Rexroth IndraDrive Drive Controllers Power Sections HCS02

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IndustrialHydraulicsElectric Drivesand ControlsLinear Motion andAssembly ulicsRexroth IndraControl VCP 20Rexroth IndraDrive CDrive ControllersPower Sections HCS02.1Project Planning ManualR911306138Edition 03

About this DocumentationTitleIndraDrive CRexroth IndraDrive CDrive ControllersPower Sections HCS02.1Type of DocumentationDocument TypecodeInternal File ReferenceRecord of RevisionsCopyrightProject Planning ManualDOK-INDRV*-HCS02.1****-PR02-ENDocument number INDRV*-HCS02.1****-PR01-EN04.2004First onDOK-INDRV*-HCS02.1****-PR03-EN01.2006Revision Bosch Rexroth AG2006Copying this document, giving it to others and the use or communicationof the contents thereof without express authority, are forbidden. Offendersare liable for the payment of damages. All rights are reserved in the eventof the grant of a patent or the registration of a utility model or design(DIN 34-1).ValidityPublished byThe specified data only serve to describe the product. No statementsconcerning a certain condition or suitability for a certain application can bederived from our information. The given information does not release theuser from the obligation of own judgement and verification. It must beremembered that our products are subject to a natural process of wearand aging.Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 2 D-97816 Lohr a. MainTelefon 49 (0)93 52 / 40-0 Tx 68 94 21 Fax 49 (0)93 52 / 40-48 85 BRC/EDY1 (RR/US)NoteThis document has been printed on chlorine-free bleached paper.DOK-INDRV*-HCS02.1****-PR03-EN-P

Rexroth IndraDrive CContents IContents1Introduction1.11-1Documentation. 1-1About this Documentation . 1-1Documentations - Overview . 1-21.2Basic Design of a Drive Controller. 1-3Power Section. 1-3Control Section . 1-41.3Drive Controllers - Block Diagram . 1-4HCS02.1E-W0012-NNNN . 1-4HCS02.1E-W0012-NNNV. 1-5HCS02.1E-W0028-NNNN . 1-5HCS02.1E-W0028-NNNV. 1-6HCS02.1E-W0054/70-NNNN . 1-6HCS02.1E-W0054/70-NNNV. 1-71.42General Information on How to Install the Drive Controller . 1-8Important Directions for Use2.12-1Appropriate Use. 2-1Introduction . 2-1Areas of Use and Application . 2-22.23Inappropriate Use . 2-2Safety Instructions for Electric Drives and Controls3.13-1General Information . 3-1Using the Safety Instructions and Passing them on to Others. 3-1Instructions for Use. 3-1Explanation of Warning Symbols and Degrees of Hazard Seriousness . 3-3Hazards by Improper Use. 3-43.2Instructions with Regard to Specific Dangers. 3-5Protection Against Contact with Electrical Parts . 3-5Protection Against Electric Shock by Protective Low Voltage (PELV) . 3-6Protection Against Dangerous Movements . 3-7Protection Against Magnetic and Electromagnetic Fields During Operation andMounting . 3-9Protection Against Contact with Hot Parts . 3-10Protection During Handling and Mounting. 3-11Battery Safety . 3-11Protection Against Pressurized Systems . 3-12DOK-INDRV*-HCS02.1****-PR03-EN-P

II Contents4Rexroth IndraDrive CIdentification4.14-1Device Types . 4-1Type Code . 4-14.2Type Plates . 4-2Type Plate Arrangement. 4-2Type Plate Power Section (Example). 4-2Type Plate Control Section. 4-24.35Scope of Delivery. 4-3Mechanical Data5.15-1Dimensions . 5-1HCS02.1E-W0012 . 5-1HCS02.1E-W0028 . 5-2HCS02.1E-W0054 and HCS02.1E-W0070 . 5-35.2Weight. 5-45.3Temperatures Above the Top of the Device. 5-5Outlet Temperatures in Normal Operation . 5-66Electrical Data6-16.1Power Section – Mains Supply. 6-16.2Power Section – DC Bus . 6-26.3Power Section – DC Bus Power . 6-3Allowed DC Bus Continuous Power with Three-Phase Mains Connection. 6-5Allowed DC Bus Continuous Power with Single-Phase Mains Connection . 6-6Mains Connection Power and DC Bus Continuous Power . 6-76.4Power Section – Braking Resistor . 6-96.5Power Section – Inverter . 6-106.6Power Section - Examples of Allowed Load Profiles. 6-126.7Power Section - Operating Standard Motors. 6-136.8Power Section – Cooling, Power Dissipation, Insulation Resistance, Sound Pressure. 6-156.9Control Voltage . 6-20Devices without Internal Control Voltage Supply (HCS02.1E-W00xx-NNNN). 6-20Devices with Internal Control Voltage Supply Generation from DC bus(HCS02.1E-W00xx-NNNV). 6-216.10 Connections . 6-23Complete Connection Diagram . 6-23Connections at HCS02.1E-W0012. 6-24Connections at HCS02.1E-W0028, -W0054, -W0070 . 6-26X1, Module Bus . 6-29X3, Mains Connection . 6-30X5, Motor Connection. 6-32X6, Motor Temperature Monitoring and Motor Holding Brake . 6-34X9, Connection of Braking Resistor. 6-37X13, Control Voltage ( 24 V, 0 V) . 6-38DC Bus (L , L-). 6-41Connection Point of Equipment Grounding Conductor and Equipment GroundingConnections. 6-42DOK-INDRV*-HCS02.1****-PR03-EN-P

Rexroth IndraDrive CContents IIIGround Connection of Housing . 6-42XS1, Shield Connection (Control Wires) . 6-43XS2, Shield Connection (Motor Cable) . 6-4478Touch Guard7-17.1Cutouts. 7-17.2Mounting . 7-2Disposal and Environmental Protection8.18-1Disposal . 8-1Products. 8-1Packaging Materials . 8-18.2Environmental Protection. 8-1No Release of Hazardous Substances . 8-1Materials Contained in the Products . 8-1Recycling . 8-29Service & Support9-19.1Helpdesk . 9-19.2Service-Hotline . 9-19.3Internet. 9-19.4Vor der Kontaktaufnahme. - Before contacting us. . 9-19.5Kundenbetreuungsstellen - Sales & Service Facilities . 9-210 IndexDOK-INDRV*-HCS02.1****-PR03-EN-P10-1

IV ContentsRexroth IndraDrive CDOK-INDRV*-HCS02.1****-PR03-EN-P

Introduction 1-1Rexroth IndraDrive C1Introduction1.1DocumentationAbout this DocumentationThis documentation basically contains the technical data of the RexrothIndraDrive C HCS02.1 drive controllers.Personal injury and property damage caused byincorrect project planning for applications,machines and installations!WARNING Take the content of the Project Planning Manual"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 youneed, in any case, the Project Planning Manual "Rexroth IndraDrive DriveSystem" (DOK-INDRV*-SYSTEM*****-PRxx-EN-P; part no. R911309636).This Project Planning Manual, among other things, contains:DOK-INDRV*-HCS02.1****-PR03-EN-P specifications for the components of the drive system configuration of the drive system components arrangement of the components in the control cabinet electromagnetic compatibility (EMC) types of mains connection requirements to the mains connection control circuits for the mains connection connections of the components in the drive system fusing and selecting the mains contactor accessories in the drive system calculations (determining appropriate drive controller; mainsconnection; leakage capacitance; operating data of mains filters;selecting the 24V supply; braking behavior when using a DC busresistor unit) notes on how to replace devices

1-2 IntroductionRexroth IndraDrive CDocumentations - OverviewFor project planning of the drive system the following documentations areavailable:1)TitleKind of DocumentationDocument TypecodeRexroth IndraDriveDrive SystemProject Planning ManualDOK-INDRV*-SYSTEM*****-PRxx-EN-PRexroth IndraDriveDrive ControllersControl Sections CSxProject Planning ManualDOK-INDRV*-CSH********-PRxx-EN-PRexroth IndraDrive MDrive ControllersPower Sections HMxProject Planning ManualDOK-INDRV*-HMS HMD****-PRxx-EN-PRexroth IndraDrive CDrive ControllersPower Sections HCS02.1Project Planning ManualDOK-INDRV*-HCS02.1****-PRxx-EN-PRexroth IndraDrive CDrive ControllersPower Sections HCS03.1Project Planning ManualDOK-INDRV*-HCS03.1****-PRxx-EN-PRexroth IndraDriveSupply UnitsProject Planning tic Compatibility (EMC) inDrive and Control SystemsProject Planning ManualDOK-GENERAL-EMV********-PRxx-EN-PRexroth IndraDriveIntegrated Safety TechnologyFunctional and Application DOK-INDRV*-SI*-**VRS**-FKxx-EN-PDescriptionRexroth Connection CablesSelection DataDOK-CONNEC-CABLE*STAND-AUxx-EN-PSafety Instructions for Electrical DrivesSafety h IndraDriveAdditional ComponentsProject Planning ManualDOK-INDRV*-ADDCOMP****-PRxx-EN-PRexroth IndraDriveFirmware for Drive ControllersFunctional DescriptionDOK-INDRV*-MP*-02VRS**-FKxx-EN-PRexroth IndraDriveFirmware for Drive ControllersFunctional DescriptionDOK-INDRV*-MP*-03VRS**-FKxx-EN-PRexroth IndraDriveFirmware for Drive ControllersFunctional DescriptionDOK-INDRV*-MP*-04VRS**-FKxx-EN-PRexroth IndraDriveFirmware for Drive ControllersParameter DescriptionDOK-INDRV*-GEN-**VRS**-PAxx-EN-PRexroth IndraDriveFirmware for Drive ControllersTroubleshooting GuideDOK-INDRV*-GEN-**VRS**-WAxx-EN-PRexroth IndraDyn SSynchronous Motors MSKProject Planning ManualDOK-MOTOR*-MSK********-PRxx-EN-PRexroth IndraDyn AAsynchronous Motors MAD/MAFProject Planning ManualDOK-MOTOR*-MAD/MAF****-PRxx-EN-PRexroth IndraDyn TSynchronous Torque Motors MBTProject Planning ManualDOK-MOTOR*-MBT********-PRxx-EN-PRexroth IndraDyn HSynchronous Kit –Spindle Motors MBS-HProject Planning ManualDOK-MOTOR*-MBS-H******-PRxx-EN-PRexroth IndraDyn LSynchronous Linear Motors MLFProject Planning ManualDOK-MOTOR*-MLF********-PRxx-EN-PThird Party MotorsProject Planning Manualand NDRV*-HCS02.1****-PR03-EN-P

Introduction 1-3Rexroth IndraDrive C1)in the document typecodes "xx" is a wild card for the current edition ofthe documentation (example: "PR01" is the first edition of a ProjectPlanning Manual)Fig. 1-1: Documentations - overview1.2Basic Design of a Drive Controller21hcs lt rt.fh71:Power section2:Control sectionFig. 1-2: Basic designThe drive controller consists of two essential parts: Power section Control sectionPower SectionThe following are connected to the power section:DOK-INDRV*-HCS02.1****-PR03-EN-P mains motor (with optional motor holding brake and motor temperaturemonitoring) 24 V power supply DC bus (not for HCS02.1-W0012)

1-4 IntroductionRexroth IndraDrive C module bus (for cross communication in the case of DC busconnection with other devices; not for HCS02.1-W0012) braking resistor (optional; not for HCS02.1-W0012 and –W0028)Control SectionThe control section is a separate component that is plugged into thepower section. The drive controller is supplied ex works complete withcontrol section.The control section may only be replaced by qualified personnel.The contacts X31/1 and X31/2 are connected to the control section as Bbcontacts.Note:1.3The control sections are describeddocumentation (see page 1-2).inaseparateDrive Controllers - Block 3line input withbridge circuitrectifierbraking resistorcircuitchargingcurrent limitDC buscapacitanceA3converterbridge circuitwith output tothe motorhcs block 12n.FH7Fig. 1-3:HCS02.1E-W0012-NNNN - Block diagramDOK-INDRV*-HCS02.1****-PR03-EN-P

Introduction 1-5Rexroth IndraDrive CHCS02.1E-W0012-NNNVRSoftstartRBL1A1A2L2CZWL3line input withbridge pplybraking resistorcircuitDC buscapacitancechargingcurrent limitA3converterbridge circuitwith output tothe motorhcs block 12v.FH7Fig. 1-4:HCS02.1E-W0012-NNNV - Block diagramHCS02.1E-W0028-NNNNL RSoftstartRBL1A1A2L2CZWL3A3Lline input withbridge circuitrectifierbraking resistorcircuitchargingcurrent limitDC buscapacitanceconverterbridge circuitwith output tothe motorDC busconnectionhcs block 28n.FH7Fig. -NNNN - Block diagram

1-6 IntroductionRexroth IndraDrive CHCS02.1E-W0028-NNNVL RSoftstartRBL1A1A2L2CZWL3A3Lline input withbridge pplybraking resistorcircuitDC buscapacitanceconverterbridge circuitwith output tothe motorchargingcurrent limitDC busconnectionhcs block 28v.FH7Fig. 1-6:HCS02.1E-W0028-NNNV - Block diagramHCS02.1E-W0054/70-NNNNL 2CZWL3A3Lline input withbridge circuitrectifierbraking resistorcircuitchargingcurrent limitDC buscapacitanceconverterbridge circuitwith output tothe motorDC busconnectionhcs block 54 70n.FH7Fig. 1-7:HCS02.1E-W0054/70-NNNN - Block diagramDOK-INDRV*-HCS02.1****-PR03-EN-P

Introduction 1-7Rexroth IndraDrive CHCS02.1E-W0054/70-NNNVL 2CZWL3A3Lline input withbridge pplybraking resistorcircuitchargingcurrent limitDC busconverterDC buscapacitance bridge circuit connectionwith output tothe motorhcs block 54 70v.FH7Fig. /70-NNNV - Block diagram

1-8 Introduction1.4Rexroth IndraDrive CGeneral Information on How to Install the Drive ControllerDamage can be caused to the drive controller or circuit boards ifelectrostatic charging present in people and/or tools is discharged acrossthem. Therefore, please note the following information:Electrostatic charges can cause damage toelectronic components and interfere with theiroperational safety!CAUTION Exposed conductive parts coming into contact withcomponents and circuit boards must be discharged bymeans of grounding. Otherwise errors may occurwhen triggering motors and moving elements.Such exposed conductive parts include: the copper bit when soldering the human body (ground connection caused by touching a conductive,grounded item) parts and tools (place them on a conductive support)Endangered components may only be stored or dispatched in conductivepackaging.Note:Rexroth connection diagrams are only to be used forproducing installation connection diagrams. The machinemanufacturer’s installation connection diagrams must be usedfor wiring the installation! Lay signal lines separately from the load resistance lines because ofthe occurrence of interference. Transmit analog signals (e.g. command values, actual values) viashielded lines. Do not connect mains, DC bus or power leads to low voltages or allowthem to come into contact with these. When carrying out a high voltage test or an applied-overvoltagewithstand test on the machine’s electrical equipment, disconnect allconnections to the devices. This protects the electronic components(allowed in accordance with EN 60204-1). During their routine testing,Rexroth drive components are tested for high voltage and insulation inaccordance with EN 50178.Risk of damage to the drive controller byconnecting and disconnecting live connections! Do not connect and disconnect live P

Important Directions for Use 2-1Rexroth IndraDrive C2Important Directions for Use2.1Appropriate UseIntroductionRexroth products represent state-of-the-art developments andmanufacturing. They are tested prior to delivery to ensure operating safetyand reliability.The products may only be used in the manner that is defined asappropriate. If they are used in an inappropriate manner, then situationscan develop that may lead to property damage or injury to personnel.Note:Rexroth as manufacturer is not liable for any damagesresulting from inappropriate use. In such cases, the guaranteeand the right to payment of damages resulting frominappropriate use are forfeited. The user alone carries allresponsibility of the risks.Before using Rexroth products, make sure that all the pre-requisites foran appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must firstread and understand the relevant safety instructions and be familiarwith appropriate use. If the products take the form of hardware, then they must remain intheir original state, in other words, no structural changes are permitted.It is not permitted to decompile software products or alter sourcecodes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the mannerdescribed in the relevant documentation.DOK-INDRV*-HCS02.1****-PR03-EN-P

2-2 Important Directions for UseRexroth IndraDrive CAreas of Use and ApplicationDrive controllers made by Bosch Rexroth are designed to controlelectrical motors and monitor their operation.Control and monitoring of the motors may require additional sensors andactors.Note:The drive controllers may only be used with the accessoriesand parts specified in this document. If a component has notbeen specifically named, then it may not be either mounted orconnected. The same applies to cables and lines.Operation is only permitted in the specified configurations andcombinations of components using the software and firmwareas specified in the relevant Functional Descriptions.Every drive controller has to be programmed before commissioning,making it possible for the motor to execute the specific functions of anapplication.The drive controllers have been developed for use in single- and multiaxis drive and control tasks.To ensure an application-specific use, the drive controllers are availablewith different drive power and different interfaces.Typical applications of the drive controllers include: handling and mounting systems, packaging and food machines, printing and paper processing machines and machine tools.The drive controllers may only be operated under the assembly andinstallation conditions described in this documentation, in the specifiedposition of normal use and under the ambient conditions as described(temperature, degree of protection, humidity, EMC, etc.).2.2Inappropriate UseUsing the drive controllers outside of the operating conditions described inthis documentation and outside of the indicated technical data andspecifications is defined as "inappropriate use".Drive controllers must not be used, if . they are subject to operating conditions that do not meet thespecified ambient conditions. This includes, for example, operationunder water, under extreme temperature fluctuations or extremely highmaximum temperatures. Furthermore, the drive controllers must not be used in applicationswhich have not been expressly authorized by Rexroth. Please carefully follow the specifications outlined in the general P

Safety Instructions for Electric Drives and Controls 3-1Rexroth IndraDrive C3Safety Instructions for Electric Drives and Controls3.1General InformationUsing the Safety Instructions and Passing them on to OthersDo not attempt to install or commission this device without first reading alldocumentation provided with the product. Read and understand thesesafety instructions and all user documentation prior to working with thedevice. If you do not have the user documentation for the device, contactyour responsible Bosch Rexroth sales representative. Ask for thesedocuments to be sent immediately to the person or persons responsiblefor the safe operation of the device.If the device is resold, rented and/or passed on to others in any otherform, then these safety instructions must be delivered with the device.WARNINGImproper use of these devices, failure to followthe safety instructions in this document ortampering with the product, including disablingof safety devices, may result in materialdamage, bodily harm, electric shock or evendeath!Instructions for UseRead these instructions before the initial startup of the equipment in orderto eliminate the risk of bodily harm or material damage. Follow thesesafety instructions at all times. Bosch Rexroth AG is not liable for damages resulting from failure toobserve the warnings provided in this documentation. Read the operating, maintenance and safety instructions in yourlanguage before starting up the machine. If you find that you cannotcompletely understand the documentation for your product, please askyour supplier to clarify. Proper and correct transport, storage, assembly and installation aswell as care in operation and maintenance are prerequisites foroptimal and safe operation of this device. Only assign trained and qualified persons to work with electricalinstallations: Only persons who are trained and qualified for the use andoperation of the device may work on this device or within itsproximity. The persons are qualified if they have sufficientknowledge of the assembly, installation and operation of theequipment as well as an understanding of all warnings andprecautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified toswitch electrical circuits and devices on and off in accordance withtechnical safety regulations, to ground them and to mark themaccording to the requirements of safe work practices. They musthave 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 specificapplication as practiced in the country of use.DOK-INDRV*-HCS02.1****-PR03-EN-P

3-2 Safety Instructions for Electric Drives and ControlsRexroth IndraDrive C The devices have been designed for installation in industrialmachinery. The ambient conditions given in the product documentation must beobserved. Only use safety-relevant applications that are clearly and explicitlyapproved in the Project Planning Manual. If this is not the case, theyare excluded.Safety-relevant ar

Take the content of the Project Planning Manual "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

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