filter (-Combination) Hnk01.1

    5-12 Mains Filter Rexroth IndraDrive Mains Filter (-Combination) HNK01.1 Type Code HNK01.1 Abbrev. Column Product Line Design EMC area per DIN EN 61800-3 Applications Supply system Nominal current Degree of protection Mains connecting voltage Other design Standard reference Standard Title Edition Fig.
  • Page 41: Type Plate Hnk01.1

    5-13 Rexroth IndraDrive Mains Filter Type Plate HNK01.1 Each mains filter is identified by a type designation. A type plate is attached to all units. Fig. 5-15: Example of a type plate HNK01.1 Type plate arrangement: Fig. 5-16: Type plate arrangement...
  • Page 42: Mechanical Data Hnk01.1

    5-14 Mains Filter Rexroth IndraDrive Mechanical Data HNK01.1 Dimensional Drawings dimensions in mm Fig. 5-17: Dimensional drawing mains filter HNK01.1A-A075-E0050 DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 43 5-15 Rexroth IndraDrive Mains Filter dimensions in mm Fig. 5-18: Dimensional drawing mains filter HNK01.1A-A075-E0050 with HAS02 DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 44 5-16 Mains Filter Rexroth IndraDrive dimensions in mm Fig. 5-19: Dimensional drawing mains filter HNK01.1A-A075-E0080/0106 dimensions in mm Fig. 5-20: Dimensional drawing mains filter HNK01.1A-A075-E0080/0106 with HAS02 DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 45 5-17 Rexroth IndraDrive Mains Filter dimensions in mm Fig. 5-21: Dimensional drawing mains filter HNK01.1A-A075-E0146 dimensions in mm Fig. 5-22: Dimensional drawing mains filter HNK01.1A-A075-E0146 with HAS02 DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 46: Technical Data Hnk01.1

    5-18 Mains Filter Rexroth IndraDrive Technical Data HNK01.1 Mains filter HNK01.1A-A075 Unit E0050 E0080 E0106 E0146 Nominal voltage 3*AC400…500 Nominal current Inductance µH Connection cross section mm² 16 (AWG 6) 25 (AWG 3) 25 (AWG 3) 50 (AWG 1/0) Protection category...
  • Page 47: Arrangement Of Components

    5-19 Rexroth IndraDrive Mains Filter Arrangement of Components Fig. 5-25: Arrangement of drive controller and mains filter E0050 DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 48 5-20 Mains Filter Rexroth IndraDrive Fig. 5-26: Arrangement of drive controller and mains filter E0080 and E0106 Fig. 5-27: Arrangement of drive controller and mains filter E0146 DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 49: Mains Choke

    Rexroth IndraDrive Mains Choke Mains Choke Identification Type Code Abbrev. Column Product Line Design Supply system Nominal inductance Additionl option Nominal current Degree of protection Mains connecting voltage Other design Standard reference Standard Title Edition typenschl_hnl_de.EPS Fig. 6-1: Type code...
  • Page 50: Type Plate

    Mains Choke Rexroth IndraDrive Type Plate Feld Text Benennung Einheit Beispiel MNR: Fig. 6-2: Type Plate DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 51: Mains Choke Hnl01.1E (Feeding)

    Rexroth IndraDrive Mains Choke Mains Choke HNL01.1E (feeding) HNL01.1E-1000-N0012-A-500-NNNN, HNL01.1E-1000-N0020-A-500-NNNN, HNL01.1E-0600-N0032-A-500-NNNN, HNL01.1E-0571-N0050-A-500-NNNN, HNL01.1E-0400-N0051-A-480-NNNN, HNL01.1E-0362-N0080-A-500-NNNN, HNL01.1E-0240-N0106-A-500-NNNN, HNL01.1E-0200-N0125-A-480-NNNN, HNL01.1E-0170-N0146-A-500-NNNN, HNL01.1E-0100-N0202-A-480-NNNN Technical Data Dimensions Type 1: DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 52 Mains Choke Rexroth IndraDrive Dimensions Type 2: Dimensions Type 3: DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 53 Rexroth IndraDrive Mains Choke Mains choke Type Dimensions Weight [mm] [kg] HNL01.1E-1000-N0012-A-500-NNNN 6,4 x 11 HNL01.1E-1000-N0020-A-500-NNNN 66,5 49,5 6,4 x 11 HNL01.1E-0600-N0032-A-500-NNNN 66,5 49,5 6,4 x 11 HNL01.1E-0571-N0050-A-500-NNNN 8,5 x 12 HNL01.1E-0400-N0051-A-480-NNNN 7 x 15 13,5 HNL01.1E-0362-N0080-A-500-NNNN 8,5 x 12 HNL01.1E-0240-N0106-A-500-NNNN...
  • Page 54: Mains Choke Hnl01.1R (Regenerating)

    Mains Choke Rexroth IndraDrive Mains Choke HNL01.1R (regenerating) HNL01.1R-0980-C0026-A-480-NNNN, HNL01.1R-0590-C0065-A-480-NNNN, HNL01.1R-0540-C0094-A-480-NNNN Mains choke Dimensions [mm] Weight [kg] HNL01.1R-0980-C0026-A-480-NNNN 8 x 12 HNL01.1R-0590-C0065-A-480-NNNN 11 x 15 HNL01.1R-0540-C0094-A-480-NNNN 11 x 15 long hole in "B" direction Fig. 6-5: Mechanical data HNL..C Mains choke [µH]...
  • Page 55: Mains Chokes Hnl01.1E-****-S (Current Compensated)

    Rexroth IndraDrive Mains Choke Mains Chokes HNL01.1E-****-S (current compensated) HNL01.1E-5700-S0051-A-480-NNNN, HNL01.1E-2800-S0125-A-480-NNNN, HNL01.1E-3400-S0202-A-480-NNNN, HNL01.1R-4200-S0026-A-480-NNNN, HNL01.1R-6300-S0065-A-480-NNNN, HNL01.1R-3000-S0094-A-480-NNNN General Data Input supply voltage 3 x AC 380...480V ±10%, 50/60Hz ±2% Minimum inductance L 0,8*L at I Protection category IP20 Materials free of asbestos and silicone Certification according to UL 508 and CSA C22.2 No.
  • Page 56 Mains Choke Rexroth IndraDrive Dimensional drawing Fig. 6-9: Dimensional drawing Mains choke HNL01.1E-5700-S0051-A-480-NNNN HNL01.1E-2800-S0125-A-480-NNNN HNL01.1E-3400-S0202-A-480-NNNN HNL01.1R-4200-S0026-A-480-NNNN HNL01.1R-6300-S0065-A-480-NNNN HNL01.1R-3000-S0094-A-480-NNNN Fig. 6-10: Dimensions HNL..S DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 57 Rexroth IndraDrive Mains Choke Circuit Diagram (Example HNL01.1R-6300-S0065- A-480-NNNN) Fig. 6-11: Circuit diagram HNL..S DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 58 6-10 Mains Choke Rexroth IndraDrive Notes DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 59: Dc Bus Capacitor Unit Hlc01.1

    Rexroth IndraDrive DC Bus Capacitor Unit HLC01.1 DC Bus Capacitor Unit HLC01.1 Application Instructions Possible damage to the drive controller! In operating cycles of more than 30 cycles per minute the DC bus capacitors within the drive controller can be overloaded when the mains supply voltage decreases.
  • Page 60: Identification

    DC Bus Capacitor Unit HLC01.1 Rexroth IndraDrive Identification Types Abbrev. Column Product Line Design Mounting depth Nominal capacitance Degree of protection DC bus nominal voltage Other design Standard reference Standard Title Edition Note: Fig. 7-1: Type code DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 61: Mounting

    Rexroth IndraDrive DC Bus Capacitor Unit HLC01.1 Mounting Details • Mount the DC bus capacitor unit directly besides the drive controller with the highest DC bus continuous power. • To compensate the different mounting depths of a DC bus capacitor unit HLC01.1C and a IndraDrive M drive controller we have suitable...
  • Page 62: Mechanical Data

    DC Bus Capacitor Unit HLC01.1 Rexroth IndraDrive Mechanical Data Dimensions HLC01.1C minimum mounting clearance view from the rear! Fig. 7-3: Dimensions HLC01.1C DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 63 Rexroth IndraDrive DC Bus Capacitor Unit HLC01.1 Dimensions HLC01.1D minimum mounting clearance view from the rear! Fig. 7-4: Dimensions HLC01.1D Weight Type Weight [kg] HLC01.1C-01M0-A-007-NNNN HLC01.1C-02M4-A-007-NNNN HLC01.1D-05M0-A-007-NNNN Fig. 7-5: Weight DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 64: Installation

    ⇒ beginning to work to make sure that the voltage is below 50 V. Note: If you use a supply unit Rexroth IndraDrive HMV01 you can shorten the discharging time by using the DC bus short circuit function ("ZKS"). DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 65 Rexroth IndraDrive DC Bus Capacitor Unit HLC01.1 Overview Fig. 7-7: Connections - overview DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 66 DC Bus Capacitor Unit HLC01.1 Rexroth IndraDrive X1, Bus Module The bus module permits data exchange between the devices. At the DC bus capacitor unit the bus module is looped through to other devices without influencing the data. Note: Abandon on connecting the bus module, if the DC bus capacitor unit is the last device in the row of devices.
  • Page 67 Rexroth IndraDrive DC Bus Capacitor Unit HLC01.1 Risk of damage due to polarity reversal the DC bus connections L+ and L-! Pay attention to correct polarity. ⇒ CAUTION Length of the twisted cables max. 2 m Wire cross-section min. 10 mm²,...
  • Page 68 7-10 DC Bus Capacitor Unit HLC01.1 Rexroth IndraDrive Notes DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 69: Dc Bus Resistor Unit Hlb01.1C And Hlb01.1D

    Rexroth IndraDrive DC Bus Resistor Unit HLB01.1C and HLB01.1D DC Bus Resistor Unit HLB01.1C and HLB01.1D Description The DC bus resistor unit is useful: • for increasing the available continuous regenerated power • for increasing the available peak regenerated power •...
  • Page 70: Mounting Hlb01.1

    DC Bus Resistor Unit HLB01.1C and HLB01.1D Rexroth IndraDrive Mounting HLB01.1 Mechanical Data HLB01.1 Dimensions HLB01.1C minimum mounting clearance rear view! Fig. 8-2: Dimensions HLB01.1C DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 71 Rexroth IndraDrive DC Bus Resistor Unit HLB01.1C and HLB01.1D Dimensions HLB01.1D minimum mounting clearance rear view! Fig. 8-3: Dimensions HLB01.1D DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 72 DC Bus Resistor Unit HLB01.1C and HLB01.1D Rexroth IndraDrive Weight Type Weight [kg] HLB01.1C HLB01.1D 12,2 Fig. 8-4: Weight DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 73: Installation Hlb01.1

    Rexroth IndraDrive DC Bus Resistor Unit HLB01.1C and HLB01.1D Installation HLB01.1 Electrical Data HLB01.1 Designation Symbol Unit Type HLB01.1C HLB01.1D mains input voltage DC (254…750) DC (254…750) braking resistor switch-on threshold continuous power peak power maximum regenerated power derating if devices are...
  • Page 74: Connections

    DC Bus Resistor Unit HLB01.1C and HLB01.1D Rexroth IndraDrive Connections Overview HLB01.1C Fig. 8-6: Connections HLB01.1C Connection see page L+, L- (DC bus) Equipment grounding conductor X1 in, X1 out (bus module) 8-10 X2 (RS232 interface) 8-12 X13 (control voltage)
  • Page 75 Rexroth IndraDrive DC Bus Resistor Unit HLB01.1C and HLB01.1D Overview HLB01.1D Fig. 8-7: Connections HLB01.1D Connection see page 24V, 0V (control voltage) L+, L- (DC bus) Equipment grounding conductor X1 in, X1 out (bus module) 8-10 X2 (RS232 interface) 8-12...
  • Page 76 DC Bus Resistor Unit HLB01.1C and HLB01.1D Rexroth IndraDrive DC Bus L+, L- Designation The DC bus is connected by contact rails and screws (M6) to the front of Design the device. Cross section of a contact rail: • HLB01.1D: 72 mm² (6 mm x 12 mm) •...
  • Page 77 Rexroth IndraDrive DC Bus Resistor Unit HLB01.1C and HLB01.1D Control Voltage HLB01.1C Designation Design Type Number of poles Type of design Spring power female (connector) Fig. 8-9: Design Connection Cross Section Cross section Cross section Cross section single-wire multi-wire in AWG [mm²]...
  • Page 78 8-10 DC Bus Resistor Unit HLB01.1C and HLB01.1D Rexroth IndraDrive Module Bus X1 in, X1 out Designation The module bus permits data exchange between the devices. Function Design Type Number of Type of design poles Flat line connector Connector on device...
  • Page 79 8-11 Rexroth IndraDrive DC Bus Resistor Unit HLB01.1C and HLB01.1D X31, Connection for Messages Design Type Number of poles Type of design Spring power female (connector) Fig. 8-12: Design Connection Cross Section Cross section Cross section Cross section single-wire multi-wire in AWG [mm²]...
  • Page 80 8-12 DC Bus Resistor Unit HLB01.1C and HLB01.1D Rexroth IndraDrive X32, DC Bus Short Circuit, Clearing Errors, Braking Resistor Threshold Design Type Number of Poles Type of Design Spring power female (connector) Fig. 8-14: Design Connection Cross Section Cross section...
  • Page 81 8-13 Rexroth IndraDrive DC Bus Resistor Unit HLB01.1C and HLB01.1D ZKS1, ZKS2 (HLB01.1D) 200 nF 100 nF 10 V 0,7 V Fig. 8-17: Circuit ZKS (HLB01.1D) ZKS1 Input Input voltage: Min. Max. High 19,2 V 28,8 V Operate delay t approx.
  • Page 82 8-14 DC Bus Resistor Unit HLB01.1C and HLB01.1D Rexroth IndraDrive Clearing Errors Input Input circuit: High input open 0 V (bridge Pin 4 / Pin 5) A negative edge on the input effects a clearing of all pending and clearable Clearing Errors Usage errors.
  • Page 83: Diagnostic Leds And Reset-Pushbutton

    8-15 Rexroth IndraDrive DC Bus Resistor Unit HLB01.1C and HLB01.1D Diagnostic LEDs and Reset-Pushbutton hlb_S1H2H3.eps Fig. 8-20: Diagnostic LEDs and Reset-Pushbutton Is used for resetting errors. Reset-Pushbutton S1 Diagnostic LED H2 (green) State Meaning ≤ 50 V blinking device is ready for operation and U...
  • Page 84 8-16 DC Bus Resistor Unit HLB01.1C and HLB01.1D Rexroth IndraDrive Notes DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 85: Braking Resistors Hlr01.1

    Rexroth IndraDrive Braking Resistors HLR01.1 Braking Resistors HLR01.1 General Information For the drive controllers HCS02 and HCS03 there are external standard braking resistors HLR01.1N-xxxx-Nxxx-A-007-NNNN available. The drive controller HCS monitors the external braking resistor by means of the firmware which calculates a thermal image of the current braking power.
  • Page 86 Braking Resistors HLR01.1 Rexroth IndraDrive Assigning Standard Braking Resistors to Drive Controllers HCS02 and HCS03 Braking resistor Drive controller HCS02.1E-W0054 HCS02.1E-W0070 HLR01.1N-0300-N17R5-A-007-NNBN HCS03.1E-W0070 HLR01.1N-0470-N11R7-A-007-NNBN HCS03.1E-W0100 HLR01.1N-0780-N07R0-A-007-NNBN HCS03.1E-W0150 HLR01.1N-1K08-N05R0-A-007-NNBN HCS03.1E-W0210 Fig. 9-1: Assignment of standard braking resistors HLR Assigning Reinforced Braking Resistors to Drive...
  • Page 87: Identification

    Rexroth IndraDrive Braking Resistors HLR01.1 Identification Type Code HLR01.1 Abbrev. Column Product Line Design Mountin style Continous output Additional option Resistance Degree of protection DC bus nominal voltage Other design Standard reference Standard Title Edition Fig. 9-3: Type code braking resistor HLR01.1...
  • Page 88: Type Plate Hlr01.1

    Braking Resistors HLR01.1 Rexroth IndraDrive Type Plate HLR01.1 Each braking resistor is identified by a type designation. There is a type plate attached to all components. Fig. 9-4: Type Plate HLR01.1 Fig. 9-5: Type plate position Technical Characteristics of the Standard Braking Resistors HLR01.1...
  • Page 89: Mechanical Data Of The Standard Braking Resistors Hlr01.1

    Rexroth IndraDrive Braking Resistors HLR01.1 Mechanical Data of the Standard Braking Resistors HLR01.1 Dimensioned Drawings Fig. 9-6: Dimension sheet braking resistor HLR01.1N-0300-N17R5-A-007- NNNN Fig. 9-7: Dimension sheet braking resistor HLR01.1N-0470-N11R7-A-007-NNNN and HLR01.1N-0780-N07R0-A-007-NNNN DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 90 Braking Resistors HLR01.1 Rexroth IndraDrive Fig. 9-8: Dimension sheet braking resistor HLR01.1N-1K08-N05R0-A-007- NNNN DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 91: Arrangement Of The Components Device / Braking Resistor Hlr01.1N-0300-N17R- A-007-Nnnn

    Rexroth IndraDrive Braking Resistors HLR01.1 Arrangement of the Components Device / Braking Resistor HLR01.1N- 0300-N17R-A-007-NNNN Fig. 9-9: Sample mounting device / braking resistor HLR01.1N-0300-N17R5-A-007-NNNN DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 92 Braking Resistors HLR01.1 Rexroth IndraDrive Fig. 9-10: Sample mounting device / braking resistor HLR01.1N-0470-N11R7-A-007-NNNN and HLR01.1N-0780-N07R7-A-007-NNNN DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 93 Rexroth IndraDrive Braking Resistors HLR01.1 Joint bar is part of accessories HAS01. Fig. 9-11: Sample mounting device / braking resistor HLR01.1N-1K08-N05R0-A-007-NNNN Note: The standard braking resistors are intended to be mounted above the drive controllers HCS03; otherwise, forced convection (blower) with a volume stream of 200 m³/hour is to be provided.
  • Page 94: Technical Data Of The Standard Braking Resistors Hlr01.1

    9-10 Braking Resistors HLR01.1 Rexroth IndraDrive Technical Data of the Standard Braking Resistors HLR01.1 Braking resistor 0300-N17R5 0470-N11R7 0780-N07R0 1K08-N05R0 HLR01.1N-xxxx-Nxxxx-A-007-NNNN peak power [kW] peak power duty cycle 0,83 0,83 0,83 0,83 load cycle T=120 s [ED %] peak power...
  • Page 95: Technical Data Of The Reinforced Braking Resistors Hlr01.1

    9-11 Rexroth IndraDrive Braking Resistors HLR01.1 reduced in the same ratio. For example with a duty cycle of 10 s, the clearing time is as follows: × example Fig. 9-14: Sample calculation of the required clearing time Duty Cycles einmax in s...
  • Page 96 9-12 Braking Resistors HLR01.1 Rexroth IndraDrive Braking resistors for HCS03 ... 0070 Peak power P_s and Energy absorption W 10000 [kWs] Energy HLR01.1N-10K0-N18R0 HLR01.1N-06K5-N18R0 1000 HLR01.1N-04K5-N18R0 HLR01.1N-03K5-N19R0 P_s [kW] HLR01.1N-01K6-N18R0 Power HLR01.1N-10K0-N18R0 HLR01.1N-06K5-N18R0 HLR01.1N-04K5-N18R0 HLR01.1N-03K5-N19R0 HLR01.1N-01K6-N18R0 1000 Duty cycle [s] Fig.
  • Page 97: Braking Resistors For Hcs03.1E-W0100

    9-13 Rexroth IndraDrive Braking Resistors HLR01.1 Braking Resistors for HCS03.1E-W0100 HLR01.1N-xxxx-xxxxx-A-007- -02K0-N15R0 -05K0-N15R0 -07K0-N14R0 -09K5-N13R0 -14K5-N13R0 NNNN continuous power 14,5 Ω resistance value in 16,7 16,9 15,7 14,6 14,6 operating status type connection cross mm² section connection cross section Energy absorption at peak power, duty cycle t=x sec and load cycle T=120 sec...
  • Page 98 9-14 Braking Resistors HLR01.1 Rexroth IndraDrive Braking resistors for HCS03 ... 0100 Peak power P_s and Energy absorption W 10000 [kWs] Energy HLR01.1N-14K5-N13R0 HLR01.1N-09K5-N13R0 1000 HLR01.1N-07K0-N14R0 HLR01.1N-05K0-N15R0 P_s [kW] Power HLR01.1N-14K5-N13R0 HLR01.1N-09K5-N13R0 HLR01.1N-07K0-N14R0 HLR01.1N-05K0-N15R0 1000 Duty cycle [s] Fig. 9-19: Selection aid for braking resistors for HCS03.1E-W0100...
  • Page 99: Braking Resistors For Hcs03.1E-W0150

    9-15 Rexroth IndraDrive Braking Resistors HLR01.1 Braking Resistors for HCS03.1E-W0150 HLR01.1N-xxxx-xxxxx-A-007- -04K5-N07R4 -08K5-N08R0 -11K0-N07R3 -15K0-N08R1 -24K0-N07R2 NNNN continuous power Ω resistance value in operating status type connection cross mm² section connection cross section Energy absorption at peak power, duty cycle t=x sec and load cycle T=120 sec...
  • Page 100 9-16 Braking Resistors HLR01.1 Rexroth IndraDrive Braking resistors for HCS03 ... 0150 Peak power P_s and Energy absorption W 10000 Energy [kWs] HLR01.1N-24K0-N07R2 HLR01.1N-15K0-N08R1 HLR01.1N-11K0-N07R3 HLR01.1N-08K5-N08R0 1000 HLR01.1N-04K5-N07R4 P_s [kW] Power HLR01.1N-24K0-N07R2 HLR01.1N-15K0-N08R1 HLR01.1N-11K0-N07R3 HLR01.1N-08K5-N08R0 HLR01.1N-04K5-N07R4 1000 Duty cycle [s] Fig.
  • Page 101: Braking Resistors For Hcs03.1E-W0210

    9-17 Rexroth IndraDrive Braking Resistors HLR01.1 Braking Resistors for HCS03.1E-W0210 HLR01.1N-xxxx-xxxxx-A-007- -06K5-N06R1 -12K5-N05R5 -17K0-N05R1 -23K0-N05R5 -36K0-N05R4 NNNN continuous power 12,5 Ω resistance value in operating status type connection cross mm² section connection cross section Energy absorption at peak power, duty cycle t=x sec and load cycle T=120 sec...
  • Page 102: Line Cross Sections For Reinforced Braking Resistors Hlr01.1

    9-18 Braking Resistors HLR01.1 Rexroth IndraDrive Braking resistors for HCS03 ... 0210 Peak power P_s and Energy absorption W 10000 Energy HLR01.1N-36K0-N05R4 [kWs] HLR01.1N-23K0-N05R5 HLR01.1N-17K0-N05R1 HLR01.1N-12K5-N05R5 HLR01.1N-06K5-N06R1 1000 P_s [kW] Power HLR01.1N-36K0-N05R4 HLR01.1N-23K0-N05R5 HLR01.1N-17K0-N05R1 HLR01.1N-12K5-N05R5 HLR01.1N-06K5-N06R1 1000 Duty cycle [s] Fig.
  • Page 103: Mechanical Data Of The Reinforced Braking Resistors Hlr01.1

    9-19 Rexroth IndraDrive Braking Resistors HLR01.1 Mechanical Data of the Reinforced Braking Resistors HLR01.1 Fixed Resistors IP 20 Type A Fig. 9-24: Type A5 – A6 Type Dimensions in mm Weight in kg Fig. 9-25: Dimensions table braking resistor type A...
  • Page 104: Steel Grid Fixed Resistors Ip 20 Type B

    9-20 Braking Resistors HLR01.1 Rexroth IndraDrive Steel Grid Fixed Resistors IP 20 Type B Fig. 9-26: Type B1 – B4 Type Dimensions in mm Weight in kg 1000 Fig. 9-27: Dimensions table braking resistor type B DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 105: Steel Grid Fixed Resistors Ip 20 Type C

    9-21 Rexroth IndraDrive Braking Resistors HLR01.1 Steel Grid Fixed Resistors IP 20 Type C Fig. 9-28: Type C1 – C7 Type Dimensions in mm Weight in kg Fig. 9-29: Dimensions table braking resistor type C Note: Under consideration of the technical data for the minimum braking resistance and the brake chopper, other braking resistors can be used alternatively.
  • Page 106 9-22 Braking Resistors HLR01.1 Rexroth IndraDrive Notes DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 107: Motor Filter Hmf01.1

    10-1 Rexroth IndraDrive Motor Filter HMF01.1 Motor Filter HMF01.1 10.1 Type Code Abbrev. Column Product Line Design Mounting style Filter class Motor frequency Switching frequency Nominal current Degree of protection Voltage rating Other design Standard reference Standard Title Edition Fig. 10-1: Type code of motor filter HMF01.1...
  • Page 108: 10.2 Type Plate

    10-2 Motor Filter HMF01.1 Rexroth IndraDrive 10.2 Type Plate Each motor filter is identified by a type designation. There is a type plate attached to all components. Fig. 10-2: Type plate 10.3 Electrical Data Motor filter du/dt out_max p_max out_max µH...
  • Page 109: 10.4 Mechanical Data

    10-3 Rexroth IndraDrive Motor Filter HMF01.1 10.4 Mechanical Data Dimensional Drawings Fig. 10-3: Dimensional drawing motor filter HMF01.1A-D0K2-D0045-A-500- NNNN DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 110 10-4 Motor Filter HMF01.1 Rexroth IndraDrive Fig. 10-4: Dimensional drawing motor filter HMF01.1A-N0K2-D0073-A-500-NNNN, HMF01.1A-N0K2-D0095-A-500-NNNN and HMF01.1A-N0K2-D0145-A-500-NNNN Type Dimensions in mm 0073 0095 0145 Fig. 10-5: Dimensional drawing motor filter DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 111: Arrangement Of The Components Hcs03.1 / Motor Filter Hmf

    10-5 Rexroth IndraDrive Motor Filter HMF01.1 10.5 Arrangement of the Components HCS03.1 / Motor Filter Fig. 10-6: Sample mounting HCS03.1E-W0070 / HMF01.1A-D0K2-D0045 DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 112 10-6 Motor Filter HMF01.1 Rexroth IndraDrive Fig. 10-7: Sample mounting HCS03.1E-W0100 0150 0210 / motor filter HCS03.1E- W0100 W0150 W0210 Fig. 10-8: Dimensions table for sample mounting HCS03.1E-.. / motor filter DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 113: Arrangement Of The Components Hcs03.1 / Motor Filter And Mains Filter

    10.6 Arrangement of the Components HCS03.1 / Motor Filter and Mains Filter Fig. 10-9: Arrangement HCS03.1E-W0070 / motor filter and mains filter + HAS05.1-001 + HAS05.1-002 Note: For information on the HAS accessories see Project Planning Manual on the drive system Rexroth IndraDrive. DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 114 10-8 Motor Filter HMF01.1 Rexroth IndraDrive Fig. 10-10: Arrangement of device 0100, 0150, 0210 / motor filter and mains filter DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 115 10-9 Rexroth IndraDrive Motor Filter HMF01.1 HCS03.1E- W0100 W0150 W0210 1090 Fig. 10-11: Dimensions table for sample mounting HCS03.1E-.. / mains filter / motor filter DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 116 10-10 Motor Filter HMF01.1 Rexroth IndraDrive Notes DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 117: Service & Support

    11-1 Rexroth IndraDrive Service & Support Service & Support 11.1 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 118: 11.5 Kundenbetreuungsstellen

    11-2 Service & Support Rexroth IndraDrive 11.5 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 119 - 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 120 11-4 Service & Support Rexroth IndraDrive 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 121 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 122 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 123 12-1 Rexroth IndraDrive Index Index Additional components mains choke 6-1 Appropriate use 2-1 autotransformers 4-2 Battery safety 3-11 bleeder 8-1 Braking resistor 9-1 Bus module 7-8 Capacitor Unit 7-1 Choke 6-1 Commutation choke 6-1 Connection bus module 7-8 X1 7-8...
  • Page 124 12-2 Index Rexroth IndraDrive 0362-N0080-A-500-NNNN 6-3 0400-N0051-A-480-NNNN 6-3 0571-N0050-A-500-NNNN 6-3 0600-N0032-A-500-NNNN 6-3 1000-N0012-A-500-NNNN 6-3 1000-N0020-A-500-NNNN 6-3 2800-S0125-A-480-NNNN 6-7 3400-S0202-A-480-NNNN 6-7 5700-S0051-A-480-NNNN 6-7 HNL01.1R- 0540-C0094-A-480-NNNN 6-6 0590-C0065-A-480-NNNN 6-6 0980-C0026-A-480-NNNN 6-6 3000-S0094-A-480-NNNN 6-7 4200-S0026-A-480-NNNN 6-7 6300-S0065-A-480-NNNN 6-7 Improper use hazards 3-2 Inappropriate use 2-2...
  • Page 125 12-3 Rexroth IndraDrive Index transformers 4-1 Type code HNL 6-1 mains choke 6-1 ungrounded power supply lines 4-1 directions for use 2-1 hazards by improper use 3-2 inappropriate 2-2 Warning symbols 3-1 X1 7-8 DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 126 12-4 Index Rexroth IndraDrive DOK-INDRV*-ADDCOMP****-PR02-EN-P...
  • Page 128 Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Phone +49 93 52-40-50 60 +49 93 52-40-49 4 1 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany R911306140 DOK-INDRV*-ADDCOMP****-PR02-EN-P...

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