-
Rexroth IndraControl VCP 20
IndustrialHydraulics
Electric Drivesand Controls
Linear Motion and Assembly Technologies Pneumatics
ServiceAutomation
MobileHydraulics
Rexroth IndraDrive CDrive ControllersPower Sections HCS03.1
R911307049Edition 03
Project Planning Manual
-
About this Documentation Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Rexroth Indra Drive C
Drive Controllers
Power Sections HCS03.1
Project Planning Manual
DOK-INDRV*-HCS03.1****-PR03-EN-P
• Box: M8*-01VRS• Document Number 120-2400-B316-03/EN
This documentation provides information on …
• how to design the control cabinet• how to mount the drive
controllers in the control cabinet• how to install the drive
system
Description ReleaseDate
Notes
DOK-INDRV*-HCS03.1****-PR01-EN 03.2004 First Edition
DOK-INDRV*-HCS03.1****-PR02-EN 02.2005 Revision
DOK-INDRV*-HCS03.1****-PR03-EN 01.2006 Revision
Bosch Rexroth AG, 2006
Copying 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).
The 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.
MainTelephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93
52/40-48 85http://www.boschrexroth.com/
Dept. BRC/EDY1 (RR, US)
This document has been printed on chlorine-free bleached
paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Copyright
Validity
Published by
Note
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Rexroth IndraDrive C HCS03.1 Contents I
DOK-INDRV*-HCS03.1****-PR03-EN-P
Contents
1 Indroduction 1-1
1.1
Documentation..............................................................................................................................
1-1
About this Documentation
.......................................................................................................
1-1
Documentations - Overview
....................................................................................................
1-2
1.2 Basic Design of a Drive
Controller................................................................................................
1-3
1.3 General Information on How to Install the Drive Controller
.......................................................... 1-5
2 Important Directions for Use 2-1
2.1 Appropriate
Use............................................................................................................................
2-1
Introduction
..............................................................................................................................
2-1
Areas of Use and Application
..................................................................................................
2-2
2.2 Inappropriate Use
.........................................................................................................................
2-2
3 Safety Instructions for Electric Drives and Controls 3-1
3.1 General Information
......................................................................................................................
3-1
Using the Safety Instructions and Passing them on to
Others................................................ 3-1
Instructions for
Use..................................................................................................................
3-1
Explanation of Warning Symbols and Degrees of Hazard Seriousness
................................. 3-3
Hazards by Improper
Use........................................................................................................
3-4
3.2 Instructions with Regard to Specific
Dangers...............................................................................
3-5
Protection Against Contact with Electrical Parts
.....................................................................
3-5
Protection Against Electric Shock by Protective Low Voltage
(PELV) .................................... 3-6
Protection Against Dangerous Movements
.............................................................................
3-7
Protection Against Magnetic and Electromagnetic Fields During
Operation andMounting
..................................................................................................................................
3-9
Protection Against Contact with Hot Parts
............................................................................
3-10
Protection During Handling and
Mounting.............................................................................
3-11
Battery Safety
........................................................................................................................
3-11
Protection Against Pressurized Systems
..............................................................................
3-12
4 Identification 4-1
4.1 Device Types
................................................................................................................................
4-1
Type Code
...............................................................................................................................
4-1
4.2 Type Plates
...................................................................................................................................
4-2
Type Plate Power Section
(Example)......................................................................................
4-3
Type Plate Control
Section......................................................................................................
4-3
4.3 Scope of
Delivery..........................................................................................................................
4-3
Overview..................................................................................................................................
4-3
-
II Contents Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
5 Mechanical Data 5-1
5.1 Dimensions
...................................................................................................................................
5-1
Drive Controller
HCS03.1E-W0070.........................................................................................
5-1
Drive Controller HCS03.1E-W0070 with HAS02
.....................................................................
5-1
Drive Controller HCS03.1E-W0100, -W0150
..........................................................................
5-2
Drive Controller HCS03.1E-W0100, -W0150 with HAS02
...................................................... 5-2
Drive Controller
HCS03.1E-W0210.........................................................................................
5-3
Drive Controller HCS03.1E-W0210 with HAS02
.....................................................................
5-3
5.2
Weight...........................................................................................................................................
5-6
Mounting Position
....................................................................................................................
5-7
Temperatures Above the Top of the
Device............................................................................
5-7
6 Electrical Data 6-1
6.1 Power Section - Mains
Supply......................................................................................................
6-1
6.2 Power Section - DC Bus
...............................................................................................................
6-1
6.3 Power Section - DC Bus
Power....................................................................................................
6-2
Mains Connection Power and DC Bus Continuous Power
..................................................... 6-3
6.4 Power Section - Braking
Resistor.................................................................................................
6-6
6.5 Power Section - Inverter
...............................................................................................................
6-7
6.6 Power Section - Examples of Allowed Output Current
Profiles....................................................
6-8
6.7 Power Section - Operating Standard
Motors..............................................................................
6-10
6.8 Power Section - Cooling, Power Dissipation, Insulation
Resistance, Sound Pressure.............. 6-11
6.9 Control Voltage
...........................................................................................................................
6-12
Devices with Control Voltage Generation from DC Bus
(HCS03.1E-W0xxx-NNxV)............. 6-12
6.10
Connections................................................................................................................................
6-14
Overall Connection Diagram
.................................................................................................
6-14
6.11 Connections at Power Section
HCS03.1....................................................................................
6-15
Optional Control Voltage
.......................................................................................................
6-18
DC Bus
..................................................................................................................................
6-18
X1, Module Bus
.....................................................................................................................
6-19
X3, Mains Connection
...........................................................................................................
6-20
X5, Motor
Connection............................................................................................................
6-21
X6, Motor Temperature Monitoring and Motor Holding Brake
.............................................. 6-23
X9, Braking
Resistor..............................................................................................................
6-26
XS1, Shield
Connection.........................................................................................................
6-27
Ground Connection of Housing
.............................................................................................
6-27
Connection Point of Equipment Grounding Conductor
......................................................... 6-28
7 Touch Guard 7-1
Cutouts
....................................................................................................................................
7-1
Mounting
..................................................................................................................................
7-2
8 Replacing Devices 8-1
8.1 General Information
......................................................................................................................
8-1
8.2 How to Proceed When Replacing
Devices...................................................................................
8-1
Replacing the Drive
Controller.................................................................................................
8-1
-
Rexroth IndraDrive C HCS03.1 Contents III
DOK-INDRV*-HCS03.1****-PR03-EN-P
Replacing the Motor
................................................................................................................
8-2
Replacing Cables
....................................................................................................................
8-3
8.3 Fault Report
..................................................................................................................................
8-4
9 Disposal and Environmental Protection 9-1
9.1 Disposal
........................................................................................................................................
9-1
Products...................................................................................................................................
9-1
Packaging Materials
................................................................................................................
9-1
9.2 Environmental
Protection..............................................................................................................
9-1
No Release of Hazardous Substances
...................................................................................
9-1
Materials Contained in the Products
.......................................................................................
9-1
Recycling
.................................................................................................................................
9-1
10 Service & Support 10-1
10.1
Helpdesk.....................................................................................................................................
10-1
10.2 Service-Hotline
...........................................................................................................................
10-1
10.3
Internet........................................................................................................................................
10-1
10.4 Vor der Kontaktaufnahme... - Before contacting us...
................................................................
10-1
10.5 Kundenbetreuungsstellen - Sales & Service Facilities
...............................................................
10-2
11 Index 11-1
-
IV Contents Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
-
Rexroth IndraDrive C HCS03.1 Indroduction 1-1
DOK-INDRV*-HCS03.1****-PR03-EN-P
1 Indroduction
1.1 Documentation
About this DocumentationThis documentation basically contains
the technical data of the RexrothIndraDrive C HCS03.1 drive
controllers.
WARNING
Personal injury and property damage caused byincorrect project
planning for applications,machines and installations!⇒ 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:
• 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; mains
connection; 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 Indroduction Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Documentations - OverviewFor project planning of the drive
system the following documentations areavailable:
Title Kind of documentation Document typecode1)
Rexroth IndraDriveDrive System
Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P
Rexroth IndraDriveDrive ControllersControl Sections CSx
Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P
Rexroth IndraDrive MDrive ControllersPower Sections HMx
Project Planning Manual DOK-INDRV*-HMS+HMD****-PRxx-EN-P
Rexroth IndraDrive CDrive ControllersPower Sections HCS02.1
Project Planning Manual DOK-INDRV*-HCS02.1****-PRxx-EN-P
Rexroth IndraDrive CDrive ControllersPower Sections HCS03.1
Project Planning Manual DOK-INDRV*-HCS03.1****-PRxx-EN-P
Rexroth IndraDriveSupply Units
Project Planning Manual DOK-INDRV*-HMV-*******-PRxx-EN-P
Rexroth IndraDriveAdditional Components
Project Planning Manual DOK-INDRV*-ADDCOMP****-PRxx-EN-P
Rexroth IndraDriveIntegrated Safety Technology
Functional and ApplicationDescription
DOK-INDRV*-SI*-**VRS**-FKxx-EN-P
Rexroth IndraDriveFirmware for Drive Controllers
Functional Description DOK-INDRV*-MP*-02VRS**-FKxx-EN-P
Rexroth IndraDriveFirmware for Drive Controllers
Functional Description DOK-INDRV*-MP*-03VRS**-FKxx-EN-P
Rexroth IndraDriveFirmware for Drive Controllers
Functional Description DOK-INDRV*-MP*-04VRS**-FKxx-EN-P
Rexroth IndraDriveFirmware for Drive Controllers
Parameter Description DOK-INDRV*-GEN-**VRS**-PAxx-EN-P
Rexroth IndraDriveFirmware for Drive Controllers
Troubleshooting Guide DOK-INDRV*-GEN-**VRS**-WAxx-EN-P
Rexroth Connection Cables Selection Data
DOK-CONNEC-CABLE*STAND-AUxx-EN-P
Rexroth IndraDyn AAsynchronous Motors MAD/MAF
Project Planning Manual DOK-MOTOR*-MAD/MAF****-PRxx-EN-P
Rexroth IndraDyn SSynchronous Motors MSK
Project Planning Manual DOK-MOTOR*-MSK********-PRxx-EN-P
Rexroth IndraDyn TSynchronous Torque Motors MBT
Project Planning Manual DOK-MOTOR*-MBT********-PRxx-EN-P
Rexroth IndraDyn HSynchronous Kit –Spindle MotorsMBS-H
Project Planning Manual DOK-MOTOR*-MBS-H******-PRxx-EN-P
Rexroth IndraDyn LSynchronous Linear Motors MLF
Project Planning Manual DOK-MOTOR*-MLF********-PRxx-EN-P
Safety Instructions for Electrical Drives Safety Guidelines
DOK-GENERAL-DRIVE******-SVSx-MS-P
1) In the document typecodes "xx" is a wild card for the current
editionof the documentation (example: "PR01" is the first edition
of aProject Planning Manual)
Fig. 1-1: Documentations - overview
-
Rexroth IndraDrive C HCS03.1 Indroduction 1-3
DOK-INDRV*-HCS03.1****-PR03-EN-P
1.2 Basic Design of a Drive Controller
�
�
1: Power section2: Control section
Fig. 1-2: Basic design
The drive controller consists of two essential parts:
• Power section• Control section
-
1-4 Indroduction Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Power SectionThe following are connected to the power
section:
• mains voltage• motor• 24 V power supply (optional)• module bus
(for cross communication in the case of DC bus
connection with other devices)
• motor holding brake (optional)• motor temperature sensor
(optional)• braking resistor (optional)
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: The control sections are described in a
separatedocumentation (see page 1-2).
-
Rexroth IndraDrive C HCS03.1 Indroduction 1-5
DOK-INDRV*-HCS03.1****-PR03-EN-P
1.3 General Information on How to Install the Drive
Controller
Damage 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:
CAUTION
Electrostatic charges can cause damage toelectronic components
and interfere with theiroperational safety!Exposed conductive parts
coming into contact with
components 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.
CAUTION
Risk of damage to the drive controller byconnecting and
disconnecting live connections!⇒ Do not connect and disconnect live
connections.
-
1-6 Indroduction Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
-
Rexroth IndraDrive C HCS03.1 Important Directions for Use
2-1
DOK-INDRV*-HCS03.1****-PR03-EN-P
2 Important Directions for Use
2.1 Appropriate Use
IntroductionRexroth 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
manner
described in the relevant documentation.
-
2-2 Important Directions for Use Rexroth IndraDrive C
HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Areas 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
multi-axis 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.).
2.2 Inappropriate Use
Using 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 SafetyInstructions!
-
Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric
Drives and Controls 3-1
DOK-INDRV*-HCS03.1****-PR03-EN-P
3 Safety Instructions for Electric Drives and Controls
3.1 General Information
Using 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.
WARNING
Improper 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,
pleaseask your 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 specific
application as practiced in the country of use.
-
3-2 Safety Instructions for Electric Drives and Controls Rexroth
IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
• 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 are all such
applications which can cause danger topersons and material
damage.
• The information given in the documentation of the product with
regardto the use of the delivered components contains only examples
ofapplications and suggestions.
The machine and installation manufacturer must
• make sure that the delivered components are suited for
hisindividual application and check the information given in
thisdocumentation with regard to the use of the components,
• make sure that his application complies with the
applicablesafety regulations and standards and carry out the
requiredmeasures, modifications and complements.
• Startup of the delivered components is only permitted once it
is surethat the machine or installation in which they are installed
complieswith the national regulations, safety specifications and
standards ofthe application.
• Operation is only permitted if the national EMC regulations
for theapplication are met.
• The instructions for installation in accordance with EMC
requirementscan be found in the documentation "EMC in Drive and
ControlSystems".
• The machine or installation manufacturer is responsible
forcompliance with the limiting values as prescribed in the
nationalregulations.
• Technical data, connections and operational conditions are
specifiedin the product documentation and must be followed at all
times.
-
Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric
Drives and Controls 3-3
DOK-INDRV*-HCS03.1****-PR03-EN-P
Explanation of Warning Symbols and Degrees of Hazard
SeriousnessThe safety instructions describe the following degrees
of hazardseriousness. The degree of hazard seriousness informs
about theconsequences resulting from non-compliance with the safety
instructions:
Warning symbol with signalword
Degree of hazard seriousness accordingto ANSI Z 535
DANGER
Death or severe bodily harm will occur.
WARNING
Death or severe bodily harm may occur.
CAUTION
Bodily harm or material damage may occur.
Fig. 3-1: Hazard classification (according to ANSI Z 535)
-
3-4 Safety Instructions for Electric Drives and Controls Rexroth
IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Hazards by Improper Use
DANGER
High electric voltage and high working current!Risk of death or
severe bodily injury by electricshock!
DANGER
Dangerous movements! Danger to life, severebodily harm or
material damage byunintentional motor movements!
WARNING
High electric voltage because of incorrectconnection! Risk of
death or bodily injury byelectric shock!
WARNING
Health hazard for persons with heartpacemakers, metal implants
and hearing aids inproximity to electrical equipment!
CAUTION
Hot surfaces on device housing! Danger ofinjury! Danger of
burns!
CAUTION
Risk of injury by improper handling! Risk ofbodily injury by
bruising, shearing, cutting,hitting, or improper handling of
pressurizedlines!
CAUTION
Risk of injury by improper handling of batteries!
-
Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric
Drives and Controls 3-5
DOK-INDRV*-HCS03.1****-PR03-EN-P
3.2 Instructions with Regard to Specific Dangers
Protection Against Contact with Electrical Parts
Note: This section only concerns devices and drive components
withvoltages of more than 50 Volt.
Contact with parts conducting voltages above 50 Volts can
causepersonal danger and electric shock. When operating electrical
equipment,it is unavoidable that some parts of the devices conduct
dangerousvoltage.
DANGER
High electrical voltage! Danger to life, electricshock and
severe bodily injury!⇒ Only those trained and qualified to work
with or on
electrical equipment are permitted to operate,maintain and
repair this equipment.
⇒ Follow general construction and safety regulationswhen working
on electrical power installations.
⇒ Before switching on the device, the equipmentgrounding
conductor must have been non-detachably connected to all electrical
equipment inaccordance with the connection diagram.
⇒ Do not operate electrical equipment at any time,even for brief
measurements or tests, if theequipment grounding conductor is not
permanentlyconnected to the mounting points of the
componentsprovided for this purpose.
⇒ Before working with electrical parts with voltagepotentials
higher than 50 V, the device must bedisconnected from the mains
voltage or powersupply unit. Provide a safeguard to
preventreconnection.
⇒ With electrical drive and filter components, observethe
following:Wait 30 minutes after switching off power to
allowcapacitors to discharge before beginning to work.Measure the
voltage on the capacitors beforebeginning to work to make sure that
the equipment issafe to touch.
⇒ Never touch the electrical connection points of acomponent
while power is turned on.
⇒ Install the covers and guards provided with theequipment
properly before switching the device on.Before switching the
equipment on, cover andsafeguard live parts safely to prevent
contact withthose parts.
⇒ A residual-current-operated circuit-breaker or r.c.d.cannot be
used for electric drives! Indirect contactmust be prevented by
other means, for example, byan overcurrent protective device
according to therelevant standards.
⇒ Secure built-in devices from direct touching ofelectrical
parts by providing an external housing, forexample a control
cabinet.
European countries: according to EN 50178/ 1998,
-
3-6 Safety Instructions for Electric Drives and Controls Rexroth
IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
section 5.3.2.3.
USA: See National Electrical Code (NEC), NationalElectrical
Manufacturers' Association (NEMA), as well aslocal engineering
regulations. The operator must observeall the above regulations at
any time.
With electrical drive and filter components, observe the
following:
DANGER
High housing voltage and large leakage current!Risk of death or
bodily injury by electric shock!⇒ Before switching on, the housings
of all electrical
equipment and motors must be connected orgrounded with the
equipment grounding conductor tothe grounding points. This is also
applicable beforeshort tests.
⇒ The equipment grounding conductor of the electricalequipment
and the units must be non-detachablyand permanently connected to
the power supply unitat all times. The leakage current is greater
than3.5 mA.
⇒ Over the total length, use copper wire of a crosssection of a
minimum of 10 mm2 for this equipmentgrounding connection!
⇒ Before start-up, also in trial runs, always attach
theequipment grounding conductor or connect with theground wire.
Otherwise, high voltages may occur atthe housing causing electric
shock.
Protection Against Electric Shock by Protective Low Voltage
(PELV)All connections and terminals with voltages between 5 and 50
Volt atRexroth products are protective extra-low voltage systems
which areprovided with touch guard according to the product
standards.
WARNING
High electric voltage by incorrect connection!Risk of death or
bodily injury by electric shock!⇒ To all connections and terminals
with voltages
between 0 and 50 Volt, only devices, electricalcomponents, and
conductors may be connectedwhich are equipped with a PELV
(Protective Extra-Low Voltage) system.
⇒ Connect only voltages and circuits which are safelyisolated
from dangerous voltages. Safe isolation isachieved for example by
isolating transformers, safeoptocouplers or battery operation
without mainsconnection.
-
Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric
Drives and Controls 3-7
DOK-INDRV*-HCS03.1****-PR03-EN-P
Protection Against Dangerous MovementsDangerous movements can be
caused by faulty control of connectedmotors. Some common examples
are:
• improper or wrong wiring of cable connections• incorrect
operation of the equipment components• wrong input of parameters
before operation• malfunction of sensors, encoders and monitoring
devices• defective components• software or firmware errorsDangerous
movements can occur immediately after equipment isswitched on or
even after an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be
sufficient to avoidfaulty operation in the connected drives.
Regarding personal safety,especially the danger of bodily harm and
material damage, this alonecannot be relied upon to ensure complete
safety. Until the integratedmonitoring functions become effective,
it must be assumed in any casethat faulty drive movements will
occur. The extent of faulty drivemovements depends upon the type of
control and the state of operation.
-
3-8 Safety Instructions for Electric Drives and Controls Rexroth
IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
DANGER
Dangerous movements! Danger to life, risk ofinjury, severe
bodily harm or material damage!⇒ For the above reasons, ensure
personal safety by
means of qualified and tested higher-level monitoringdevices or
measures integrated in the installation.They have to be provided
for by the user accordingto the specific conditions within the
installation and ahazard and fault analysis. The safety
regulationsapplicable for the installation have to be taken
intoconsideration. Unintended machine motion or othermalfunction is
possible if safety devices are disabled,bypassed or not
activated.
To avoid accidents, bodily harm and/or materialdamage:
⇒ Keep free and clear of the machine’s range ofmotion and moving
parts. Possible measures toprevent people from accidentally
entering themachine’s range of motion:- use safety fences
- use safety guards
- use protective coverings
- install light curtains or light barriers
⇒ Fences and coverings must be strong enough toresist maximum
possible momentum.
⇒ Mount the emergency stop switch in the immediatereach of the
operator. Verify that the emergency stopworks before startup. Don’t
operate the device if theemergency stop is not working.
⇒ Isolate the drive power connection by means of anemergency
stop circuit or use a safety relatedstarting lockout to prevent
unintentional start.
⇒ Make sure that the drives are brought to a safestandstill
before accessing or entering the dangerzone.
⇒ Additionally secure vertical axes against falling ordropping
after switching off the motor power by, forexample:- mechanically
securing the vertical axes,
- adding an external braking/ arrester/ clampingmechanism or
- ensuring sufficient equilibration of the verticalaxes.
The standard equipment motor brake or an externalbrake
controlled directly by the drive controller arenot sufficient to
guarantee personal safety!
-
Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric
Drives and Controls 3-9
DOK-INDRV*-HCS03.1****-PR03-EN-P
⇒ Disconnect electrical power to the equipment using amaster
switch and secure the switch againstreconnection for:- maintenance
and repair work
- cleaning of equipment
- long periods of discontinued equipment use
⇒ Prevent the operation of high-frequency, remotecontrol and
radio equipment near electronics circuitsand supply leads. If the
use of such devices cannotbe avoided, verify the system and the
installation forpossible malfunctions in all possible positions
ofnormal use before initial startup. If necessary,perform a special
electromagnetic compatibility(EMC) test on the installation.
Protection Against Magnetic and Electromagnetic Fields
DuringOperation and Mounting
Magnetic and electromagnetic fields generated by
current-carryingconductors and permanent magnets in motors
represent a seriouspersonal danger to those with heart pacemakers,
metal implants andhearing aids.
WARNING
Health hazard for persons with heartpacemakers, metal implants
and hearing aids inproximity to electrical equipment!⇒ Persons with
heart pacemakers and metal implants
are not permitted to enter following areas:- Areas in which
electrical equipment and parts are
mounted, being operated or commissioned.
- Areas in which parts of motors with permanentmagnets are being
stored, repaired or mounted.
⇒ If it is necessary for somebody with a pacemaker toenter such
an area, a doctor must be consulted priorto doing so. The
interference immunity of present orfuture implanted heart
pacemakers differs greatly, sothat no general rules can be
given.
⇒ Those with metal implants or metal pieces, as wellas with
hearing aids must consult a doctor beforethey enter the areas
described above. Otherwisehealth hazards may occur.
-
3-10 Safety Instructions for Electric Drives and Controls
Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Protection Against Contact with Hot Parts
CAUTION
Hot surfaces at motor housings, on drivecontrollers or chokes!
Danger of injury! Dangerof burns!⇒ Do not touch surfaces of device
housings and
chokes in the proximity of heat sources! Danger ofburns!
⇒ Do not touch housing surfaces of motors! Danger ofburns!
⇒ According to operating conditions, temperatures canbe higher
than 60 °C, 140 °F during or afteroperation.
⇒ Before accessing motors after having switched themoff, let
them cool down for a sufficiently long time.Cooling down can
require up to 140 minutes!Roughly estimated, the time required for
coolingdown is five times the thermal time constantspecified in the
Technical Data.
⇒ After switching drive controllers or chokes off, wait15
minutes to allow them to cool down beforetouching them.
⇒ Wear safety gloves or do not work at hot surfaces.⇒ For
certain applications, the manufacturer of the end
product, machine or installation, according to therespective
safety regulations, has to take measuresto avoid injuries caused by
burns in the endapplication. These measures can be, for
example:warnings, guards (shielding or barrier),
technicaldocumentation.
-
Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric
Drives and Controls 3-11
DOK-INDRV*-HCS03.1****-PR03-EN-P
Protection During Handling and MountingIn unfavorable
conditions, handling and assembling certain parts andcomponents in
an improper way can cause injuries.
CAUTION
Risk of injury by improper handling! Bodilyinjury by bruising,
shearing, cutting, hitting!⇒ Observe the general construction and
safety
regulations on handling and assembly.⇒ Use suitable devices for
assembly and transport.⇒ Avoid jamming and bruising by
appropriate
measures.⇒ Always use suitable tools. Use special tools if
specified.⇒ Use lifting equipment and tools in the correct
manner.⇒ If necessary, use suitable protective equipment
(for
example safety goggles, safety shoes, safetygloves).
⇒ Do not stand under hanging loads.⇒ Immediately clean up any
spilled liquids because of
the danger of skidding.
Battery SafetyBatteries consist of active chemicals enclosed in
a solid housing.Therefore, improper handling can cause injury or
damages.
CAUTION
Risk of injury by improper handling!⇒ Do not attempt to
reactivate low batteries by heating
or other methods (risk of explosion andcauterization).
⇒ Do not recharge the batteries as this may causeleakage or
explosion.
⇒ Do not throw batteries into open flames.⇒ Do not dismantle
batteries.⇒ Do not damage electrical parts installed in the
devices.
Note: Environmental protection and disposal! The batteries
installedin the product are considered dangerous goods during
land,air, and sea transport (risk of explosion) in the sense of
thelegal regulations. Dispose of used batteries separate fromother
waste. Observe the local regulations in the country ofassembly.
-
3-12 Safety Instructions for Electric Drives and Controls
Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Protection Against Pressurized SystemsAccording to the
information given in the Project Planning Manuals,motors cooled
with liquid and compressed air, as well as drive controllers,can be
partially supplied with externally fed, pressurized media, such
ascompressed air, hydraulics oil, cooling liquids, and cooling
lubricatingagents. In these cases, improper handling of external
supply systems,supply lines, or connections can cause injuries or
damages.
CAUTION
Risk of injury by improper handling of pressurizedlines!⇒ Do not
attempt to disconnect, open, or cut
pressurized lines (risk of explosion).⇒ Observe the respective
manufacturer's operating
instructions.⇒ Before dismounting lines, relieve pressure
and
empty medium.⇒ Use suitable protective equipment (for
example
safety goggles, safety shoes, safety gloves).⇒ Immediately clean
up any spilled liquids from the
floor.
Note: Environmental protection and disposal! The agents used
tooperate the product might not be economically friendly.Dispose of
ecologically harmful agents separate from otherwaste. Observe the
local regulations in the country ofassembly.
-
Rexroth IndraDrive C HCS03.1 Identification 4-1
DOK-INDRV*-HCS03.1****-PR03-EN-P
4 Identification
4.1 Device Types
Type Code
Note: The following figure illustrates the basic structure of
the typecode. Your sales representative will help with the
currentstatus of available versions.
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+,,��#������
� � � � � � � � , � � � � � , � , � , 4 4 4 )
Fig. 4-1: Type code
-
4-2 Identification Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
4.2 Type Plates
Each drive component is marked by a type designation.
There is a type plate attached to all devices.
A label (cable mark) is wrapped around ready-made cables. This
labelindicates the type designation and the length. (The
designation of thecable itself - without connector - is printed on
the cable sheath.)
The identification of accessories packed in bags is either
printed on thebag or indicated in an accompanying note.
Type Plate Arrangement
�
�
1: Power section type plate2: Control section type plateFig.
4-2: Type plate arrangement
-
Rexroth IndraDrive C HCS03.1 Identification 4-3
DOK-INDRV*-HCS03.1****-PR03-EN-P
Type Plate Power Section (Example)
(-.�/�('�0''��
��������,�����,�,��,44441$��$"� � 2�.'�3�
'+'�
�������4�����
Example 04W12 means year 2004 week 12
Production week
Serial Number Barcode Hardware index
Part number
Producing Country
Device type
Fig. 4-3: Type plate power section
Type Plate Control SectionSee Project Planning Manual of the
control sections.
4.3 Scope of Delivery
Overview
as standard optional
Power section Control section (with options where required)
Touch guard Accessories HAS02
Connector X6 Accessories HAS01
Connector X3, X5
Connector X9 (forHCS03.1E-W0070)
Accessories HAS01 optional
Further optional accessories
Fig. 4-4: Scope of delivery
-
4-4 Identification Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
-
Rexroth IndraDrive C HCS03.1 Mechanical Data 5-1
DOK-INDRV*-HCS03.1****-PR03-EN-P
5 Mechanical Data
5.1 Dimensions
Drive Controller HCS03.1E-W0070
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���
���
���
all dimensions in mmFig. 5-1: Dimensional drawing
HCS03.1E-W0070
Drive Controller HCS03.1E-W0070 with HAS02
Fig. 5-2: Dimensional drawing HCS03.1E-W0070 with HAS02
-
5-2 Mechanical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Drive Controller HCS03.1E-W0100, -W0150
���
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��
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all dimensions in mmFig. 5-3: Dimensional drawing HCS03.1E-W0100
and HCS03.1E-W150
Drive Controller HCS03.1E-W0100, -W0150 with HAS02
all dimensions in mmFig. 5-4: Dimensional drawing HCS03.1E-W0100
and HCS03.1E-W150 with
HAS02
-
Rexroth IndraDrive C HCS03.1 Mechanical Data 5-3
DOK-INDRV*-HCS03.1****-PR03-EN-P
Drive Controller HCS03.1E-W0210
���
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��
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�
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all dimensions in mmFig. 5-5: Dimensional drawing
HCS03.1E-W0210
Drive Controller HCS03.1E-W0210 with HAS02
all dimensions in mmFig. 5-6: Dimensional drawing HCS03.1E-W0210
with HAS02
-
5-4 Mechanical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Boring Dimensions
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all dimensions in mmFig. 5-7: Boring dimensions
HCS03.1E-W0070*
-
Rexroth IndraDrive C HCS03.1 Mechanical Data 5-5
DOK-INDRV*-HCS03.1****-PR03-EN-P
���
�� ��
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all dimensions in mmFig. 5-8: Boring dimensions HCS03.1E-W0100
and HCS03.1-W0150
-
5-6 Mechanical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
��
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all dimensions in mmFig. 5-9: Boring dimensions
HCS03.1E-W0210
5.2 Weight
Device Weight in kg
HCS03.1E-W0070 13
HCS03.1E-W0100 20
HCS03.1E-W0150 20
HCS03.1E-W0210 38
Fig. 5-10: Weight of the devices
Note: The control section is not contained in the weight
data.The weight of the control section is about 0.4 kg.
-
Rexroth IndraDrive C HCS03.1 Mechanical Data 5-7
DOK-INDRV*-HCS03.1****-PR03-EN-P
Mounting PositionDrive controllers and DC bus resistor unit
should be mounted in such away that their longitudinal axis
corresponds to the natural direction ofconvection (motor and power
connections facing downwards).
In this way, natural convection supports the forced cooling air
flow. Thisavoids the generation of pockets of heat in the drive
controller.
Temperatures Above the Top of the DeviceThe drive controllers
have a high efficiency. Outlet temperatures higherthan the ambient
temperature are nevertheless produced at the top of thedevices,
among other things due to the converted energies. High
outlettemperatures are particularly produced in the case of
insufficient coolingor when the cooling air current (blower
failure) fails.
CAUTION
Risk of damage caused by too high outlettemperatures!⇒ When
mounting and installing other components,
make sure the distance to the top of the drivecontrollers is
sufficient.
⇒ You have to take into account that higher outlettemperatures
can occur when the cooling air currentfails.
Outlet Temperatures
Designation Symbol Unit HCS03.1
temperature risewith distance of10 mm from top ofdevice
∆T K 30
Fig. 5-11: Outlet temperatures
-
5-8 Mechanical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-1
DOK-INDRV*-HCS03.1****-PR03-EN-P
6 Electrical Data
Note: The current and power data below apply when the
allowedmotor cable length is complied with (see data in section
"X5,Motor Connection"). They refer to 3AC400 V.
6.1 Power Section - Mains Supply
Designation Symbol Unit HCS03.1E-W0070
HCS03.1E-W0100
HCS03.1E-W0150
HCS03.1E-W0210
three-phase mainsconnection allowed
single-phase mainsconnection
not allowed
rotary field no rotary field condition
total power factor TPF atPDC with / without mainschoke
TPF 0,85/0,57 0,83/0,59 0,81/0,61 0,78/0,62
power factor offundamental componentDPF PDC with / withoutmains
choke
cosφh1 0,95/0,64 0,95/0,67 0,94/0,70 0,93/0,73
assigned mains chokeHNL01.1E-
0571-N0050-A-500-NNNN
0362-N0080-A-500-NNNN
0240-N0106-A-500-NNNN
0170-N0146-A-500-NNNN
mains input voltage range ULN
V 3AC400…500 +10% -15%
mains frequency fLN
Hz 50…60 ± 2 Hz
mains input continuouscurrent at PDC cont
IL,cont
A 50 80 106 146
maximum inrush current(at max. input voltage)
IL, trans max
(on)
A 2,8 5,7 5,7 17
mains connection powerat PDC_cont;
ULN=AC400V; with
HNL01.1E
SLN
kVA 35 55,2 72,9 99,3
mains connection powerat PDC_cont;
ULN=AC400V; without
HNL01.1E
SLN
kVA 22,6 40,3 54 76
Fig. 6-1: Electrical data: power section - mains supply
-
6-2 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.2 Power Section - DC Bus
Designation Symbol Unit HCS03.1E-W0070
HCS03.1E-W0100
HCS03.1E-W0150
HCS03.1E-W0210
DC bus voltage range(unloaded)
UDC
V uncontrolledULN * 1,41
internal DC buscapacitance
CDC
mF 0,94 1,44 1,88 4,7
max. allowed external DCbus capacitance
CDCext
mF nicht zulässig 501)
limitation of inrush current charging via resistor;N/O contact:
min. 250.000 switching actions
charging bymeans of phase
control1)
storable energy of theinternal DC bus capacitorsat 3AC400V
WDC
Ws 150 230 300 752
braking resistor switch-onthreshold
UDC
(R_DC On)
V 820…850 820…850 820…850 820…850
lower DC bus voltage limit(switch-off threshold)
UDC limit
(min)
V 400 400 400 400
upper DC bus voltage limit(switch-off threshold)
UDC limit
(max)
V 900 900 900 900
capacitance in DC busagainst ground; betweenL+ and L-
CY
nF 100 100 100 100
balancing factor for PDCcont
(for parallel operation withcommon DC bus)with/without mains
choke
- 1/0,8 1/0,8 1/0,8 1/0,8
rated power atULN = 400V
without mains chokeminimum inductance ofmains supply
PDC cont
Lmin
kW
µH
13
40
24
40
34
40
47
40
rated power atULN = 400V
with mains choke
PDC cont
kW 25 43 56 85
1): as of hardware index 03 (see type plate)Fig. 6-2: Electrical
data: power section - DC bus
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-3
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.3 Power Section - DC Bus Power
Designation Symbol Unit HCS03.1E-W0070
HCS03.1E-W0100
HCS03.1E-W0150
HCS03.1E-W0210
profile DC bus poweroverload operation
overload capacity:
base DC_
DC_peak
P
P=K
T
PDC_base
t
P
PDC_peak
t
DC bus peak powerULN = 3AC400 V, at Ta=40 °C; t=0,4 s; T=4
swithout mains chokewith mains choke
PDC_peak_1
kW
2040
3359
5489
68124
DC bus powerULN = 3AC400 V, at Ta=40 °C; t=0,4 s; T=4 swithout
mains chokewith mains choke
PDC_base_1
kW
1020
1832
2440
3767
DC bus peak powerULN = 3AC400 V, at Ta=40 °C; t=2 s; T=20
swithout mains chokewith mains choke
PDC_peak_3
kW
1836
3053
5387
68124
DC bus powerULN = 3AC400 V, at Ta=40 °C; t=2 s; T=20 swithout
mains chokewith mains choke
PDC_base_3
kW
1020
1629
2135
3564
DC bus peak powerULN = 3AC400 V, at Ta=40 °C; t=60 s; T=5
minwithout mains chokewith mains choke
PDC_peak_4
kW
1427
2544
4066
5294
DC bus powerULN = 3AC400 V, at Ta=40 °C; t=60 s; T=5 minwithout
mains chokewith mains choke
PDC_base_4
kW
1121
1729
2439
3767
DC bus peak powerULN = 3AC400 V, at Ta=40 °C; t=60 s;T=10
minwithout mains chokewith mains choke
PDC_peak_5
kW
1427
2544
4066
5294
DC bus powerULN = 3AC400 V, at Ta=40 °C; t=60 s;T=10 minwithout
mains chokewith mains choke
PDC_base_5
kW
1121
1729
2439
3767
Fig. 6-3: Electrical data: power section - DC bus power
-
6-4 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
WARNING
Damage due to drive controller overload!⇒ Make sure the
specified performance data - peak
power and continuous power - are complied with bycorrect drive
dimensioning and selective fusing in themains connection.
Mains Connection Power and DC Bus Continuous PowerThe diagrams
below illustrate the interrelation between mains connectionpower
(SLN) and DC bus continuous power (PDCcont) with and without theuse
of mains chokes.
SLN depending on PDC cont for HCS03.1-E-W0070 @3AC400V/4kHz
0,00
10,00
20,00
30,00
40,00
50,00
2,5 5 7,5 10 12,5 15 17,5 20 22,5 25 27,5 30
PDC cont [kW]
SL
N [
kVA
]
with mains choke without mains choke
Fig. 6-4: Interrelation of SLN / PDC for HCS03.1-E-W0070
SLN depending on PDC cont for HCS03.1-E-W0100 @3AC400V/4kHz
0,00
10,00
20,00
30,00
40,00
50,00
60,00
70,00
0 10 20 30 40 50PDC cont [kW]
SL
N [
kVA
]
with mains choke without mains choke
Fig. 6-5: Interrelation of SLN / PDC for HCS03.1-E-W0100
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-5
DOK-INDRV*-HCS03.1****-PR03-EN-P
SLN depending on PDC cont for HCS03.1-E-W0150 @3AC400V/4kHz
0,00
20,00
40,00
60,00
80,00
100,00
0 10 20 30 40 50 60 70
PDC cont [kW]
SL
N [
kVA
]
with mains choke without mains choke
Fig. 6-6: Interrelation of SLN / PDC for HCS03.1-E-W0150
SLN depending on PDC cont for HCS03.1-E-W0210 @3AC400V/4kHz
0,00
20,00
40,00
60,00
80,00
100,00
120,00
0 10 20 30 40 50 60 70 80 90 100PDC cont [kW]
SL
N [k
VA
]
with mains choke without mains choke
Fig. 6-7: Interrelation of SLN / PDC for HCS03.1-E-W0210
-
6-6 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.4 Power Section - Braking Resistor
Designation Symbol Unit HCS03.1E-W0070
HCS03.1E-W0100
HCS03.1E-W0150
HCS03.1E-W0210
nominal brakingresistor
RDC(Bleeder) Ohm internally not contained
operating externalbraking resistor(optional)
allowed allowed allowed allowed
braking resistorswitch-on threshold
RDC (R_DC On) V see Functional Description of firmware
balancing factor forPBD(for parallel operationwith common DC
bus)
0,8 0,8 0,8 0,8
min. resistance valueof external brakingresistor
RDC(Bleeder) Ohm 17,5 11,7 7 5
allowed continuouspower of externalbraking resistor
Pcontchopper kW 13,2 18,9 25,2 42,6
ext. braking resistorpeak powerat ED=60% andt=120s
PBS kW 22 31,5 42 71
peak power brakechopper for t=1s
Ppeakchopper kW 42 63 97 137
Fig. 6-8: Data power section - braking resistor
60% 72120
peakchoppercontchopper
PP s
s= ×
Pcontchopper: brake chopper continuous powerPpeakchopper: brake
chopper peak power
Fig. 6-9: Example for calculating brake chopper continuous
power
Example for Calculating BrakeChopper Continuous Power
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-7
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.5 Power Section - Inverter
Designation Symbol Unit HCS03.1E-W0070
HCS03.1E-W0100
HCS03.1E-W0150
HCS03.1E-W0210
output voltagefundamentalcomponent ofvoltage
Uoutwith open-loop
U/f ctrlwith closed-loop oper.
V
V
UDC * 0,85 / 1,41
UDC * 0,85 / 1,41
output frequencyrange- at fs = 4 kHz– at fs = 8 kHz– at fs = 12
kHz– at fs = 16 kHz
fout Hz
0…4000…800
0…12000…1600
0…4000…800
0…12000…1600
0…4000…800
0…12000…1600
0…4000…800
0…12000…1600
rise of voltage atoutput at ULN=400Vand 15 m motorcable length
1)
dv/dt
10% - 90%
kV/µs
5 5 5 5
maximum outputcurrent
Iout_max (4 kHz)Iout_max (8 kHz)Iout_max (12 kHz)Iout_max (16
kHz)
A 70624734
100866050
15013710586
210190135105
continuous outputcurrent or ratedcurrent
Iout_cont (4 kHz)Iout_cont (8 kHz)Iout_cont (12 kHz)Iout_cont
(16 kHz)
A 45332418
73503727
95664837
1451007254
continuous outputcurrent or ratedcurrent
at electric rotationalfrequency 0 Hz
Iout_cont (4 kHz)Iout_cont (8 kHz)Iout_cont (12 kHz)Iout_cont
(16 kHz)
A 2918128
47302115
61402720
93583828
1) recommended value; see following noteFig. 6-10: Data power
section - inverter
Note: Observe that the load at the motor terminal is
almostindependent of the power section used.
Especially when using standard motors, make sure that theycan
withstand the voltage load.
Observe section "Using Third-Party Motors in Drive SystemRexroth
IndraDrive" of the Project Planning Manual "RexrothIndraDrive Drive
System".
Note: Depending on the electric rotational frequency, the
outputcurrent is reduced for thermal protection of the power
section.
The output current is reduced when the value of the
electricrotational frequency falls below 4 Hz.
-
6-8 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.6 Power Section - Examples of Allowed Output
CurrentProfiles
The capacity of the drive controllers when operated with mains
choke isdescribed below with examples of load profiles.
Designation Symbol Unit HCS03.1E-W0070
HCS03.1E-W0100
HCS03.1E-W0150
HCS03.1E-W0210
output current profilefor overloadoperation
overload capacity:
Iout_baseIout_peak
=K
T
Iout_base
t
I
Iout_peak
t
maximum outputcurrentt=400ms; T=4s
Iout_peak1 (4 kHz)
Iout_peak1 (8 kHz)
Iout_peak1 (12 kHz)
Iout_peak1 (16 kHz)
A 70
50
36
28
100
70
50
40
150
100
75
60
210
150
100
75
base load currentavailable atmaximum currentt=400ms; T=4s
Iout_base1 (4 kHz)
Iout_base1 (8 kHz)
Iout_base1 (12 kHz)
Iout_base1 (16 kHz)
A 35
25
18
14
54
37
28
19
67
50
36
26
116
78
59
45
maximum outputcurrentt=2s; T=20s
Iout_peak3 (4 kHz)
Iout_peak3 (8 kHz)
Iout_peak3 (12 kHz)
Iout_peak3 (16 kHz)
A 63
45
32
23
90
65
45
32
147
100
70
50
210
150
100
80
base load currentavailable atmaximum currentt=2s; T=20s
Iout_base3 (4 kHz)
Iout_base3 (8 kHz)
Iout_base3 (12 kHz)
Iout_base3 (16 kHz)
A 35
25
19
15
49
30
25
21
59
44
35
28
109
73
57
41
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-9
DOK-INDRV*-HCS03.1****-PR03-EN-P
Designation Symbol Unit HCS03.1E-W0070
HCS03.1E-W0100
HCS03.1E-W0150
HCS03.1E-W0210
maximum outputcurrentt=60s; T=5min
Iout_peak4 (4 kHz)
Iout_peak4 (8 kHz)
Iout_peak4 (12 kHz)
Iout_peak4 (16 kHz)
A 47
34
25
19
75
52
38
28
111
80
60
45
160
110
80
60
base load currentavailable atmaximum currentt=60s; T=5min
Iout_base4 (4 kHz)
Iout_base4 (8 kHz)
Iout_base4 (12 kHz)
Iout_base4 (16 kHz)
A 37
23
16
10
50
34
21
19
66
42
28
22
115
80
55
42
maximum outputcurrentt=60s; T=10min
Iout_peak5 (4 kHz)
Iout_peak5 (8 kHz)
Iout_peak5 (12 kHz)
Iout_peak5 (16 kHz)
A 47
34
25
19
75
52
38
28
111
80
60
45
160
110
80
60
base load currentavailable atmaximum currentt=60s; T=10min
Iout_base5 (4 kHz)
Iout_base5 (8 kHz)
Iout_base5 (12 kHz)
Iout_base5 (16 kHz)
A 37
23
16
10
50
34
21
19
66
42
28
22
118
82
56
43
Fig. 6-11: Technical data for power section
Note: The load profiles are characterized by their time flow and
thecorresponding currents and represent the output currentcapacity.
These profiles are limited by the drive controller viathe thermal
effect of the output current. When the currentlimitation is
triggered, it is therefore necessary to compare theactual load with
the above data and, if necessary,
• reduce the load with Iout_max or• reduce the pulse time or•
increase the cycle time or• reduce the switching frequency fs
or
• use a device with higher type current(See also Functional
Description and Troubleshooting Guideof the firmware.)
Note: The load profiles are available if particularly the
maximumcurrent at switching frequencies of 8, 12 and 16 kHz
isexternally (e.g. by the control unit) limited to the
indicatedvalues.
-
6-10 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.7 Power Section - Operating Standard Motors
The following table specifies the nominal power PNenn of 4-pole
standardmotors, which can be operated with the respective drive
controller. Thereapply following conditions:
• the dedicated mains choke is used• switching frequency: 4 kHz•
output frequency: > 4 Hz• ambient temperature: Ta < Tamax
°C
• control factor: a0 > 0,8• relation of overload: K =
peak baseP P
ULN = 3AC400V, 48…62 Hz:
Designation Symbol Unit HCS03.1E-W0070 1)
HCS03.1E-W0100 1)
HCS03.1E-W0150 1)
HCS03.1E-W0210 1)
standard motor nominal power foroverload operation:t=2 s; T=20
s; K=2,0
PNenn kW 15 22 33 55
standard motor nominal power foroverload operation:t=60 s; T=5
min; K=1,5
PNenn kW 15 22 33 55
standard motor nominal power foroverload operation:t=60 s; T=10
min; K=1,1
PNenn kW 18,5 27 35 60
standard motor nominal power forcontinuous operation:t>10
min; K=1,0
PNenn kW 22 37 45 75
1) preliminary dataFig. 6-12: Standard motors 3AC400V, 50 Hz
ULN = 3AC460…480V, 48…62 Hz
Designation Symbol Unit HCS03.1E-W0070 1)
HCS03.1E-W0100 1)
HCS03.1E-W0150 1)
HCS03.1E-W0210 1)
standard motor nominal power foroverload operation:t=2 s; T=20
s; K=2,0
PNenn kW 15 22 33 55
standard motor nominal power foroverload operation:t=60 s; T=5
min; K=1,5
PNenn kW 15 22 33 55
standard motor nominal power foroverload operation:t=60 s; T=10
min; K=1,1
PNenn kW 18,5 27 35 60
standard motor nominal power forcontinuous operation:t>10
min; K=1,0
PNenn kW 22 37 45 75
1) preliminary dataFig. 6-13: Standard motors 3AC460V, 60 Hz
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-11
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.8 Power Section - Cooling, Power Dissipation,
InsulationResistance, Sound Pressure
Designation Symbol Unit HCS03.1E-W0070
HCS03.1E-W0100
HCS03.1E-W0150
HCS03.1E-W0210
cooling of power section forced forced forced forced
volumetric capacity offorced cooling
m³/h 265 367 367 780
max. device powerdissipation at ratedcurrent(with inverter,
chopperand rectifier losses;without continuousbraking resistor
powerand without controlsection)
PDiss,Drive W 800 950 1150 2000
min. insulationresistance at DC500 V
Ris MOhm 11 11 11 11
capacitance powersection against housing
CKop nF 210 210 210 210
sound pressure level dB(A) 85 80 80 95
Fig. 6-14: Data power section - cooling, power dissipation,
insulationresistance, sound pressure
-
6-12 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.9 Control Voltage
Devices with Control Voltage Generation from DC Bus
(HCS03.1E-W0xxx-NNxV)
The internally generated control voltage is used for stand-alone
supply ofthe drive controller or for buffering in case the external
24V supply fails. Itis not used for supplying motor holding
brakes.
(Data based on an ambient temperature of 25 °C)
Designation Symbol Unit Value
external control voltage supply UN3 V 24 ±20%(if no motor
holding brake has to be supplied)
If motor holding brakes are to be supplied, observe thedata of
the motor documentation. The following valuesare normally
sufficient:24 ±5% with motor cable length < 50 m26 ±5% with
motor cable length > 50 m
max. ripple content w - mustn't exceed the control voltage
range
max. allowed overvoltage UN3max V 33 (max. 1 ms)
max. inrush current IEIN3 A2,8plus inrush current of control
section (see Project PanningManual IndraDrive Control Sections)
max. pulse width of IEIN3 tEIN3Lade ms 5
max. input capacitance CN3 mF 1,2 * 0,47
power consumption (in the case of external supply)*:
HCS03.1E-W0070 PN3 W approx. 22.5
HCS03.1E-W0100 PN3 W approx. 25
HCS03.1E-W0150 PN3 W approx. 25
HCS03.1E-W0210 PN3 W approx. 30
internally generated controlvoltage
UN3 V 24 ±10%
(not used for supplying the motor holding brake)
*: data without motor holding brake and control section taken
intoaccount
Fig. 6-15: Control voltage
Note: Overvoltage of more than 33V has to be discharged by
meansof the appropriate electrical equipment of the machine
orinstallation.This includes:
• 24V power supply units that reduce incoming overvoltagesto the
allowed value.
• Overvoltage limiters at the control cabinet input that
limitexisting overvoltage to the allowed value. This, too,applies
to long 24V lines that have been run in parallel topower cables and
mains cables and can absorbovervoltages by inductive or capacitive
coupling.
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-13
DOK-INDRV*-HCS03.1****-PR03-EN-P
Block Diagram of Control Voltage Generation from theDC Bus
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Br: brake circuitLT: power sectionST: control sectionSMPS:
internal switching-mode power supplyZK: DC bus
Fig. 6-16: Block diagram of internal control voltage
generation
-
6-14 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.10 Connections
Overall Connection Diagram
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Fig. 6-17: Overall connection diagram
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-15
DOK-INDRV*-HCS03.1****-PR03-EN-P
6.11 Connections at Power Section HCS03.1
Overview
���
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-
6-16 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
No. Designation Design Connectionobligatory?
Note on terminal description
1 Module bus X1 Ribbon cable no The module bus connection is
onlynecessary if a converter of identical ratingor an inverter is
connected to L+ and L-.
1.1 Park position X1
2 Control voltage; +24 Vand 0 V
Bars yes (forcompliance
with UL termsand utilizationof integrated
safetytechnology)
Connection of an external 24 V supply isonly necessary if an
external mainscontactor or a holding brake is used.If connection
with bars is not possible,short twisted wires may be used as
analternative.
3 DC bus; L+ and L- Bars no Connection is only necessary if
twoconverters of identical rating are to belinked via the DC bus or
if an inverter isconnected.If connection with bars is impossible,
linesmay be used as an alternative.
4 Connection of equipmentgrounding conductor
Joint bar yes If connection with joint bar is impossible,lines
may be used as an alternative.
5 Motor (X5) yes 4 connections: A1, A2, A3, PE
6 Shield connection of motorcable
Shielded motorcable
yes Alternatively, shield connection can berealized via the
mounting plate availableas an option.
7 Motor temperaturemonitoring and motorholding brake (X6)
Shielded cable orshielded motor
cable withintegrated
connection cablefor X6
no This connection is only required if themotor is equipped with
temperaturemonitoring function and/or holding brakeand if these
functions are to be used.
8 Mains connection Single cores or4-core non-
metallic-sheathed cable
yes
9 Braking resistor connection Single cores no
Fig. 6-19: Connections at power section (overview)
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-17
DOK-INDRV*-HCS03.1****-PR03-EN-P
HCS03.1E
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Fig. 6-20: Connections at power section (front)
HCS03.1E-W0100…210�
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9��9��9��&�
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X3: Mains connectionX5: Motor connectionX6: Connection of motor
temperature, motor holding brake
Fig. 6-21: Connections at power section (bottom)
HCS03.1E-W0070
-
6-18 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
Optional Control VoltageControl voltage is supplied by an
external 24V power supply unit.
Note: Technical data of control voltage: See page 6-12
The control voltage supply is connected via contact bars and
screws (M6)at the front of the drive controller (cross section of a
contact bar:6 x 12 mm). Depending on the width of the drive
controllers, there arecontact bars of different lengths.
6 Nm
DC BusBy means of the DC bus connection, the following
components are linked:
• the converter to other inverters• external additional
capacitors are not allowed (except –W0210)
The DC bus is connected via contact bars and screws (M6) at the
front ofthe drive controller (cross section of a contact bar: 6 x
12 mm).Depending on the width of the drive controllers, there are
contact bars ofdifferent lengths.
6 Nm
If in special cases it is not possible to use the DC bus rails
for connection,connection must be established using the shortest
possible twisted wires.
Length of twisted wire max. 4 m
Wire cross section minimum 10 mm2 (AWG 8)but not less than
supply feedercross section
Wire protection by means of fuses in the mainssupply
Dielectric strength of single strand againstground
> 750 V DC(e.g.: strand type – H07)
CAUTION
Damage caused by voltage arcing!⇒ When electrical lines and not
the contact bars are
used to connect the converter, the connections mustbe executed
correctly.
CAUTION
Damage caused by voltage arcing!⇒ If drive controllers are
stacked in the control cabinet,
the connections for the DC buses between the drivecontrollers
have to be correctly made.
Design
Tightening Torque
Design
Tightening Torque
DC Bus Wiring
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-19
DOK-INDRV*-HCS03.1****-PR03-EN-P
CAUTION
Damage due to converter overload!⇒ Only converters of identical
DC bus power may be
connected.
X1, Module BusThe module bus is used to exchange data between
two converters ofidentical rating or between one converter and
inverters connected to theDC bus.
X1f2.FH7
8��� 8����
Fig. 6-22: Graphic representation module bus
Type No. of poles Type of design
Ribbon cable connector 8 Connector at device
Ribbon cable socket 8 Socket at ribbon cable
Fig. 6-23: Design module bus
Note: When extension cables are used for the module bus,
theymust be shielded. Their total length must not exceed 40 m.
Graphic Representation
Design
-
6-20 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
X3, Mains ConnectionOperation in IT mains is possible without
restrictions up to a pulsefrequency = 8 kHz. Operation at a pulse
frequency of > 8 kHz is notallowed.
For operation in grounded IT mains take into account that when
filter HNKis used, leakage currents can occur which might trigger
circuit breakers orearth-leakage monitors.
Install an isolating transformer.
HCS03.1E- Type No. of poles Type of design
W0070 Connector 4 Screw connection
W0100 Terminal block 3 Screw connection for M6 ringcable
lugs
W0150 Terminal block 3 Screw connection for M6 ringcable
lugs
W0210 Terminal block 3 Screw connection for M10 ringcable
lug
Fig. 6-24: Design mains connection
Identification of the individual connections:
Identification Significance
L1 phase 1
L2 phase 2
L3 phase 3
(PE) equipment grounding conductor
Fig. 6-25: Identification of the individual connections mains
connection
HCS03.1E- Cross section
[mm²]
Cross sectionflexible[mm²]
Cross section
AWG
W0070 16 - 6
W0100 35 - 2
W0150 50 2*25 0
W0210 95 2*50 4/0
Fig. 6-26: Connection cross sections mains connection
HCS03.1E- Tightening torque [Nm]
W0070 1.5
W0100 6
W0150 6
W0210 18
Fig. 6-27: Tightening torques mains connection
Remedy
Design
Connection Cross Section
Tightening Torque
-
Rexroth IndraDrive C HCS03.1 Electrical Data 6-21
DOK-INDRV*-HCS03.1****-PR03-EN-P
DANGER
Dangerous movements caused by unbrakedcoasting to stop of the
motor in case supplyvoltage fails!⇒ Do not stay within the motional
range of the machine.
Possible measures to prevent personnel accidentallyaccessing the
machine:- protective fencing- protective grid- protective cover-
light barrier.
⇒ Fencing and covers must be adequately securedagainst the
maximum possible force of movement.
X5, Motor Connection
HCS03.1E- Type No. ofpoles
Type of design
W0070 Connector 4 Screw connection
W0100 Terminal block 3 Screw connection for M6 ringcable
lugs
W0150 Terminal block 3 Screw connection for M6 ringcable
lugs
W0210 Terminal block 3 Screw connection for M10 ringcable
lugs
Fig. 6-28: Design motor connection
Identification of the individual connections:
Identification Significance
A1 phase 1
A2 phase 2
A3 phase 3
(PE) equipment grounding conductor
Fig. 6-29: Identification of the individual connections motor
connection
HCS03.1E- Cross section
[mm²]
Cross sectionflexible[mm²]
Cross section
in AWG
W0070 16 - 6
W0100 35 - 2
W0150 50 2*25 0
W0210 95 2*50 4/0
Fig. 6-30: Connection cross sections motor connection
Design
Connection Cross Section
-
6-22 Electrical Data Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR03-EN-P
HCS03.1E- Tightening torque [Nm]
W0070 1.5
W0100 6
W0150 6
W0210 18
Fig. 6-31: Tightening torques motor connection
CAUTION
Damage to the drive controller!⇒ Strain relief for the motor
power cables cannot be
provided at the drive controller. Therefore, makesure strain
relief of the motor power cables isprovided in the control
cabinet.
For the connection between drive controller and motor, use
Rexroth motorpower cables.
The Rexroth motor power cable comprises:
• three conductors for motor power connection• one conductor for
equipment grounding connection• a separately shielded pair of
conductors for motor temperature
monitoring
• a separately shielded pair of conductors for motor holding
brake• an overall shield to be applied to shield contact.
Alternatively the cable can be composed of four twisted single
wires(3 phases, 1 equipment grounding conductor) with separately
guided,shielded wires for temperature monitoring and connecting the
brake.
Note: For more details on the technical data, connection and
crosssection, please refer to the respective motor description.
To avoid overload of the drive controller the motor cable length
is limitedat a switching frequency > 4 kHz.
The lengths indicated in the table below are recommended as
guidevalues (at an ambient temperature of ≤ 40 °C in accordance
withEN 60 204).
Allowed line lengths for motor connection without filter
measures atmotor output:
Drive controller switchingfrequency
Max. length for 2nd environment(industrial area), EN61800-3
4 kHz 75 m
8 kHz 50 m
12 kHz 25 m
16 kHz 18