Bosch IndraDrive Operating Instruction

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Electric Drives and Controls Pneumatics

Service

Linear Motion and Assembly Technologies

Hydraulics

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About this Documentation Rexroth IndraDrive

Title

Type of Documentation

Document Typecode

Internal File Reference

Purpose of Documentation

Record of Revisions

Rexroth IndraDrive C Drive Controllers HCS02.1, HCS03.1 Operating Instructions

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Document Number, 120-2400-B327-01/EN; Mat. No.: R911314905

This documentation describes the mounting, installation, commissioning, parameterization and troubleshooting of Rexroth IndraDrive controller s on the basis of the power sections HCS02 or HCS03 and the control sections BASIC OPENLOOP or BASIC PROFIBUS with comfort control panel.

Description Release

Notes

Date

DOK-INDRV*-FU*********-IB01-EN-P 06-2006 First Release

Validity

Published by

Note



Bosch Rexroth AG 2006

Copying this document, giving it to others and the use or com munication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).

The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of own judgement and verification. It must be remembered that our products are subject to a natural process of wear and aging.

Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main

Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85 http://www.boschrexroth.de/ Dept. EDY1 (RR/US/BB)

This document has been printed on chlorine-free bleached paper.

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Rexroth IndraDrive Contents I

1 Introducing the Products 1-1

1.1 Introduction................................................................................................................................... 1-1

Terms, Basic Principles........................................................................................................... 1-1

1.2 Rexroth IndraDrive Hardware Platform ........................................................................................ 1-6

Drive Controllers...................................................................................................................... 1-6

Motors and Measuring Systems.............................................................................................. 1-7

Master Communication............................................................................................................1-8

1.3 Rexroth IndraDrive Firmware Platform.........................................................................................1-8

Type Code............................................................................................................................... 1-8

Functions Overview................................................................................................................. 1-9

1.4 Rexroth IndraDyn Motors............................................................................................................ 1-12

Housing Motors...................................................................................................................... 1-12

Kit Motors............................................................................................................................... 1-12

1.5 Third-Party Motors at IndraDrive Controllers.............................................................................. 1-13

General Information on Third-Party Motors........................................................................... 1-13

Requirements on Third-Party Motors .................................................................................... 1-14

Requirements on the Encoder of the Third-Party Motor ....................................................... 1-17

Notes on Selection and Commissioning................................................................................ 1-17

1.6 Approval, Listing ......................................................................................................................... 1-18

Conformities........................................................................................................................... 1-18

C-UL-US-Listing..................................................................................................................... 1-18

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 Mo vem ents............................................................................. 3-7

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II Contents Rexroth IndraDrive

Protection Against Magnetic and Electromagnetic Fields During Operation and

Mounting.................................................................................................................................. 3-9

Protection Against Contact with Hot Parts ............................................................................ 3-10

Protection During Handli ng and Mounting............................................................................. 3-11

Battery Safety........................................................................................................................ 3-11

Protection Against Pressurized Systems .............................................................................. 3-12

4 Identification, Transport, Storage, Installation Conditions 4-1

4.1 Identification.................................................................................................................................. 4-1

Type Code............................................................................................................................... 4-1

Type Plates.............................................................................................................................. 4-4

4.2 Transport and Storage.................................................................................................................. 4-6

Transport of the Devices ......................................................................................................... 4-6

Storage of the Devices ............................................................................................................ 4-6

4.3 Installation Conditions................................................................................................................... 4-7

Ambient and Operating Conditions.......................................................................................... 4-7

Compatibility with Foreign Matters .......................................................................................... 4-9

5 Electrical Data 5-1

5.1 Power Sections............................................................................................................................. 5-1

Type Current and Connected Load......................................................................................... 5-1

Control Voltage Supply............................................................................................................ 5-2

Power Voltage Supply- Mains Connection.............................................................................. 5- 3

Limited Length of Motor Power Cables ................................................................................... 5-4

5.2 Control Sections ........................................................................................................................... 5-6

Relay Contact Type 1.............................................................................................................. 5-6

Relay Contact Type 2.............................................................................................................. 5-6

Relay Contact Type 3.............................................................................................................. 5-7

Digital Inputs/Outputs .............................................................................................................. 5-7

Analog Inputs/Outputs............................................................................................................. 5-9

5.3 Additional Components............................................................................................................... 5-15

Mains Filter HNF.................................................................................................................... 5-15

Mains Filter (-Combination) HNK........................................................................................... 5-16

Mains Choke HNL01.1E (feeding)......................................................................................... 5-16

Mains Choke HNL01.1E-****-S (Current-Compensated) ...................................................... 5-17

Braking Resistor HLR............................................................................................................5-17

Motor Filter HMF.................................................................................................................... 5-26

6 Mounting and Installation 6-1

6.1 Mounting....................................................................................................................................... 6-1

Dimensions – Power Sections................................................................................................. 6-1

Dimensions – Mains Filter HNF............................................................................................... 6-7

Dimensions – Mains Choke HNL01.1E (infeeding)................................................................. 6-9

Dimensions – Standard Brak ing Resistors HLR01.1............................................................. 6-12

Dimensions – Reinforced Braking Resistors HLR01.1.......................................................... 6-14

Dimensions – Motor Filter HMF............................................................................................. 6-17

Combination of Drive Controllers of the Rexroth IndraDrive C Product Range .................... 6-22

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Rexroth IndraDrive Contents III

Multiple-Line Arrangement of Drive Controllers .................................................................... 6-24

6.2 Electrical Installation................................................................................................................... 6-25

Rules for Design of Installations with Drive Controllers in Compliance with EMC................ 6-25

EMC-Optimal Installation in Facility and Control C ab inet...................................................... 6-26

Ground Connections..............................................................................................................6-32

Installing Signal Lines and Cab les......................................................................................... 6-33

General Measures of Radio Interference Suppression for Relays, Contactors,

Switches, Chokes, Inductive Loads....................................................................................... 6-34

Installing the 24V Supply.......................................................................................................6-35

Connection Diagram..............................................................................................................6-36

Connections and Connectors................................................................................................ 6-38

Accessories HAS................................................................................................................... 6-67

7 Commissioning and Parameterization 7-1

7.1 Basics ........................................................................................................................................... 7-1

Control Panels ......................................................................................................................... 7-1

Parameters.............................................................................................................................. 7-1

Master Communication Interfaces........................................................................................... 7-3

Parameterization Mode / Operating Mode .............................................................................. 7-4

Default Settings in the Motor Encoder Data Memory ("Load Defaults Procedure")................ 7-9

7.2 Parameterization......................................................................................................................... 7-12

Control Panels ....................................................................................................................... 7-12

Menu Structure...................................................................................................................... 7-16

7.3 Overview of Parameters – Base Package.................................................................................. 7-36

S-0-0000 – S-0-0100 .............................................................................................................7-36

S-0-0101 – S-0-0200 .............................................................................................................7-41

S-0-0201 – S-0-0300 .............................................................................................................7-45

S-0-0301 – S-0-0400 .............................................................................................................7-47

S-0-0401 – S-0-1000 .............................................................................................................7-50

P-0-0001 – P-0-0689 (General Functions)............................................................................ 7-51

P-0-0690 – P-0-0899 (Synchronization Mo de)...................................................................... 7-85

P-0-1100 – P-0-1299 (Velocity Control) ................................................................................ 7-87

P-0-1500 – P-0-1599 (General Device Parameters)............................................................. 7-96

P-0-2000 – P-0-2999 (General Device Parameters.............................................................. 7-96

P-0-3600 – P-0-4095 (General Device Parameters)............................................................. 7-97

7.4 Basic Functions ........................................................................................................................ 7-108

Serial Communication ......................................................................................................... 7-108

Master Communication........................................................................................................ 7-110

Profile Types........................................................................................................................ 7-114

Motor Control....................................................................................................................... 7-117

Scaling of Physical Data...................................................................................................... 7-118

7.5 Voltage-Controlled Operation (Open-Loop U/f Control) ........................................................... 7-121

Overview.............................................................................................................................. 7-121

Automatic Setting of Motor Control Param eters.................................................................. 7-122

7.6 Closed-Loop Axis Control (Closed-Loop Operation)................................................................ 7-131

Automatic Setting of Axis Control........................................................................................ 7-136

7.7 Positioning Block Mode ............................................................................................................ 7-137

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IV Contents Rexroth IndraDrive

8 Diagnostic and Service Functions 8-1

8.1 Diagnostic System........................................................................................................................ 8-1

Diagnostic Status Messages ................................................................................................... 8-1

Diagnostic Command Messages............................................................................................. 8-1

Warnings.................................................................................................................................. 8-1

General Description of Error Messages and Error Reactions................................................. 8-2

8.2 Recommended Actions for Operating States, Activities and Reactions of the Drive

Controller ...................................................................................................................................... 8-5

8.3 Troubleshooting.......................................................................................................................... 8-21

Check Drive Components...................................................................................................... 8-21

Replacing Devices................................................................................................................. 8-21

Cables.................................................................................................................................... 8-23

Replacing the Firmware......................................................................................................... 8-24

Firmware Release Update..................................................................................................... 8-25

Firmware Version Upgrade.................................................................................................... 8-29

Possible Problems during Firmware Replacement ............................................................... 8-35

8.4 Service and Maintenance ........................................................................................................... 8-36

Deactivation........................................................................................................................... 8-36

Dismantling............................................................................................................................ 8-36

Disposal................................................................................................................................. 8-37

Environmental Protection ...................................................................................................... 8-37

9 Service & Support 9-1

9.1 Helpdesk....................................................................................................................................... 9-1

9.2 Service-Hotline ............................................................................................................................. 9-1

9.3 Internet.......................................................................................................................................... 9-1

9.4 Vor der Kontaktaufnahme... - Before contacting us... .................................................................. 9-1

9.5 Kundenbetreuungsstellen - Sales & Service Facilities................................................................. 9-2

10 Index 10-1

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Rexroth IndraDrive Introducing the Products 1-1

1 Introducing the Products

1.1 Introduction

Terms, Basic Principles

Parameters

Communication between master and drive takes place, with a few exceptions, by means of parameters.

Parameters are used for:

• determining the configuration

• parameterizing the control loop

• triggering and controlling drive functions and commands

• transmitting command values and actual values (according to

requirements, cyclically or acyclically)

Data Memory

Condition As Supplied

Storing the Application-Specific

Parameter Values

Saving Parameter Values

All operating data are mapped to parameters! The operating data stored in parameters can be identified by means of

the IDN. They can be read and transferred, if required. The user write access to parameters depends on the properties of the respective parameter and the current communication phase. Specific parameter values (operating data) are checked for validity by the drive firmware.

Data Storage and Parameter Handling

Several non-volatile data memories are available in an IndraDrive device:

• in the controller

• in the motor encoder (depending on motor type)

In addition, a volatile data memory (working m emory) is available in the controller.

Condition as supplied of the Rexroth drive components:

• The controller memor y contains the drive firmware and the controllerspecific parameter values.

• The motor encoder memory contains the encoder-specific and, depending on the motor type, the motor-specific parameter values.

The application-specific parameter values are stored in the controller. Due to the limited number of writing cycles of non-volatile storage media, application-specific parameter values can be stored in the working memory (volatile memory) , too.

Saving application-specific param eter values is required in the following cases:

• after initial commissioning of the machine axis or the motor

• before replacing the controller for servicing (if possible)

Application-specific parameter values can be saved via:

• "IndraWorks D" commis sioning tool → saving the param eter values on external data carrier

• control master → saving the parameter values on master-side data carrier

• comfort control panel

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1-2 Introducing the Products Rexroth IndraDrive

Parameter IDN Lists

Loading Parameter Values

Checksum of Parameter Values

The drive supports master-side saving of parameter values by listing parameter identification numbers (IDNs). Using these lists guarantees complete storage of the application-specific param eter values. It is also possible to determine IDN lists defined by the customer.

Loading parameter values is required in the following cases:

• initial commissioning of the motor (loading basic param eter values and motor-specific parameter values)

• serial com m issioning of mac hine axes at series mac hines (loading the values saved after initial commissioning)

• reestablis hing a defined original status (repeated loading of the values saved after initial commissioning)

• replacing the controller for servicing (loading the current parameter values saved before servicing)

• Possibilities of loading parameter values to the controller:

• motor encoder data memory → loading the parameter values by

command or via the control panel during initial motor commissioning

• "IndraWorks D" commissioning tool → loading the parameter values from external data carrier

• control master → loading the parameter values from master-s ide data carrier

By means of checksum comparison, the control master can determine whether the values of the application-specific parameter values currently active in the drive correspond to the values saved on the master side.

Kinds of Passwords

Password

IndraDrive controllers provide the poss ibility to protect param eter values against accidental or unauthorized change by means of a pass word. With regard to write protection, there are 3 groups of parameters that can be written:

• Parameters that are write-protected as a standard, such as motor parameters, hardware code parameters, encoder parameters, error memory etc. ("administration parameters"). The values of these parameters guarantee correct function and performance of the drive.

• Parameters the customer can combine in groups and protect them with a so-called customer password. T his allows protecting parameter values, that are used for adjusting the dr ive to the axis, after having determined them.

• All other parameters that can be written and are not contained in the above-mentioned groups. They are not write-protected.

The drive firm ware allows activating and deactivating the write protection for parameter values by means of three hierarchically different passwords:

• Customer password The parameter values of a parameter group combined by the

customer can be protected.

• Control password Parameters protected by a customer password can be written;

"administration parameters" remain write-protected.

• Master password All parameters that can be written, including "administration

parameters" and parameters protected by a customer password, can be changed.

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Rexroth IndraDrive Introducing the Products 1-3

Commands

Commands are used to activate and control complex functions or monitoring features in the drive. The higher-level master can start, interrupt or clear commands.

Each command is assigned to a parameter by means of which the execution of the comm and can be controlled. During the exec ution of the command the display of the control panel reads "Cx", "C" representing the diagnostic command message and "x" representing the number of the command.

Note: Each command that was started must be actively cleared

again.

All commands available in the drive are stored in the S-0-0025, IDN-list

of all procedure commands parameter.

Kinds of Commands

There are 3 different kinds of commands:

• Drive control commands

• can cause automatic drive motion,

• can be started only when drive enable has been set,

• deactivate the active operating mode during its execution.

• Monitoring commands

• activate or deactivate monitors or functions in the drive.

• Administration commands

• carry out administration tasks,

• cannot be interrupted.

See also "Command Processing" in chapter "Master Communication"

Operating Modes

The selection of operating m odes defines which comm and values will be processed in which way, in order to lead to the desired dr ive motion. The operating mode does not determine how these command values are transmitted from the master to the slave.

One of the four or eight (for SERCOS) operating modes defined in parameters is always active when the following conditions have been fulfilled:

• control section and power section are ready for operation

• drive enable signal sees a positive edge

• drive follows command value

• "Drive Halt" function has not been activated

• no drive control command is active

• no error reaction is carried out

The display of the control panel reads "AF" when an operating mode was activated.

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Note: All implemented operating modes are s tored in the S-0-0292,

List of all operating modes parameter.

1.2 Rexroth IndraDrive Hardware Platform

Drive Controllers

Overview

The drive controller consists of two essential parts:

• power section

• control section

Power section

Control section

300 mm Design

The power section incorporates the c ontrol section and has the following connections:

• mains voltage connection (at supply modules and HCS devices)

• motor connection (with optional motor holding brake and motor

temperature monitor)

• 24 V control voltage

• DC bus connection

• module bus connection

• connection for external braking resistor (at HCS devices)

The control section is a separate component that is plugged into the power section. The drive controller is supplied complete with factoryinstalled (possibly configured) control section.

Power Sections

IndraDrive C

• HCS02.1E-W0012

• HCS02.1E-W0028

• HCS02.1E-W0054

• HCS02.1E-W0070

400 mm Design

• HCS03.1E-W0070

• HCS03.1E-W0100

• HCS03.1E-W0150

• HCS03.1E-W0210

Control Sections

• BASIC OPENLOOP (single axis; type CSB01.1N-FC-…)

• BASIC PROFIBUS (single axis CSB01.1N-PB-…)

Supported Control Section Configurations

The configurable control sections differ with regard to the scope of their configurability. It basically depends on the control section type and the corresponding firmware variant. The following abbreviations are used:

Options for master communication:

• PB → PROFIBUS-DP

• FC → FC Interface

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Rexroth IndraDrive Introducing the Products 1-7

Motors and Measuring Systems

Supported Motors

The table below contains an overview of the Rexroth motors which can be operated at IndraDrive controllers.

Housing motors Kit motors

synchronous asynchronous synchronous asynchr.

Third party motors

Motor Encoders and External

Optional Encoders

MHD MKD MKE

MSK (IndraDyn S)

MAL

SF (Bosch)

Fig. 1-2: Appropriate Rexroth motors for IndraDrive

2AD

ADF MAD (IndraDyn A) MAF (IndraDyn A)

MLF (IndraDyn L)

MBS (Standard)

MBSxx2 (IndraDyn H)

MBT (IndraDyn T)

LSF

1MB

Third party motors must meet the specified requirements.

Supported Measuring Systems

In addition to the encoders integrated in the Rexroth motors, the IndraDrive firmware can evaluate the following measuring systems as motor encoders or as external optional control encoders:

• Bosch Rexroth GDS or GDM encoders (single-turn or multi-turn type)

• resolvers according to Rexroth signal specification (single-turn or

multi-turn type)

)

• encoders with sine signals and EnDat2.1 interface (1 V

• encoders with sine signals (1 V

)

• encoders with square-wave signals (TTL)

• Hall sensor box and encoder with sine signals (1 V

• Hall sensor box and encoder with square-wave signals (TTL)

• encoders with sine signals and HIPERFACE interface (1 V

Measuring Encoders

For measuring purposes the firmware can evaluate the following measuring systems (measuring encoders, no control encoders):

• Bosch Rexroth GDS or GDM encoders (single-turn or multi-turn type)

• encoders with sine signals and EnDat2.1 interface (1 V

• encoders with sine signals (1 V

)

• encoders with square-wave signals (TTL)

• encoders with sine signals and HIPERFACE interface (1 V

)

• motor encoders of MSK, MHD, 2AD, ADF, MAD, MAF motors

• SSI encoders

Note: Resolvers cannot be evaluated as measuring encoders!

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1-8 Introducing the Products Rexroth IndraDrive

Master Communication

PROFIBUS Interface

General Features

• cyclic data exchange of command and actual value (max. 32 byte each direction; min. cycle time of 500 µs)

• parameter channel for parameterization and diagnosing via field bus

• safe process data channel (PROFIsafe), optional

• free configuration of telegram contents possible (many cyclic

configurable parameter IDN)

1.3 Rexroth IndraDrive Firmware Platform

Type Code

Structure of the Firmware Type

Designation

IndraDrive-Firmware

Basic single-axis

FWA-INDRV*

Firmware Types That Can Be

Ordered

Control section

Basic single-axis

Firmware range

FWA-INDRV*- MPB- 04 VRS- D5- 0- NNN -NN base package (open-loop) FWA-INDRV*- MPB- 04 VRS- D5- 0- SNC -NN base package (open-loop) + synchronization FWA-INDRV*- MPB- 04 VRS- D5- 0- MSP -NN base package (open-l oop) + main spindle FWA-INDRV*- MPB- 04 VRS- D5- 0- ALL -NN base package (open-loop) + all altern. functions FWA-INDRV*- MPB- 04 VRS- D5- 0- NNN -ML base package (open-loop) + IndraMotion MLD-S FWA-INDRV*- MPB- 04 VRS- D5- 0- *** -ML FWA-INDRV*- MPB- 04 VRS- D5- 1- NNN -NN base package (closed-loop) FWA-INDRV*- MPB- 04 VRS- D5- 1- SRV -NN base package (cl osed-loop) + servo function FWA-INDRV*- MPB- 04 VRS- D5- 1- SNC -NN base package (closed-loop) + synchroni zat i on FWA-INDRV*- MPB- 04 VRS- D5- 1- MSP -NN base package (closed-loop) + main spindle FWA-INDRV*- MPB- 04 VRS- D5- 1- ALL -NN base pack age (closed-loop) + all altern. functions FWA-INDRV*- MPB- 04 VRS- D5- 1- NNN -ML base package (closed-l oop) + IndraMotion MLD-S FWA-INDRV*- MPB- 04 VRS- D5- 1- *** -ML

Base

package

The individual functional packages can be com bined to for m the f ollowing firmware types that can be ordered:

Base package of

variant …

(depending on

control section)

-MPB-

Version

04 VRS- D5- x- xxx- xx

Release

Language

Open-/closed-

loop

Alternative

expansion

packages

Additive

expansion

Fig. 1-3: Basic structure of the firmware type designation

The following overview shows the available scope of functions of the respective base package:

Version

Release

Language

Open/closed-

loop

Alternative

functional

packages

IndraMotion

MLD-S

Scope of functional packages

base package (open-loop) + *** + IndraMotion MLD-S

base package (closed-loop) + *** +

*** selected option "alternative functional packages" according to

availability

Fig. 1-4: Overview of firmware types and functional packages they are

containing

IndraMotion MLD-S

packages

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Rexroth IndraDrive Introducing the Products 1-9

Functions Overview

Supported Operating Modes

The drive firmware supports the following operating modes:

• torque/force control

• velocity control

• position control with cyclic command value input

• drive-internal interpolation

• drive-controlled positioning

• positioning block mode

• synchronization modes:

• velocity synchronization with real/virtual master axis

• phase synchronization with real/virtual master axis

• electronic cam shaft with real/virtual master axis

• electronic motion profile with real/virtual master axis

Note: The operating modes supported by the firmware depend on

the hardware and firmware and are contained in parameter

S-0-0292, List of all operating modes.

Drive Functions

These are the most important drive functions of the MPX-04 firmware:

• Drive Halt

• establishing the position data reference

• drive-controlled homing

• setting absolute measuring

• shifting the position data reference

• drive error reactions

• best possible deceleration

• package reaction on error

• NC reaction on error

• E-Stop function

• compensation functions/corrections

• friction torque compensation

• encoder correction

• axis error correction

• quadrant error correction

• spindle positioning

• drive-integrated command value generator

• parameter set switching

• probe function

• encoder emulation

• programmable position switch

• drive-integrated PLC (IndraMotion MLD-S)

• integrated safety technology

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1-10 Introducing the Products Rexroth IndraDrive

• monitoring functions

• limitations that can be parameterized

• output of control signals

• numerous diagnostic possibilities

• drive-internal generation of diagnostic messages

• analog output

• status displays, status classes

• oscilloscope function

• monitoring function

• patch function

• code of optional card

• parameter value check

• operating hours counter, logbook function, error memory

Performance Data

Overview

For the control performance of the IndraDrive range we basically distinguish three levels with regard to the clock rates (cycle times):

• Basic performance → standard control performance by medium internal clock rates for the

control loops and the signal processing of inputs/outputs or driveintegrated PLC (IndraMotion MLD-S)

In this documentation the clock rate data refer to the following characteristic values:

• current loop clock T

• velocity loop clock T

• position loop clock T

• cycle time of PLC (IndraMotion MLD-S) T

• cycle time of master communication T

A_current

A_velocity

A_position

MLD-S

MastCom

Control section type/ firmware

CSB01.1/MPB

Functional packages

all, except for "synchronization" and "IndraMotion"

Perform. level

Basic

The table below contains an overview of the clock rates depending on the respective control performance. The detailed assignment of the c lock rate to control section design, performance level and parameter setting is contained in the table in section "Control Section Design and Performance" (see below).

Performance

Basic

Fig. 1-5: Clock rates (depending on the available performance)

A_currentTA_velocityTA_posit.TMLD-STMastCom

125 µs 250 µs 500 µs

: can be set via P-0-0001

P-0-0556: config word of axis controller

Fig. 1-6: Performance depending on the control section design

A_Strom

A_Geschw

A_Lage

MLD-S

FKM

62,5/83,3/125 µs 250 µs 500 µs 2000 µs 500/1000 µs

Switching

frequency

1000 µs

4000 Hz 0 0

8000 Hz 0 0

P-0-0556

bit 2 bit 5

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Rexroth IndraDrive Introducing the Products 1-11

Selecting Performance via

Parameter P-0-0556

Restricted Performance with

Certain Functional Packages

For certain applications it is neces sary to use the same clock rates in all axes so that the slowest drive sets the clock. It is therefore possible to specifically reduce the performance via bit 2 and bit 5 of parameter P-0-0556, Config word of axis controller.

• For BASIC control sections it is possible to select the perf ormance levels "Basic" or "Economy" via bit 5 of P-0-0556.

See also Parameter Description "P-0-0556, Config word of axis controller"

Note: The effective clock rates of the active performance level are

contained in the table "Performance depending on the control section design" in section "Control Section Design and Performance" (see above).

If you use extensive and complex functions, the internal clock rates for BASIC control sections (CSB with firmware MPB and CDB with firmware MPD) are automatically reduced. This applies to the us e of the following functional packages:

• drive-integrated PLC "IndraMotion MLD-S" (functional package "ML")

• expansion package "synchronization" (functional package "SNC")

If you use one of these functional packages for BASIC control s ections, the clock rates (position loop, velocity loop) are reduced to the lowest performance level "Economy!"

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1-12 Introducing the Products Rexroth IndraDrive

1.4 Rexroth IndraDyn Motors

Housing Motors

Type Code S

Example

Product

MSK 030 B 0900 NN S1 U G 0 NNNN

Motor size

Motor length

MSK030B-0900-NN-S1-UG0-NNNN

Windings code

Fig. 1-7: Basic structure of type code

Housing design

Encoder

Electrical

Connection

Shaft

Holding brake

Other design

Type Code IndraDyn A

Example

MAF130B-0150-FQ-M0-LH0-05-N1

Product

MAF 130 B 0150 FQ M0 L H 0 05 N 1

Motor size

Motor length

Windings code

Cooling mode

Fig. 1-8: Basic structure of type code

Encoder

Electrical Connection

Shaft

Holding brake

Mounting style

Bearings

Kit Motors

Type Code IndraDyn L

Example

Product

MLP 100 A 0120 F S N0 CN NNNN

Motor size

MLP100A-0120-FS-N0CN-NNNN

Motor length

Fig. 1-9: Basic structure of type code

Windings code

Cooling mode

Encapsulation

Encoder

Electrical

Connection

Vibration severity

grade

Other design

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Rexroth IndraDrive Introducing the Products 1-13

Type Code IndraDyn H

Example 1

Product

MRS 102 B 1N 0046 NNNN

Product

MSS 102 B 0800 F A N0 CN NNNN

Motor size

Example 2

MRS102B-1N-0046-NNNN

Motor length

Fig. 1-10: Basic structure of type code

MSS102B-0800-FA-N0CN-NNNN

Motor length

Fig. 1-11: Basic structure of type code

Windings code

Cooling mode

Mounting style

Cooling

connector

Internal diameter

of the rotor

Encoder

Electrical

connection

Other design

1.5 Third-Party Motors at IndraDrive Controllers

General Information on Third-Par ty Motors

Why Use Third-Party Motors at IndraDrive?

Today machine axes are mainly moved with electric drives. Motors of standard design are used in most cases as this is the most cost-ef ficient solution.

Special Requirements

Undeliverable Motor Design

Check Before Using Third-Party

Motors

Additional Aspects to be

Observed

Due to special requirements at machine axes, constructional or safetyrelated aspects, it may be necessary for the m achine manufacturer to us e a motor construction diverging from the standard.

For these cases there is the demand on the drive supplier to realize, apart from the deliverable standard drive consisting of (standard) motor, controller, cable and, if required, m achine control unit, drives with motors that are not included in his own product range due to the special design.

At Rexroth controllers of the IndraDrive range it is also possible to use third-party motors. For this purpose, check whether the third-party motor complies with the requirements of use.

Which are the Important Directives?

According to the legal requirements

• of the EU directives EMC89/336/EEC and

• the German EMC laws

installations and machines have to be designed and built according to the present state of standardization. In order to comply with the machine directives regarding "electromagnetic compatibility (EMC)", a conformity test of the drive system (motor with controller and connection design) has

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Page 20

1-14 Introducing the Products Rexroth IndraDrive

to be carried out. The test of the drive system and com pliance with the directives have to be guaranteed by the machine manufacturer.

Third-Party Motors to be Controlled

Motor Types

The following motor types can be controlled:

• asynchronous motors, rotary

• asynchronous motors, linear

• synchronous motors, rotary

• synchronous motors, linear

These motors c an be operated within the scope of the technical data of the selected IndraDrive controller. If motors have been provided with a holding brake, it should be controlled via the controller. Make sure that the relevant technical data of the motor holding brake are complying with those of the holding brake output.

Note: For third-party motors Bosch Rexroth, as a m atter of principle,

does not assume the guarantee for the power data at the motor shaft!

Synchronous Motors

In the case of synchronous motors, the com mutation off set has to be set during commiss ioning. The drive firmware provides several methods for determining this offset so that it is possible to determine the value for different motor characteristics.

Note: Observe the restrictions in conjunction with the commutation

offset determination when using synchronous motors! See Functional Description of firmware "Motor Control: Commutation Setting" in chapter "Drive Control"

Possibly available reluctance property cannot be used for synchronous third-party motors! For third-party motors it is impossible to determine f ailsafe motor parameter values for using the reluctance property; the respective bit of P-0-4014, Type of construction of motor therefore mustn't be set!

Requirements on Third-Party Motors

For successful and fail-safe use of a third-party motor check

• whether the third-party motor to be controlled satisfies the voltage loads,

• which controller, including supply, is suitable due to the motor power to be delivered,

• whether the third-party motor has the required minimum inductance,

• whether the motor can be protected against inadm issible temperature

rise in the case of overload (temperature evaluation),

• whether the mounted position measur ing system can be evaluated by the controller or which position measuring system can be selected for kit motors.

Voltage Load of the Third-Party Motor

The voltage load of the insulation system of a motor oc curring in prac tical application is mainly influenced by the following characteristics:

• The output variables of the drive controller which is used (feed the transmission distance).

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Rexroth IndraDrive Introducing the Products 1-15

• The cable parameters depending on cable design and length (determine the properties of the transmission distance, such as the attenuation).

• The motor design regarding c apacitive and inductive properties (form the end of the transmission distance).

As a result of the variables, the insulation system of the third-par ty motor, as regards voltage, is loaded by the values

• peak voltage U

and

• voltage change dv/dt.

The occurring peak voltages at the motor are caused by reflections in the motor cable. The insulation of the motor is thereby loaded with other peak voltages and voltage changes than the ones occurr ing at the output of the power section.

Note: Determine the occurring voltage load at the terminals of the

third-party motor in the application with all involved components.

Use of Voltage-Reducing

Components, Motor Filter HMF

Use voltage-reducing components (e.g. motor filter HMF), if one of the following criteria applies:

• allowed voltage change (dv/dt) of third-party motor smaller than 5 kV/µs

• allowed peak voltage (crest value) of third-par ty motor between phas ephase and phase-housing smaller than 1500 V

• motor cable length smaller than 25 m

• mains voltage greater than AC440V

Note: Apart from the nominal current IN, especially take the

maximum allowed switching frequency of the power output stage (f

) into account with which the motor filter HMF m ay be

operated. Verify the success of the voltage-reducing measure.

Minimum Inductance of Third-Party Motor

Depending on the controller used, the motor has to have a minimum value for inductance. The actually available inductance of a motor c an be measured directly between two motor terminals by means of an inductance measuring bridge. The measurement has to be made for a complete motor wired f or normal operation but not yet connected. Dur ing the measurement one motor terminal remains open! For asynchronous motors the measured value can only be used if the rotor doesn't have closed slots!

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Controller type Minimum required motor inductance

HCS with 3*AC230V HMS, HMD at HMV (3*AC400V)

HMS, HMD at HCS (3*AC400V) HMS, HMD at HMV (3*AC480V)

HMS, HMD at HCS (3*AC480V)

: maximum controller current acc. to type code (rms value)

Typ

: desired switching frequency in kHz

Fig. 1-12: Minimum inductances depending on controller data, supply units and

supply voltage

= 60* 4/(√2 * I

U-V

= 80* 4/(√2 * I

U-V

= 116* 4/( √

U-V

* fs)(in mH)

Typ

* fs)(in mH)

Typ

2 *

* fs) (in mH)

Typ

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1-16 Introducing the Products Rexroth IndraDrive

Use a three-phase choke in the motor feed wire, if the inductance of the third-party motor is smaller than indicated in the table above. T his choke has to increase the inductance that can be measur ed between two motor terminals to the minimum value.

Note: When the inductanc e is measured, diff erent induc tanc e values

can be determined at differ ent rotor positions within one pole pair distance of the motor . The average value is relevant for the check of the minimum value.

Correct values can only be determined when the motor is in

standstill!

Available third-party motor Planned third-party motor

Calculating the leakage inductance (asynchronous motor) or inductance (synchronous motor) of the third-party motor by means of the single-phase equivalent circuit diagram (manufacturer's specification!).

Determine choke by means of calculation, if necessary.

It is recommended to contact Rexroth!

- L

U-V

Motor

)

U-Vmin

3x L

LDr = 0,5 * (L

U-Vmin

(inductance measurement with 1 kHz) mounting of 3x L

(three-phase choke)

Requirements on the choke:

-I

≥ I

n_Dr

n_Mot

The rated current of the choke has to be greater than or equal to the rated motor current.

- Depending on the maximum speed, the choke is loaded with the respective output frequency and the PWM frequency of the controller.

- The insulation class has to correspond at least to that of the motor or has to be dimensioned for higher temperatures.

- The voltage load of the choke depends on the controller used.

Fig. 1-13: Data for possibly required choke

Temperature Evaluation of Third-Party Motor

Only operate such motors with incorporated temperature sensor at IndraDrive controllers so that the m otor can be ther mally monitored by the controller and protected against destruction by too high temperatur e rise (see P-0-0512, Temperature sensor).

When, in exceptional cases, you want to operate third-party motors without temperature sensor at IndraDrive contr ollers, you must determ ine the thermal time constants of motor housing (P-0-4035) and motor winding (P-0-4034, P-0-4037). The firmware-internal motor temperature model can thereby reflect the cooling situation of the motor correctly.

Note: In case the motor housing or blower is dirty, this worsens the

cooling situation of the motor and protection against thermal overload is therefore insufficient!

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Rexroth IndraDrive Introducing the Products 1-17

Requirements on the Encoder of the Third-Party Motor

Motor Encoder of Asynchronous Third-Party Motor

Asynchronous motors can also be controlled by IndraDrive controllers in "open-loop" operation (without motor encoder). In "closed-loop" operation (with motor encoder) a relative measuring system is sufficient for asynchronous motors.

Motor Encoder of Synchronous Third-Party Motor

For fail-safe drives with synchronous third-party motors at IndraDrive controllers the following possible com binations or restrictions have to be taken into account when selecting the measuring system:

Drive range Motor measuring system Synchronous third-

party motor

IndraDrive

+ … advantageous combination o … Combination is possible (restrictions specific to application),

commissioning may be more complicated!

Fig. 1-14: Possible combinations of synchronous third-party motor and motor

measuring system

absolute +

relative o

Note: The control section integrated in the controller can evaluate

measuring systems as a m otor encoder if they are contained in P-0-0074, Encoder type 1 (motor encoder) (see also Project Planning Manual of the IndraDrive control sections).

For information on absolute and relative measuring systems see section "Measuring Systems" of Functional Description of firmware!

Notes on Selection and Commissioning

Selecting the Controller as Regards Continuous Current

The controller required for the respective motor and the supply unit are determined by comparing the motor data to the data of these devices (see documentation for HMS/HMD and HMV or HCS).

Note: The continuous current of the controller should be greater than

that of the motor, the continuous power of the supply must be greater than the sum of all average powers of the ax es of the drive system!

Selecting the Connection Technique

The available power and encoder cables are described in the documentation "Connection Cables; Selection Data" (DOK-CONNECCABLE*STAND-AU...).

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Notes on Commissioning

Note: For further information, notes on commissioning and

supporting documents (e.g. forms for entering the required data) see Functional Description of firmware.

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1-18 Introducing the Products Rexroth IndraDrive

1.6 Approval, Listing

Conformities

Declaration of Conformity

CE Label

For Rexroth IndraDrive components there are declarations of conformity available. These declarations conf irm that the components are designed according to valid EC directives. If required, you can ask your sales representative for these declarations.

Low-Voltage Directive

The Rexroth products of a drive s ystem mentioned in this docum entation comply with the requirements of the EC Directive 73/23/EEC (LowVoltage Directive), annex III B.

EMC Directive

The Rexroth products of a drive s ystem mentioned in this docum entation comply with the requirements of the EC Directive 89/336/EEC (EMC Directive) with the amendments 91/263/EEC and 93/68/EEC.

Fig. 1-15: CE label

CEf1.fh7

C-UL-US-Listing

Devices approved by the UL agency carry the following label:

Fig. 1-16: C-UL-US label

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Rexroth IndraDrive Introducing the Products 1-19

Motors approved by the UL agency carry the following label:

Fig. 1-17: C-UR-US label

C-UL-US Listed Components

Product Component File Number

HMS01.1N- W0020, W0036, W0054, W0070, W0150,

W0210 HMS02.1N- W0028, W0054 E 134201 HMD01.1N- W0012, W0020, W0036 E 134201 HCS02.1E- W0012, W0028, W0054, W0070 E 134201 HCS03.1E- W0070, W0100, W0150, W0210 Manufacturer REFU

HMV01.1E- W0030-A-07, W0075-A-07, W0120-A-07 E 134201 HMV01.1R- W0018-A-07, W0045-A-07, W0065-A-07 E 134201 HMV02.1R- W0015 E 134201 HLB01.1C- 01K0-N06R0-A-007-NNN E 134201 HLB01.1D- 02K0-N03R4-A-007-NNN E 134201 HLC01.1C- 01M0-A-007, 02M4-A-007 E 134201 HLC01.1D- 05M0-A-007 E 134201 NFD03.1- -007, -016, -030, -055, -075, -130, -180 E 172117 and CSA

HNL01.1- ..... CSA Cert.

HNF01.1 In preparation E 134201 HNK01.1 In preparation E 134201 HLR01.1 In preparation E 134201

E 134201

E254781

Cert. 1038841Master Contr. 171321

1492099Master Contr. 222887

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Fig 1-18: C-UL-US listed Rexroth IndraDrive components

Note: The com ponents are lis ted by the file number of „Underwriters

Laboratories Inc.®" (UL). The doc umented evidence of listing can be seen in the internet: http://www.ul.com, "Certif ications", enter file number or "Company name: Rexroth.

The control sections are included in the listing of the power sections. The control sections are not listed separately.

Page 26

1-20 Introducing the Products Rexroth IndraDrive

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Page 27

Rexroth IndraDrive Important Directions for Use 2-1

2 Important Directions for Use

2.1 Appropriate Use

Introduction

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

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

Note: Rexroth as manufacturer is not liable for any damages

resulting from inappropriate us e. In such cases , the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks.

Before using Rexroth products, mak e sure that all the pre-requisites for an appropriate use of the products are satisfied:

• Personnel that in any way, shape or form uses our pr oducts mus t first read and understand the relevant safety instructions and be familiar with appropriate use.

• If the products take the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes.

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

• Make sure that the products have been installed in the manner

described in the relevant documentation.

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2-2 Important Directions for Use Rexroth IndraDrive

Areas of Use and Application

Drive controllers made by Bosch Rexroth are designed to control electrical motors and monitor their operation.

Control and monitoring of the motors may require additional sensor s and actors.

Note: The drive controllers m ay only be used with the accessories

and parts specified in this document. If a com ponent has not been specifically named, then it may not be either m ounted or connected. The same applies to cables and lines.

Operation is only permitted in the specified configurations and combinations of com ponents using the software and f irmware as 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 an application.

The drive controllers have been developed for use in single- and multiaxis drive and control tasks.

To ensure an application-specific use, the drive contr ollers are available with 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 and installation conditions described in this documentation, in the specified position 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 in this documentation and outside of the indicated technical data and specifications is defined as "inappropriate use".

Drive controllers must not be used, if

• ... they are subject to operating conditions that do not meet the

• Furthermore, the drive controllers must not be used in applications

• Please car efully follow the specific ations outlined in the general Saf ety

specified ambient conditions. This includes, for example, operation under water, under extreme temperature f luctuations or extr emely high maximum temperatures.

which have not been expressly authorized by Rexroth.

Instructions!

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Page 29

Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-1

3 Safety Instructions for Electric Drives and Controls

3.1 General Information

Using the Safety Instructions and Passing them on to Others

Do not attempt to install or com m iss ion this device without firs t reading all documentation provided with the product. Read and understand these safety instructions and all user documentation prior to working with the device. If you do not have the user documentation for the device, contact your responsible Bosch Rexroth sales representative. Ask for these documents to be sent immediately to the person or pers ons responsible for the safe operation of the device.

If the device is resold, rented and/or passed on to others in any other form, then these safety instructions must be delivered with the device.

Improper use of these devices, failure to follow the safety instructions in this document or tampering with the product , i ncluding disabling

WARNING

of safety devices, may result in material damage, bodily harm, electric shock or even death!

Instructions for Use

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

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

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

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

• Only assign trained and qualified persons to work with electrical installations:

Only persons who are trained and qualified for the use and

operation of the device may work on this device or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the equipment as well as an understanding of all warnings and precautionary measures noted in these instructions.

Furthermore, they must be trained, instructed and qualified to

switch electrical circuits and devic es on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safety equipment and be trained in first aid.

• Only use spare parts and accessories approved by the manufacturer.

• Follow all safety regulations and requirements for the specific

application as practiced in the country of use.

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Page 30

3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive

• The devices have been designed for installation in industrial machinery.

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

• Only use safety-relevant applications that are clearly and explicitly approved in the Project Planning Manual. If this is not the case, they are excluded. Safety-relevant are all such applications which can cause danger to persons and material damage.

• The info rmation given in the docum entation of the product with regard to the use of the delivered components contains only examples of applications and suggestions.

The machine and installation manufacturer must

make sure that the delivered components are suited for his

individual application and check the information given in this documentation with regard to the use of the components,

make sure that his application complies with the applicable safety

regulations and standards and carry out the r equired measures, modifications and complements.

• Startup of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application.

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

• The instructions for installation in accor dance with EMC requirements can be found in the documentation "EMC in Drive and Control Systems".

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

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

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Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-3

Explanation of Warning Symbols and Degrees of Hazard Seriousness

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

Warning symbol with signal word

Degree of hazard seriousness according to ANSI Z 535

Death or severe bodily harm will occur.

DANGER

Death or severe bodily harm may occur.

WARNING

Bodily harm or material damage may occur.

CAUTION

Fig. 3-1: Hazard classification (according to ANSI Z 535)

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3-4 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive

Hazards by Improper Use

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

DANGER

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

DANGER

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

WARNING

CAUTION

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

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

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

Risk of injury by improper handling of batteries!

CAUTION

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Page 33

Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-5

3.2 Instructions with Regard to Specific Dangers

Protection Against Contact with Electrical Parts

Note: This section only concerns devices and drive com ponents with

voltages of more than 50 Volt.

Contact with parts conducting voltages above 50 Volts can cause personal danger and electric shock. W hen operating electrical equipm ent, it is unavoidable that some parts of the devices conduct dangerous voltage.

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

⇒

Only those trained and qualified to work with or on

DANGER

electrical equipment are permitted to operate, maintain and repair this equipment.

⇒

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

⇒

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

⇒

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

⇒

Before working with electrical parts with voltage potentials higher than 50 V, the device must be disconnected from the mains voltage or power supply unit. Provide a safeguard to prevent reconnection.

⇒

With electr ical drive and filter components, obser ve the following:

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

⇒

Never touch the electrical connection points of a

component while power is turned on.

⇒

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

⇒

A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives! Indirect contact must be prevented by other means, for exam ple, by an overcurrent protective device according to the relevant standards.

⇒

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

European countries: according to EN 50178/ 1998,

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3-6 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive

section 5.3.2.3. USA: See National Electrical Code (NEC), National

Electrical Manufacturers' Assoc iation (NEMA), as well as local engineering regulations. The operator m ust observe all the above regulations at any time.

With electrical drive and filter components, observe the following:

High housing voltage and large leakage current! Risk of death or bodily injury by electric shock!

⇒

Before switching on, the housings of all electrical

DANGER

equipment and motors must be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests.

⇒

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

3.5 mA.

⇒

Over the total length, use copper wire of a cross section of a minim um of 10 mm grounding connection!

⇒

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

for this equipment

Protection Against Electric Shock by Protective Low Voltage (PELV)

All connections and terminals with voltages between 5 and 50 Volt at Rexroth products are protective extra-low voltage systems which are provided with touch guard according to the product standards.

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

⇒

To all connections and terminals with voltages

WARNING

between 0 and 50 Volt, only devices, electrical components, and conductors may be connected which are equipped with a PELV (Protective ExtraLow Voltage) system.

⇒

Connect only voltages and circuits which are s afely isolated from dangerous voltages. Safe isolation is achieved for example by isolating transfor mers, saf e optocouplers or battery operation without mains connection.

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Page 35

Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-7

Protection Against Dangerous Movements

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

• improper or wrong wiring of cable connections

• incorrect operation of the equipment components

• wrong input of parameters before operation

• malfunction of sensors, encoders and monitoring devices

• defective components

• software or firmware erro rs

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

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

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Page 36

3-8 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive

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

⇒

For the above reasons, ensure personal safety by

DANGER

means of qualified and tested higher-level monitoring devices or measures integrated in the installation.

They have to be provided for by the user according to the specific conditions within the installation and a hazard and fault analysis. The safety regulations applicable for the installation have to be taken into consideration. Unintended machine motion or other malfunction is possible if s af ety devices are dis abled, bypassed or not activated.

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

⇒

Keep free and clear of the machine’s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine’s range of motion:

- use safety fences

- use safety guards

- use protective coverings

- install light curtains or light barriers

⇒

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

⇒

Mount the emergency stop switch in the immediate reach of the operator. Verify that the em er gency stop works before startup. Don’t oper ate the device if the emergency stop is not working.

⇒

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

⇒

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

⇒

Additionally secure vertical axes against falling or dropping after switching off the m otor power by, for example:

- mechanically securing the vertical axes,

- adding an external braking/ arrester/ clamping mechanism or

- ensuring sufficient equilibration of the vertical axes.

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

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Page 37

Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-9

⇒

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

- maintenance and repair work

- cleaning of equipment

- long periods of discontinued equipment use

⇒

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

Protection Against Magnetic and Electromagnetic Fiel ds During Operation and Mounting

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

WARNING

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

⇒

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

- Areas in which electrical equipm ent and parts are mounted, being operated or commissioned.

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

⇒

If it is necessary for som ebody with a pacemaker to enter such an area, a doctor must be cons ulted prior to doing so. The interference im munity of present or future implanted heart pacemakers dif f er s greatly, so that no general rules can be given.

⇒

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

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Page 38

3-10 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive

Protection Against Contact with Hot Parts

Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of burns!

⇒

CAUTION

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

⇒

Do not touch housing surfaces of m otors! Danger of

burns!

⇒

According to operating conditions, temperatures can

be higher than 60 °C, 140 °F during or after operation.

⇒

Befor e accessing m otors after having s witched them

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

⇒

After switching drive controllers or chokes off, wait

15 minutes to allow them to cool down before touching them.

⇒

Wear safety gloves or do not work at hot surfaces.

⇒

For certain applic ations, the manuf acturer of the end

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

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Page 39

Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-11

Protection During Handling and Mounting

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

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

⇒

Observe the general construction and safety

CAUTION

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, safety gloves).

⇒

Do not stand under hanging loads.

⇒

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

Battery Safety

Batteries consist of active chemicals enclosed in a solid housing. Therefore, improper handling can cause injury or damages.

Risk of injury by improper handling!

⇒

Do not attempt to reactivate low batteries by heating or other methods (risk of explosion and

CAUTION

Note: Environmental protection and disposal! The batteries installed

in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations. Dispose of used batteries separate from other waste. Observe the local regulations in the country of assembly.

cauterization).

⇒

Do not recharge the batteries as this may cause leakage or explosion.

⇒

Do not throw batteries into open flames.

⇒

Do not dismantle batteries.

⇒

Do not damage electrical parts installed in the devices.

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Page 40

3-12 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive

Protection Against Pressurized Systems

According to the information given in the Project Planning Manuals, motors cooled with liquid and com pr es sed air , as well as dr ive c ontroller s , can be partially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids, and cooling lubricating agents. In these cases, improper handling of external supply systems, supply lines, or connections can cause injuries or damages.

Risk of injury by improper handling of pressurized lines!

⇒

Do not attempt to disconnect, open, or cut

CAUTION

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 to

operate the product might not be economically friendly. Dispose of ecologically harmful agents separate from other waste. Observe the local regulations in the country of assembly.

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Page 41

Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-1

4 Identification, Transport, Storage,

Installation Conditions

4.1 Identification

Type Code

Firmware MPB-04

Control section

Basic single-axis

Firmware range

FWA-INDRV*- MPB- 04 V RS- D5- 0- NNN -NN base pack age (open-l oop) FWA-INDRV*- MPB- 04 V RS - D5- 0- SNC -NN base package (open-loop) + synchronization FWA-INDRV*- MPB- 04 V RS - D5- 0- MSP -NN base package (open-loop) + mai n spindle FWA-INDRV*- MPB- 04 V RS - D5- 0- ALL -NN base package (open-loop) + all al t ern. functions FWA-INDRV*- MPB- 04 V RS - D5- 0- NNN -ML base package (open-loop) + IndraMotion MLD-S FWA-INDRV*- MPB- 04 VRS- D5- 0- *** -ML FWA-INDRV*- MPB- 04 VRS- D5- 1- NNN -NN base package (closed-loop) FWA-INDRV*- MPB- 04 VRS- D5- 1- SRV -NN base package (cl osed-loop) + servo function FWA-INDRV*- MPB- 04 VRS- D5- 1- SNC -NN base package (closed-loop) + synchronizati on FWA-INDRV*- MPB- 04 VRS- D5- 1- MSP -NN base package (closed-loop) + main spindle FWA-INDRV*- MPB- 04 VRS- D5- 1- ALL -NN base pack age (closed-loop) + all altern. functions FWA-INDRV*- MPB- 04 VRS- D5- 1- NNN -ML base package (cl osed-loop) + IndraMotion MLD-S FWA-INDRV*- MPB- 04 VRS- D5- 1- *** -ML

Base

package

Version

Release

Language

Open/closed-

loop

Alternative

functional

packages

IndraMotion

MLD-S

Scope of functional packages

base package (open-loop) + *** + IndraMotion MLD-S

base package (closed-loop) + *** +

IndraMotion MLD-S

Power Sections HCS

Examples

HCS02.1E-W0012-A-03-NNNV (with integrated 24V supply); HCS03.1E-W0100-A-05-NNBV (with integrated brake transistor)

Product

Line

Design

Power supply

Cooling mode

Maximum current

Protection mode

Mains connecting

voltage

HCS 02 1 E W 0012 A 03 NNNV

Fig. 4-1: Basic structure of type code

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Other design

Page 42

4-2 Identification, Transport, Storage, Installation Conditions Rexroth IndraDrive

Control Sections BASIC CSB01.1N

Example

Product

CSB 01 1 N FC NNN NNN NN C NN FW

Line

Design

CSB01.1.N-FC-NNN-NNN-NN-C-NN-FW

Configuration option

Fig. 4-2: Basic structure of type code

Master communication

Option 1

Option 2

Safety option

Display

Other design

Firmware

Additional Components

Mains Choke HNL

Example

HNL01.1E-0980-N0026-A-480-NNNN

(to be ordered extra)

Product

HNL 01 1 E 0980 N 0026 A 480 NNNN

Line

Design

Supply system

Fig. 4-3: Basic structure of type code

Nominal inductance

Additional option

Nominal current

Degree of protection

Mains connecting

voltage

Other design

Mains Filter HNF, HNK

Example

Product

HNF 01 1 A F240 R 0094 A 480 NNNN HNK 01 1 A A075 E 0050 A 500 NNNN

Line

Design

HNF01.1A-F240-R0094-A-480-NNNN

EMC-area per

DIN 61800-3

Fig. 4-4: Basic structure of type code

Applications

Supply system

Nominal current

Degree of

protection

Mains connecting

voltage

Other design

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Page 43

Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-3

Motor Filter HMF

Example

Product

HMF 01 1 A N 1K5 E 0070 A 500 NNNN

Line

Design

HMF01.1A-N1K5-E0070-A-500-NNNN

Mounting style

Fig. 4-5: Basic structure of type code

Filter class

Motor frequency

Switching frequency

Nominal current

Degree of protection

Voltage rating

Other design

Braking Resistor HLR

Example

HLR01.1N-1K08-N05R0-A-007-NNNN

Product

HLR 01 1 N 1K08 N 05R0 A 007 NNNN

Line

Design

Mounting style

Fig. 4-6: Basic structure of type code

Continuous output

Additional option

Resistance

Degree of protection

DC bus nominal

voltage

Other design

Accessories

HAS01.1

Example

Product

HAS 01 1 050 048 NN

Line

HAS01.1-050-048-NN

Design

Fig. 4-7: Basic structure of type code

Device width

Bus-bar

Other design

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Page 44

4-4 Identification, Transport, Storage, Installation Conditions Rexroth IndraDrive

HAS02.1

Product

HAS 02 1 001 NNN NN

Type Plates

Example

Line

HAS02.1-001-NNN-NN

Design

Fig. 4-8: Basic structure of type code

Device assignment

Other feature

Each drive component is marked by a type designation. There is a type plate attached to all devices.

Type Plates at the Drive Controller

Other design

1: Power section type plate 2: Control section type plate 3: Firmware type plate

Fig. 4-9: Type plates at the drive controller

DG000023v01_nn.FH9

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Page 45

Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-5

Type Plates at the Control Section

Control Section Type Plate

Type

CSH01.1C-SE-EN1-EN2-MA1-L1-S-NN-FW

Part number

Serial number

MNR: R911293808 FD: 05W24 (7260)

Production week

Example: 05W24 means year 2005, week 24

SN:CSH011-00123 0A01 0S01

Barcode

Fig. 4-10: Control section type plate

Hardware index

Firmware Type Plate

Type

MPH02V12D51

SRVNN (7260) 05W24

Production week

Example: 05W24 means year 2005, week 24

R911

297901-04432

Fig. 4-11: Firmware type plate (example)

Serial number

DG000022v01_de.FH9

DG000024v01_en.fh9

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Page 46

4-6 Identification, Transport, Storage, Installation Conditions Rexroth IndraDrive

4.2 Transport and Storage

Transport of the Devices

Conditions

temperature -25…70 °C relative humidity 5…95%;

climatic category 2K3

absolute humidity 1…60 g/m

climatic category 2K3 moisture condensation not allowed icing not allowed shock test out of operation according

to EN 60068-2-27

Fig. 4-12: Conditions for transport

half sine in 3 axes: 10g / 11ms

Storage of the Devices

Extended Storage

Conditions

temperature -25…55 °C relative humidity 5…95%;

climatic category 1K3 absolute humidity 1…29 g/m

climatic category 1K3 moisture condensation not allowed icing not allowed

Fig. 4-13: Conditions for storage

Some devices contain electrolytic capacitors which may deteriorate during storage.

Note: When storing these devices for a longer period of time,

operate them once a year for at least 1 hour with power ON:

• devices HCS with mains voltage U

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Page 47

Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-7

4.3 Installation Conditions

Ambient and Operating Conditions

The drive controllers and their additional components are designed for control cabinet mounting!

Note: The user must c heck that the am bient conditions, in particular

the control cabinet temperature, are complied with by calculating the heat levels in the control cabinet and making the corresponding measurements.

In the Technical Data the power dissipation is indicated as an input value for calculating the heat levels.

Designation Data

degree of protection IP20 according to IEC529 ambient temperature 0…+40 °C ambient temperature with power

reduction temperature during storage see section 4.2 Transport and Storage temperature during transport see section 4.2 Transport and Storage installation altitude with nominal data <1000 m above sea level installation altitude with power

reduction * maximum installation altitude * 4000 m

relative humidity (operation) absolute humidity 1…29 g/m climatic category Cl. 3K3 according to IEC721

0…+55 °C; see characteristic in Fig. 4-15

see characteristic in Fig. 4-16

(upper temperature level reduced to 40 °C instead of 55 °C) 5%…95% Cl.3K5 with restriction, as not –5 °C

degree of dirt contamination degree of dirt contamination 2 in accordance with EN50178

dust, steam allowed according to EN 50178, table A.2

sine vibration during operation according to EN 60068-2-6

noise vibration (random) during operation according to IEC 68-2-36

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amplitude and frequency: 0.15 mm (peak-peak)

at 10…57 Hz acceleration and frequency: 1 g at 57…150 Hz tolerance: ±15 % frequency: 20…150 Hz spectral acceleration density amplitude: 0.005 g2/Hz tolerance: ± 3 dB rms value of the total acceleration: 1.0 g

* For installation altitudes of more than 2000 m, an overvoltage limiter

for transient overvoltage 1.2/50 µs must be installed in the installation or building in order to limit the voltage to 1.0 kV between the outer conductors and to 2.5 kV between conductor-ground.

Fig. 4-14: Ambient and operating conditions

Page 48

4-8 Identification, Transport, Storage, Installation Conditions Rexroth IndraDrive

Capacity Utilization

Where installation conditions differ, the following performance data are reduced in accordance with the diagrams (see "Fig. 4-15: " and "Fig. 4-16: "):

drive controller:

• allowed continuous DC bus power

• continuous power of braking resistor

• continuous current

motor:

• power

• continuous torque at standstill

• S1 continuous torques

• short-time service torque MKB

If differing ambient temperatures and higher installation altitudes occur simultaneously, both capacity utilization factors must be multiplied. The installation altitude must only be taken into account once, deviating ambient temperatures must be taken into account separately for motor and drive controller.

Load factor

0,7

Fig. 4-15: Capacity utilization at higher ambient temperature

40 45 50 55

Ambient temperature in °C

DK000073v01_en

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Page 49

Rexroth IndraDrive Identification, Transport, Storage, Installation Conditions 4-9

0,9

0,8

0,7

Load factor

0,6

Fig. 4-16: Capacity utilization at higher installation altitude

Compatibility with Foreign Matters

All Rexroth controls and drives are developed and tes ted accor ding to the state-of-the-art technology.

As it is impossible to follow the continuing development of all materials (e.g. lubricants in machine tools ) which m ay interact with our controls and drives, it cannot be completely ruled out that any reactions with the materials used by Bosch Rexroth might occur.

For this reason, before using the res pective material a compatibility test has to be carried out for new lubricants, cleaning agents etc. and our housings/our housing materials.

1000 2000

Installation altitude above sea level in meters

3000 4000

DK000074v01_en

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Page 50

4-10 Identification, Transport, Storage, Installation Conditions Rexroth IndraDrive

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Page 51

Rexroth IndraDrive Electrical Data 5-1

5 Electrical Data

5.1 Power Sections

Unless otherwise specified, the following data apply to

• T

= T

amax

• ULN = 3AC400V

• use of HNL and HNK mains chokes

Type Current and Connected Load

Compact converter

HCS02 W0012 HNL01.1E-1000-N0012 1,5 3,5 6 10 4 12 HCS02 W0028 HNL01.1E-1000-N0012 4,0 7,3 13 20 11 28 HCS02 W0054 HNL01.1E-1000-N0020 7,5 13,3 19 25 22 54 HCS02 W0070 HNL01.1E-0600-N0032 11 18,5 30 35 28 70 HCS03 W0070 HNL01.1E-0571-N0050

HCS03 W0100 HNL01.1E-0362-N0080;

HCS03 W0150 HNL01.1E-0240-N0106

HCS03 W0210 HNL01.1E-0170-N0146

Type

current

Attached mains choke

HNL, HNK

HNK01.1A-A075-E0080

HNK01.1A-A075-E0106

HNK01.1A-A075-E0146

(1) at fs = 4 kHz; without overload (2) for standard motor, when using mains choke HNL01; at 3 AC 400 V

Fig. 5-1: Type current and connected load

Nominal

motor power

(2)

[kW] [kVA] [A] [A] [A] [A]

18,5 35 50 3NA6820-4 45 70

30 55,2 80 3NA6824-4 73 100

45 72,9 106 3NA6832-4 95 150

75 99,3 146 3NA6836-4 145 210

variable torque, low overload

Connected load

Mains

input contin. current

L_cont

Nominal fuse current / fuse

type

character-

istic gL

Type I

Contin. current

(1)

out_cont1Iout_max

Peak

current

(1)

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Page 52

5-2 Electrical Data Rexroth IndraDrive

Control Voltage Supply

Note: The control sections are supplied via the term inal connectors

24V and 0V at the power section (24V supply).

Note: The isolated inputs/outputs at X31 and X32 are not supplied

via the connections of the 24V supply of the power section. A separate voltage supply is required for these inputs/outputs.

Note: Overvoltage of more than 33 V has to be discharged by

means of the appropriate elec trical equipment of the m achine or installation.

This equipment includes:

• 24V power supply units that reduce incoming overvoltages to the allowed value.

• Overvoltage limiters at the control cabinet input that limit existing overvoltage to the allowed value. This, too, applies to long 24V lines that have been run in parallel to power cables and mains cables and c an absorb overvoltages by inductive or capacitive coupling.

Designation Symbol Unit

24V control voltage supply HCS02.1E;

HCS03.1E

• 24 ± 20% (if no motor holding brake has to be supplied)

• If motor holding brakes are to be supplied, observe the data of the motor documentation. The following values are normally sufficient:

24 ± 5% at motor cable length < 50 m 26 ± 5% at motor cable length > 50 m

max. ripple content w - mustn't exceed the control voltage range max. allowed overvoltage U

N3max

V 33 (max. 1 ms) Power consumption of power sections 1) HCS02.1E-W0012 P HCS02.1E-W0028 P HCS02.1E-W0054 P HCS02.1E-W0070 P HCS03.1E-W0070 P HCS03.1E-W0100 P HCS03.1E-W0150 P HCS03.1E-W0210 P

W12 W14 W23 W23 W23 W25 W25

W30 Power consumption of control sections 2) CSB01.1N-FC… P CSB01.1N-PB… P

W7,5

W7,5 Typ. inrush current of control sections

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Page 53

Rexroth IndraDrive Electrical Data 5-3

CSB01.1N-FC… I CSB01.1N-PB… I

EIN3

A 1,5 (pulse width t A 5 (pulse width t

EIN3lade

ca. 120 ms)

ca. 40 ms) Power consumption of optional modules according to type code 3), 4) CP EN1 P EN2 P ENS P MA1 P MD1 P SP

W1,0 W6,0 W5,5 W5,5 W2,0 W1,0 W1,0

1) plus control section with optional modules

2) plus optional modules

3) code from the control section type code

4) at max. allowed output load without circuits to be supplied externally

Fig. 5-2: Control voltage

Power Voltage Supply- Mains Connection

Designation Symbol Unit HCS02.1E HCS03.1E

allowed range of mains input voltage, three-phase; TN-S, TN-C, TT mains

allowed range of mains input voltage, three-phase; IT mains

allowed range of mains input voltage, single-phase

V 1 * AC (200…250) +-10% not allowed

3 * AC (200…500)

+-10%

3 * AC (200…230)

+-10%

3 * AC (400…500)

+10% -15%

not allowed

rotary field no rotary field condition allowed range of mains

frequency max. allowed mains frequency

change

d f

/t Hz/s 2% * f

Hz (50…60) + - 2

Fig. 5-3: Extended range of power voltage

Note: When using HCS02 and HCS03 devic es in the mains voltage

range up to 3 * AC 500 V, make sure the additional components you use may be operated in this mains voltage range. NFD mains filters , for exam ple, can only be used up to 3 * AC 480 V.

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Page 54

5-4 Electrical Data Rexroth IndraDrive

Limited Length of Motor Power Cables

Keep in mind, that the allowed maxim um m otor cable length is depending on the switching frequency of the power output stage. On principle, the higher the switching frequency, the shorter the allowed cable length (in order to protect the drive controllers against overload).

Note: Always use switching frequencies supported by the

components of your drive system. Observe the technical data of the drive controllers and motors.

See also Parameter Description "P-0-0001, Switching frequency of the power output stage".

Limited Lengths of Motor Power

Cables

The lengths indicated in the table below are recommended as guide values (at an ambient temperature of ≤ 40 °C in accordance with EN 60 204).

Allowed line lengths for motor connection without filter measures at motor output:

Max. allowed line length [m]PWM frequency [kHz]

Shielded line Unshielded line

4 75 150

8 38 150 12 25 not allowed 16 18 not allowed

1) only allowed at HCS drive controllers

2) depending on the drive controller

Fig. 5-4: Line lengths

100 175

Operation with unshielded motor cables of up to 150 m

• aims at applications with "operation without encoder" (Open Loop)

• does not include the control voltage lines to the motor

• requires additional measures with regard to EMC on the part of the

operating company

Documentation Motor Power

Cables

Allowed line lengths for motor connection with additional components HMF or HML:

Max. allowed line length [m]PWM frequency [kHz]

Shielded line Unshielded line

1) only allowed at HCS03 drive controllers

2) higher PW M frequencies are not allowed

Fig. 5-5: Line lengths

75 200

The documentation "Rexroth Connection Cables; Selection Data" is available for selecting the motor power cables and other connections, such as encoder cables.

Rexroth IndraDrive drive systems have to be equipped with shielded motor power cables of the RKL line.

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Page 55

Rexroth IndraDrive Electrical Data 5-5

Third-Party Motor Power Cables

Requirements on third-party motor power cables: Maximum allowed cable length at A1, A2, A3:

• see description above Maximum allowed capacitance per unit length at A1, A2, A3:

• against ground, each: 0.5 nF/m

• against each other: 0.5 nF/m

Maximum allowed inductance per unit length at A1, A2, A3:

• 100 nH/m each

Note: If you use third-party motor power cables not corresponding to

the requirements, Rexroth's guarantee for the drive s ystem will expire.

Use ready-made Rexroth cables.

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Page 56

5-6 Electrical Data Rexroth IndraDrive

5.2 Control Sections

Relay Contact Type 1

Data Unit Min. Typ. Max.

current load capacity A DC 1

AC 2

voltage load capacity V DC 30

AC 250 minimum contact load mA 10 contact resistance at

minimum current switching actions at max. time

constant of load number of mechanical

switching cycles time constant of load ms 50 pick up delay ms 10 drop out delay ms 10

mOhm 1000

100.000

1 * 10

Relay Contact Type 2

Fig. 5-6: Relay contacts type 1

Data Unit Min. Typ. Max.

current load capacity A DC 1 voltage load capacity V DC 30 minimum contact load mA 10 contact resistance at

minimum current switching actions at max. time

constant of load number of mechanical

switching cycles time constant of load ms ohmic pick up delay ms 10 drop out delay ms 10

Fig. 5-7: Relay contacts type 2

mOhm 1000

1 * 10

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Page 57

Rexroth IndraDrive Electrical Data 5-7

Relay Contact Type 3

Data Unit Min. Typ. Max.

current load capacity A DC 1 voltage load capacity V DC 30 minimum contact load mA 10 contact resistance at

minimum current switching actions at max. time

constant of load number of mechanical

switching cycles time constant of load ms ohmic pick up delay ms 10 drop out delay ms 10

Fig. 5-8: Relay contacts type 3

mOhm 1000

1 * 10

Digital Inputs/Outputs

Digital Inputs

The digital inputs correspond to IEC 61131, type 1.

DA000022v01_nn.FH9

Fig. 5-9: Symbol of digital input

Data Unit Min. Typ. Max.

allowed input voltage V -3 30 On V 15 Off V 5 input current mA 2 5 input resistance kOhm non-linear, varies depending on

input voltage sampling frequency kHz depending on firmware probe input delay us 1

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Fig. 5-10: Digital inputs

Note: Probe inputs are fast inputs. For triggering use bounce-free

switches.

Page 58

5-8 Electrical Data Rexroth IndraDrive

Digital Outputs

The digital outputs correspond to IEC 61131.

Note: Do not operate digital outputs at low-resistance sources.

Observe Functional Description of the f irm ware s ection "Notes on Commisioning" particularly parameter P-0-0302, Digital I/O, Direction.

DA000024v01_nn.FH9

Fig. 5-11: Symbol of digital output

Data Unit Min. Typ. Max.

output voltage "ON" V Uext - 0,5 24 Uext output voltage "OFF" V 2,1 output current "OFF" mA 0,05 allowed output current per

output allowed output current total

or per group update interval ns depending on firmware short circuit protection present overload protection present allowed energy content of

connected inductive loads, e.g. relay coils; only allowed as single pulse

Fig. 5-12: Digital outputs

mA 500

mA 1000

mJ 400

Note: The digital outputs have been realized with so-called high-side

switches. This means that these outputs can actively supply current but not drain it.

Note: The energy absorption capacity of the outputs is us ed to limit

voltage peaks caused when inductive loads are switched off. Limit voltage peaks by using free-wheeling diodes directly at

the relay coil.

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Page 59

Rexroth IndraDrive Electrical Data 5-9

Analog Inputs/Outputs

The analog inputs correspond to IEC 61 131.

Analog Input Type 1

U+

U-

GND

AD: analog/digital converter

Fig. 5-13: Analog voltage inputs

Data Unit Min. Typ. Max.

allowed input voltage voltage inputs

input resistance voltage input

input bandwidth kHz 6 common-mode range V -20 +20 common-mode rejection dB relative measuring error

at 90% U

emax

converter width A/D converter incl. polarity sign

oversampling 8-fold dynamic converter width with

oversampling resulting resolution mV/Ink 5,5 cyclic conversion us 500 (depending on firmware) conversion time us n.s.

DA000025v01_nn.FH9

V-10 +10

kOhm 180

%-1 +1

Bit 10

Bit 12

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Fig. 5-14: Analog voltage inputs

Page 60

5-10 Electrical Data Rexroth IndraDrive

Analog Input Type 2

U+

U-

GND

AD: analog/digital converter

Fig. 5-15: Analog voltage inputs

Data Unit Min. Typ. Max.

allowed input voltage voltage inputs

input resistance voltage input

input bandwidth kHz 50 common-mode range V -50 +50 common-mode rejection dB 70 relative measuring error

at 90% U

emax

converter width A/D converter incl. polarity sign

oversampling 8-fold dynamic converter width with

oversampling resulting resolution mV/Ink 1,25 cyclic conversion us 500 (depending on firmware) conversion time us 40

DA000025v01_nn.FH9

V-10 +10

kOhm 1000

% -0,3 +0,3

Bit 12

Bit 14

Fig. 5-16: Analog voltage inputs

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Page 61

Rexroth IndraDrive Electrical Data 5-11

Analog Input Type 3

I+

DA000026v01_nn.FH9

GND

I-

AD: analog/digital converter

Fig. 5-17: Analog current inputs

Data Unit Min. Typ. Max.

allowed input current mA 0 +20 input resistance Ohm 200 input bandwidth kHz 3 common-mode range V -20 +20 common-mode rejection dB relative measuring error

at 90% U

emax

converter width A/D converter

%-1 +1

Bit 10

incl. polarity sign oversampling 8-fold dynamic converter width with

Bit 12

oversampling resulting resolution

A/Ink 5,45 cyclic conversion us 500 (depending on firmware) conversion time us n.s.

Fig. 5-18: Analog current inputs

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Page 62

5-12 Electrical Data Rexroth IndraDrive

Analog Input Type 4

U+

U-

GND

AD: analog/digital converter

Fig. 5-19: Analog voltage inputs

Data Unit Min. Typ. Max.

allowed input voltage voltage inputs

input resistance voltage input

input resistance voltage input CSH01.2C

input bandwidth kHz 10 common-mode range V -20 +20 common-mode rejection dB relative measuring error

at 90% U

emax

converter width A/D converter incl. polarity sign

oversampling 8-fold dynamic converter width with

oversampling resulting resolution mV/Ink 1,23 cyclic conversion us 500 (depending on firmware) conversion time us n.s.

DA000025v01_nn.FH9

V-10 +10

kOhm 2

kOhm 160

%-1 +1

Bit 12

Bit 14

Fig. 5-20: Analog voltage inputs

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Page 63

Rexroth IndraDrive Electrical Data 5-13

Analog Output Type 1

Data Unit Min. Typ. Max.

output voltage V 0 +10 output load kOhm 2 output current mA 0 +5 converter width digital/analog

converter incl. polarity sign resolution mV/Ink 9,8 conversion time

(incl. response time) cyclic conversion us depending on firmware short circuit protection present overload protection present

Fig. 5-21: Analog outputs type 1

Bit 10

us 10

Analog Output Type 2

Data Unit Min. Typ. Max.

output voltage V 0 +5 output load kOhm 5 output current mA 0 +1 converter width digital/analog

converter incl. polarity sign resolution mV/Ink 19,5 accuracy at R=5 kOhm % 5 of FMR accuracy at R=10 kOhm % 2,5 of FMR conversion time

(incl. response time) cyclic conversion us depending on firmware short circuit protection present overload protection present

FMR: final value of measuring range

Fig. 5-22: Analog outputs type 2

Bit 8

us 10

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Page 64

5-14 Electrical Data Rexroth IndraDrive

Analog Output Type 3

Data Unit Min. Typ. Max.

output voltage V -10 +10 output load kOhm 1 output current mA 0 +1 converter width digital/analog

converter incl. polarity sign resolution mV/Ink 5 accuracy at R = 1 kOhm % 1 of FMR accuracy at R = 10 kOhm % 0,2 of FMR conversion time

(incl. response time) cyclic conversion us depending on firmware short circuit protection present overload protection present

FMR: final value of measuring range

Fig. 5-23: Analog outputs type 3

Bit 12

us 10

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Page 65

Rexroth IndraDrive Electrical Data 5-15

5.3 Additional Components

Mains Filter HNF

HNF01.1A- … -A-480-NNNN

Unit

Power dissipation W < 89 < 91 < 127 < 174 < 238 < 373 < 73 < 77 < 163 < 157 < 135 < 146

Phase current (continuous

current)

Phase current (peak

current

Leakage current at filters

input (line side)

Leakage current at filters

output (load side)

allowed THD (Total Harmonic

Distortion)

Reduction of allowed

operating data due to

harmonic content

Input supply voltage V 3 x AC 380…480V ±10%, 50/60Hz ±2%

Sum of leakage currents at

filters input with power supply

unit switched off:

• 1 phase failed

• 2 phases failed

Leakage resistance (Phase –

Ground)

Protection category - I P20

Materials - free of asbestos and silicone

Terminal L1, L2, L3 resp. L1.1, L2.1, L3.1:

Cross section flexible min. mm

Cross section flexible max. mm

Cross section rigid min. mm

Cross section rigid max. mm

Cross section AWG min. -- 20 20 6 6 2 2 20 20 10 10 6 6

Cross section AWG max. -- 4 4 0 0 00/3 00/3 6 6 2 2 0 0

Tightening torque Nm

A 51 51 125 125 202 202 26 26 65 65 94 94

A 77 77 188 188 303 303 65 65 163 163 235 235

)

A < 2 < 2 < 2,2 < 2,2 < 2,5 < 2,5 < 2 < 2 < 2 < 2 < 2,2 < 2,2

% see Project Pl anni ng Manual " Rexroth IndraDri ve Dri ve S ystem"

- s ee Project Planning Manual "Rexroth IndraDrive Drive System"

MOhm > 15

F240-E0051

M900-E0051

F240-E0125

M900-E0125

F240-E0202

M900-E0202

F240-R0026

M900-R0026

F240-R0065

M900-R0065

• < 0,83

• < 1,4

0,5 0,5 16 16 50 50 0,5 0,5 10 10 16 16

16 16 50 50 150 150 10 10 25 25 50 50

0,5 0,5 16 16 35 35 0,5 0,5 6 6 16 16

25 25 50 50 150 150 16 16 35 35 50 50

4,8

±0,5

4,8

< 25 < 25 < 25 < 25

±0,5

4,8

±0,5

4,8

±0,5

4,8

±0,5

4,8

±0,5

1) duration: 300 ms ; cycle duration: for feeding units: 0,67 s; for regenerating units: 1,42 s; base load: 60% (continuous current)

Fig. 5-24: Data HNF

F240-R0094

< 25 < 25

M900-R0094

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Page 66

5-16 Electrical Data Rexroth IndraDrive

Mains Filter (-Combi nati on) HNK

Mains filter HNK01.1A-A075 Unit E0050 E0080 E0106 E0146

Nominal voltage V 3*AC400…500 Nominal current A 50 80 106 146 Inductance µH 571 362 240 170 Connection cross section mm² 16 (AWG 6) 25 (AWG 3) 25 (AWG 3) 50 (AWG 1/0) Protection category - IP20 Weight kg 15 20 20 28

Fig. 5-25: Data HNK

Mains Choke HNL01.1E (feeding)

Mains choke U

HNL01.1E-1000-N0012-A-500-NNNN 500 12 3 x 1000 40 25 50% of L HNL01.1E-1000-N0020-A-500-NNNN 500 20 3 x 1000 60 50 50% of L HNL01.1E-0600-N0032-A-500-NNNN 500 32 3 x 600 75 80 50% of L HNL01.1E-0571-N0050-A-500-NNNN 500 50 3 x 571 50 100 50% of L HNL01.1E-0400-N0051-A-480-NNNN 480 51 3 x 400 165 77 50% of LN16 (a, b: 2,5) HNL01.1E-0362-N0080-A-500-NNNN 500 80 3 x 362 80 160 50% of L HNL01.1E-0240-N0106-A-500-NNNN 500 106 3 x 240 100 212 50% of L HNL01.1E-0200-N0125-A-480-NNNN 480 125 3 x 200 170 188 50% of LN70 (a, b: 2,5) HNL01.1E-0170-N0146-A-500-NNNN 500 146 3 x 170 130 292 50% of L HNL01.1E-0100-N0202-A-480-NNNN 480 202 3 x 100 200 303 50% of LN150 (a, b: 2,5)

[V]

[A]

[µH]

[W]

max

[A]

at I

min

max

Connection

cross section

[mm²]

4 (a, b: 4) 6 (a, b: 4)

10 (a, b: 4)

16 (a, b: -)

35 (a, b: -) 50 (a, b: -)

95 (a, b: -)

Fig. 5-26: Data HNL

Temperature Contact a, b

Switching Capacity

Switching Temperature

1 A / AC 250 V; DC 24 V 125 °C

Note: HNL01.1E mains chokes of type 1 are equipped with a

temperature contact (a, b), types 2, 3 and 4 are not.

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Page 67

Rexroth IndraDrive Electrical Data 5-17

Mains Choke HNL01.1E-****-S (Current-Compensated)

HNL01.1 … -A-480-NNNN

Weight kg 11 26 30 12 14 24

Inductance LNmH 3 x 5,7 3 x 2,8 3 x 3,4 3 x 4,2 3 x 6,3 3 x 3,0

Nominal current A 51 125 202 26 65 94

Peak current

Total leakage current at power terminal A < 2 < 2,2 < 2,2 < 2 < 2 < 2

Allowed power dissipation at nominal current and

maximum leakage current

Input supply voltage 3 x AC 380…480V ±10%, 50/60Hz ±2%

Minimum inductance L

Protection category IP20

1) duration: 300 ms ;

Fig. 5-27: Data HNL…S

Braking Resistor HLR

HLR01.1N-xxxx-Nxxxx-A-007-NNNN

Unit

A 77 188 303 65 163 235

E-5700-S0051

E-2800-S0125

E-3400-S0202

R-4200-S0026

W 83 179 320 80 138 142

min

0,8*LN at I

max

cycle duration: for feeding units: 0,67 s; for regenerating units: 1,42 s; base load: 60%

R-6300-S0065

R-3000-S0094

Designation Symbol Unit 0300-N17R5 0470-N11R7 0780-N07R0 1K08-N05R0

nominal braking resistance braking resistor continuous

power, at Ta < 40 °C resistance value at P

braking resistor peak power at U

= 850 V

max. regenerative power that can be absorbed

max. allowed duty cycle min. allowed cycle time time constant weight

DC_Bleeder

R_max

ts 1 1 1 1 t s 120 120 120 120

mkg 3 4,5 5,5 8

Ohm 17,5 11,7 7,0 5,0

kW 0,30 0,47 0,78 1,08

Ω

kW 35 52 88 124

kWs 37 56 93 130

s 780 780 780 780

20,5 13,7 8,2 5,8

connection cross section

mm² 10 25 25 50

AWG 8 3 3 1/0

Fig. 5-28: Data

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Page 68

5-18 Electrical Data Rexroth IndraDrive

Braking Resistors for HCS03.1E-W0070

HLR01.1N-xxxx-xxxxx-A-007-

-01K6-N18R0 -03K5-N19R0 -04K5-N18R0 -06K5-N18R0 -10K0-N18R0

NNNN

continuous power kW 1,6 3,5 4,5 6,5 10 resistance value in

operating status type A5 B1 B2 B2 B3

Energy absorption at peak power, duty cycle t = x sec and load cycle T = 120 sec energy absorption at peak

power peak power kW 34 31 33 33 33 t sec 3,3 8 13 21 32 duty cycle ED % 2,7 6,7 11 17 27

Braking power at x % ED and a load cycle T = 120 sec braking power kW 15 14 14 14 15 t sec7,218304872 ED % 6 15 25 40 60

Connection cross sec t i o n

Ω

kWs 109 252 432 686 1080

mm² 2,5 4 6 10 10

AWG 14 12 10 8 8

20,0 21,3 20,2 20,2 20,2

Fig. 5-29: Technical data for braking resistors at HCS03.1E-W0070

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Page 69

Rexroth IndraDrive Electrical Data 5-19

Braking resistors for HCS03 ... 0070

Peak power P_s and Energy absorption W

10000

W [kWs]

Energy HLR01.1N-10K0-N18R0

1000

HLR01.1N-06K5-N18R0 HLR01.1N-04K5-N18R0 HLR01.1N-03K5-N19R0

P_s [kW]

HLR01.1N-01K6-N18R0

100

1 10 100 1000

Power HLR01.1N-10K0-N18R0

HLR01.1N-06K5-N18R0 HLR01.1N-04K5-N18R0 HLR01.1N-03K5-N19R0

HLR01.1N-01K6-N18R0

Duty cycle [s]

Fig. 5-30: Selection aid for braking resistors for HCS03.1E-W0070

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Page 70

5-20 Electrical Data Rexroth IndraDrive

Braking Resistors for HCS03.1E-W0100

HLR01.1N-xxxx-xxxxx-A-007NNNN

continuous power kW 2 5 7 9,5 14,5 resistance value in

operating status type A6 B2 B3 B3 B4

Energy absorption at peak power, duty cycle t = x sec and load cycle T = 120 sec energy absorption at

peak power peak power kW 40 40 43 46 46 t sec 3,4 9 16 22 34 duty cycle ED % 2,8 7,5 13 18 28

Braking power at x % ED and a load cycle T = 120 sec braking power kW 19 20 22 21 22 t sec7,218304872 ED % 6 15 25 40 60

connection cross section

kWs 137 360 672 1003 1566

mm² 4 6 10 10 16

AWG1210886

-02K0-N15R0 -05K0-N15R0 -07K0-N14R0 -09K5-N13R0 -14K5-N13R0

Ω

16,7 16,9 15,7 14,6 14,6

Fig. 5-31: Technical data for braking resistors at HCS03.1E-W0100

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Page 71

Rexroth IndraDrive Electrical Data 5-21

Braking resistors for HCS03 ... 0100

Peak power P_s and Energy absorption W

10000

W [kWs]

Energy HLR01.1N-14K5-N13R0

1000

P_s [kW]

100

HLR01.1N-09K5-N13R0

HLR01.1N-07K0-N14R0

HLR01.1N-05K0-N15R0

Power HLR01.1N-14K5-N13R0

HLR01.1N-09K5-N13R0

HLR01.1N-07K0-N14R0

HLR01.1N-05K0-N15R0

1 10 100 1000

Duty cycle [s]

Fig. 5-32: Selection aid for braking resistors for HCS03.1E-W0100

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Page 72

5-22 Electrical Data Rexroth IndraDrive

Braking Resistors for HCS03.1E-W0150

HLR01.1N-xxxx-xxxxx-A-007NNNN

continuous power kW 4,5 8,5 11 15 24 resistance value in

operating status type B1 B3 B3 B4 C3

Energy absorption at peak power, duty cycle t = x sec and load cycle T = 120 sec energy absorption at

peak power peak power kW 81 75 82 74 83 t sec 3 8,2 13 21 31 duty cycle ED % 2,5 6,8 11 18 26

Braking power at x % ED and a load cycle T = 120 sec braking power kW 34 34 35 33 36 t sec7,218304872 ED % 6 15 25 40 60

connection cross section

kWs 246 612 1056 1584 2592

mm² 10 16 25 25 35

AWG86332

-04K5-N07R4 -08K5-N08R0 -11K0-N07R3 -15K0-N08R1 -24K0-N07R2

Ω

8,3 9,0 8,2 9,1 8,1

Fig. 5-33 Technical data for braking resistors at HCS03.1E-W0150

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Page 73

Rexroth IndraDrive Electrical Data 5-23

Braking resistors for HCS03 ... 0150

Peak power P_s an d Energy absorpt ion W

10000

W [kWs]

1000

P_s [kW]

Energy HLR01.1N-24K0-N07R2 HLR01.1N-15K0-N08R1 HLR01.1N-11K0-N07R3 HLR01.1N-08K5-N08R0

HLR01.1N-04K5-N07R4

100

Power HLR01.1N-24K0-N07R2 HLR01.1N-15K0-N08R1 HLR01.1N-11K0-N07R3

1 10 100 1000

HLR01.1N-08K5-N08R0

HLR01.1N-04K5-N07R4

Duty cycle [s]

Fig. 5-34: Selection aid for braking resistors for HCS03.1-W0150

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Page 74

5-24 Electrical Data Rexroth IndraDrive

Braking Resistors for HCS03.1E-W0210

HLR01.1N-xxxx-xxxxx-A-007NNNN

continuous power kW 6,5 12,5 17 23 36 resistance value in

operating status type B2 B4 B5 C2 C4

Energy absorption at peak power, duty cycle t = x sec and load cycle T = 120 sec energy absorption at

peak power peak power kW 98 109 117 109 111 t sec 3,6 8,3 14 22 35 duty cycle ED % 3 6,9 12 18 29

Braking power at x % ED and a load cycle T = 120 sec braking power kW 49 50 54 51 54 t sec7,218304872 ED % 6 15 25 40 60

connection cross section

kWs 356 900 1632 2429 3888

mm² 16 35 35 50 50

AWG 6 2 2 1/0 1/0

-06K5-N06R1 -12K5-N05R5 -17K0-N05R1 -23K0-N05R5 -36K0-N05R4

Ω

76666

Fig. 5-35: Technical data for braking resistors at HCS03.1E-W0210

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Page 75

Rexroth IndraDrive Electrical Data 5-25

Braking resistors for HCS03 ... 0210

Peak power P_s and Energy absorption W

10000

W [kWs]

1000

P_s [kW]

100

Energy HLR01.1N-36K0-N05R4

HLR01.1N-23K0-N05R5 HLR01.1N-17K0-N05R1 HLR01.1N-12K5-N05R5

HLR01.1N-06K5-N06R1

Power HLR01.1N-36K0-N05R4

HLR01.1N-23K0-N05R5 HLR01.1N-17K0-N05R1 HLR01.1N-12K5-N05R5

HLR01.1N-06K5-N06R1

1 10 100 1000

Duty cycle [s]

Fig. 5-36: Selection aid for braking resistors for HCS03.1E-W0210

Line Cross Sections for Reinforced Braking Resistors HLR01.1

According to the standards "Electronic equipment for use in power installations" (EN 50178, chapter 5.3.2.1) and "Adjus table s peed elec tric al power drive systems" (EN 61800-5-1, chapter 4.2.5.4.2), a stationary connection of the equipment grounding conductor is required. The following requirement has to be complied with: cross section of equipment grounding conductor at least 10 mm

Note: For the equipment grounding conductor run lines with a cross

section corresponding to that of the lines for mains connection at the drive controller HCS and having at least 10 mm

Requirements for line routing:

• The cross sections are valid for one phase each in the case of stranded wires and are specified according to the regulations of VDE0298.

• Up to 50 mm

, solid wires in the cable duct.

(mechanical stability).

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Page 76

5-26 Electrical Data Rexroth IndraDrive

out_max

Motor Filter HMF

Motor filter I

[A]

[W]

[µH]

out_max

[Hz]

p_max

[kHz]

du/dt at

output

[kV]

[kV / us]

HMF01.1A-N0K2-D0045-A-500-NNNN 45 120 3 x 160 200 4 < 1 1,2 HMF01.1A-N0K2-D0073-A-500-NNNN 73 160 3 x 100 200 4 < 1 1,2 HMF01.1A-N0K2-D0095-A-500-NNNN 95 190 3 x 78 200 4 < 1 1,2 HMF01.1A-N0K2-D0145-A-500-NNNN 145 220 3 x 50 200 4 < 1 1,2

Fig. 5-37: Electrical data

Motor filter Cross section

[mm²]

Cross section

flexible

[mm²]

Cross section

[AWG]

Tightening

torque

[Nm]

HMF01.1A-N0K2-D0045-A-500-NNNN 16 - 6 1,5 HMF01.1A-N0K2-D0073-A-500-NNNN 35 - 2 6 HMF01.1A-N0K2-D0095-A-500-NNNN 50 2*25 0 6 HMF01.1A-N0K2-D0145-A-500-NNNN 95 2*50 4/0 25

Fig. 5-38: Terminal connector data

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Page 77

Rexroth IndraDrive Mounting and Installation 6-1

6 Mounting and Installation

6.1 Mounting

Dimensions – Power Sections

Device Depths, Heights and Widths

Min.

moun-

Device Device

width

[mm]

HCS02.1E-W0012 65 70 290 HCS02.1E-W0028 65 70 352 HCS02.1E-W0054 105 110 352 HCS02.1E-W0070 105 110 352 HCS03.1E-W0070 125 125 440 HCS03.1E-W0100 225 225 440 HCS03.1E-W0150 225 225 440 HCS03.1E-W0210 350 350 440

1) incl. minimum distance between the components

2) device body without mounting flange on top and bottom, as well as minimum distances for ventilation and installation

3) incl. touch guard, connector housing, bending radius of fiber optic cable, control panel "C"

Fig. 6-1: Mounting dimensions

ting

width

[mm] 1)

Device

height

[mm] 2)

Device depth [mm] 3)

265 for control cabinets with

at least 300 mm of depth

322 for control cabinets with

at least 400 mm of depth

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Page 78

6-2 Mounting and Installation Rexroth IndraDrive

Drilling Pattern for the Mounting Plate

Fig. 6-2: Drilling pattern

Note: The figure shows the back of the devices.

Device

HCS02.1E-W0012 0 316 32,5 13 7

HCS02.1E-W0028 0 378 32,5 13 7

HCS02.1E-W0054 55 378 25 13 7

HCS02.1E-W0070 55 378 25 13 7 HCS03.1E-W0070 75 466 25 13 7

HCS03.1E-W0100 175 466 25 13 7 HCS03.1E-W0150 175 466 25 13 7 HCS03.1E-W0210 250 466 50 13 7 HNL02.1 100 378 20 13 7

[mm]L[mm]M[mm]P[mm]R[mm]

HNF_bohrbild.fh7

Notes

observe additional distance to lateral neighboring devices

Fig. 6-3: Drilling pattern

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Page 79

Rexroth IndraDrive Mounting and Installation 6-3

Distances for Drive Controllers

In addition to the mounting dimensions, the components of the Rexroth IndraDrive range require additional mounting clearance

• to ventilate the components

• to mount accessories and connections

• to take temperature limits of neighboring mounting parts, such as

cable ducts etc., into account

To determine the required mounting clearances in the control cabinet, take additional distances between the components and on their tops and bottoms into account.

Distance between Drive Controllers

Owing to power dissipation in the components, espec ially due to installed braking resistors in compact devices, the temperatures of neighboring components are rising. In the case of lateral mounting, trouble-free operation therefore requires the following minimum distances in [mm] between the components.

tofrom

HCS02 HCS03 (HNK01,

HLR01)

HCS02.1E 5 -HCS03.1E with HNK01 and HLR01 -- 0

-- not allowed

Fig. 6-4: Minimum distance in [mm]

Note: For arrangement of the components in the control cabinet,

take their dimension sheets and the required minimum distances into account.

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Page 80

6-4 Mounting and Installation Rexroth IndraDrive

Distances on Top and Bottom of Components

Owing to power dissipation in the components, the temperature of the cooling air current at the device outlet is rising to values higher than ambient temperature at device inlet.

Property damage due to temperatures higher than 105 °C!

⇒

Comply with indicated minimum distances!

CAUTION

In order that drive controllers can discharge the power dissipation generated inside of them, they need space on their top (A) and bottom (B).

A: air intake B: air outlet C: mounting surface in control cabinet d: distance to top of device

Fig. 6-5: Air intake and air outlet at drive controller

kuehlluft.FH7

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Page 81

Rexroth IndraDrive Mounting and Installation 6-5

Minimum distance for ventilation

For sufficient ventilation of the com ponents you have to comply with the minimum distances below. At components without integrated braking resistor, there will be temperatures of up to 105 °C at the air outlet (B) (with an air intake temperature of 45 °C).

Component Minimum distance for

ventilation

at the bottom

(A)

[mm] 1)

HCS02 80 80 HCS03 100 80

1) for additional mounting parts, such as HAS, see dimensional drawings

2) integrated braking resistors require additional distance

Fig. 6-6: Minimum distance for ventilation

at the top

(B)

[mm] 2)

Notes

additionally take power at braking resistor into account

Note: If there are different minimum distances for the individual

components in a drive system, the greates t value determines the minimum distance to be observed.

Minimum Distance to Braking

Resistor

For components with integrated braking resistor (supply units, DC bus resistor units, HCS02 drive controllers) their higher outlet temperatures have to be taken into account.

To determine the required dist ances the res ulting outlet tem peratures are indicated in diagrams in the technical data of the components.

Input value in the diagrams is the generated power of the braking resistors or the individual output current. See exemplary diagram below:

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Page 82

6-6 Mounting and Installation Rexroth IndraDrive

Input value in the diagrams is the generated power of the braking resistors or the individual output current. See exemplary diagram below:

120

100

∆

T [K]

0 50 100 150 200 250 300 350 400 450 500

[W]

∆

T @ d~0mm

∆

T @ d~40mm

∆

T @ d~80mm

∆

T @ d~120mm

PBD: average continuous braking resistor power d: distance to top of device

Fig. 6-7: Exemplary diagram

The minimum distance for these mounting parts results from the intersection of the input value with the allowed temperature rise.

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Page 83

Rexroth IndraDrive Mounting and Installation 6-7

Dimensions – Mains Filter HNF

Drilling Pattern

HNF_bohrbild.fh7

Note: The figure shows the back of the devices.

Mains filter K [mm] L [mm] M [mm] N [mm] P [mm] R [mm]

HNF01.1A-F240-E0051-A-480-NNNN HNF01.1A-M900-E0051-A-480-NNNN

HNF01.1A-F240-E0125-A-480-NNNN HNF01.1A-M900-E0125-A-480-NNNN

HNF01.1A-F240-E0202-A-480-NNNN 125 466 12,5 7 13 6,5 HNF01.1A-M900-E0202-A-480-NNNN 150 466 50 7 13 6,5 HNF01.1A-F240-R0026-A-480-NNNN 50 466 25 7 13 6,5 HNF01.1A-M900-R0026-A-480-NNNN 100 466 25 7 13 6,5 HNF01.1A-F240-R0065-A-480-NNNN

HNF01.1A-M900-R0065-A-480-NNNN HNF01.1A-F240-R0094-A-480-NNNN

HNF01.1A-M900-R0094-A-480-NNNN

50 466 25 7 13 6,5

125 466 12,5 7 13 6,5

100 466 25 7 13 6,5

125 466 12,5 7 13 6,5

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Fig. 6-8: Drilling pattern

Page 84

6-8 Mounting and Installation Rexroth IndraDrive

Dimensions

L1L2L3

Netz

Line

Last

Load

X3.2

L1.1

L2.1

L3.1

Mains filter A

[mm]B[mm]C[mm]D[mm]E[mm]F[mm]G[mm]

HNF01.1A-F240-R0026-A-480-NNNN 480 262 100 440 - - 26 M6x20 8.6 HNF01.1A-F240-E0051-A-480-NNNN

HNF01.1A-M900-E0051-A-480-NNNN HNF01.1A-M900-R0026-A-480-NNNN 480 262 150 440 - - 26 M6x20 8.6 HNF01.1A-F240-R0065-A-480-NNNN

HNF01.1A-M900-R0065-A-480-NNNN HNF01.1A-F240-R0094-A-480-NNNN

HNF01.1A-M900-R0094-A-480-NNNN HNF01.1A-F240-E0125-A-480-NNNN

HNF01.1A-M900-E0125-A-480-NNNN HNF01.1A-F240-E0202-A-480-NNNN 480 262 150 440 40 110 63.5 M10x30 25 HNF01.1A-M900-E0202-A-480-NNNN 480 262 250 440 40 110 63.5 M10x30 25

480 262 100 440 - - 33

480 262 150 440 40 110 40

480 262 150 440 40 110 45

HNF_abmessungen.fh7

M6x16

M10x30

H max.

tightening

torque

[Nm]

2.3

4.8

Fig. 6-9: Dimensions

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Page 85

Rexroth IndraDrive Mounting and Installation 6-9

Dimensions – Mains Choke HNL01.1E (infeeding)

Dimensions Type 1:

Dimensions Type 2:

Dimensions Type 3:

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Page 86

6-10 Mounting and Installation Rexroth IndraDrive

Dimensions Type 4:

Mains choke Type

HNL01.1E-1000-N0012-A-500-NNNN 1 120 61 164 81 - 44 6,4 x 11 2,7 HNL01.1E-1000-N0020-A-500-NNNN 1 150 66,5 184 113 - 49,5 6,4 x 11 3,8 HNL01.1E-0600-N0032-A-500-NNNN 1 150 66,5 185 113 - 49,5 6,4 x 11 4,5 HNL01.1E-0571-N0050-A-500-NNNN 4 153 100 238 127 - 80 8,5 x 12 400 30 13 HNL01.1E-0400-N0051-A-480-NNNN 1 180 112 225 125 80 87 7 x 15 13,5 HNL01.1E-0362-N0080-A-500-NNNN 3 175 205 180 145 - 185 8,5 x 12 350 ca. 12 13 HNL01.1E-0240-N0106-A-500-NNNN 3 193 205 210 145 - 185 8,5 x 12 380 ca. 12 15 HNL01.1E-0200-N0125-A-480-NNNN 1 230 148 295 180 - 122 8 x 12 24 HNL01.1E-0170-N0146-A-500-NNNN 3 205 250 230 152 - 230 8,5 x 12 400 ca. 12 22 HNL01.1E-0100-N0202-A-480-NNNN 1 265 152 350 215 - 126 15 x 11 33

Dim.

[mm]

ABCDD1EF

Weight

[kg]

1) long hole in "B" direction

Fig. 6-10: Mechanical data HNL

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Page 87

Rexroth IndraDrive Mounting and Installation 6-11

Mains Choke U

[V]

[A]

[µH]

[W]

max

[A]

at I

min

max

Connection

Cross Section

[mm²]

4 (a, b: 4) 6 (a, b: 4)

10 (a, b: 4)

16 (a, b: -)

AWG 8 HNL01.1E-0400-N0051-A-480-NNNN 480 51 3 x 400 165 77 50% of LN16 (a, b: 2,5) HNL01.1E-0362-N0080-A-500-NNNN 500 80 3 x 362 80 160 50% of L

35 (a, b: -)

AWG 6 HNL01.1E-0240-N0106-A-500-NNNN 500 106 3 x 240 100 212 50% of L

35 (a, b: -)

AWG 1/0 HNL01.1E-0200-N0125-A-480-NNNN 480 125 3 x 200 170 188 50% of LN70 (a, b: 2,5) HNL01.1E-0170-N0146-A-500-NNNN 500 146 3 x 170 130 292 50% of L

50 (a, b: -)

AWG 1/0 HNL01.1E-0100-N0202-A-480-NNNN 480 202 3 x 100 200 303 50% of LN150 (a, b: 2,5)

Fig. 6-11: Electrical data HNL

Temperature Contact a, b

Switching Capacity

Switching Temperature

1 A / AC 250 V; DC 24 V 125 °C

Note: HNL01.1E mains chokes of type 1 are equipped with a

temperature contact (a, b), types 2, 3 and 4 are not.

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Page 88

6-12 Mounting and Installation Rexroth IndraDrive

Dimensions – Standard Braking Resistors HLR01.1

Note: The standard braking resistors are intended to be mounted

above the drive controllers HCS03; otherwise, forced convection (blower) with a volume stream of 200 m ³/hour is to be provided.

123

(M6)

275

19,5

Fig. 6-12: Dimensional drawing braking resistor HLR01.1N-0300-N17R5-A-

007-NNNN

300

165

196

MBZU0032EN00.FH9

235

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Page 89

Rexroth IndraDrive Mounting and Installation 6-13

223

175

(M6)

350

300

275

19,5

300

165

210

Fig. 6-13: Dimensional drawing braking resistor

HLR01.1N-0470-N11R7-A-007-NNNN and HLR01.1N-0780-N07R0-A-007-NNNN

235

MBZU0033EN00.FH9

DOK-INDRV*-FU*********-IB01-EN-P

275

19,5

300

235

165

220

MBZU0048EN00.FH9

Fig. 6-14: Dimensional drawing braking resistor HLR01.1N-1K08-N05R0-A-

007-NNNN

Note: The joint bar (ground strap) is contained in the s c ope of s upply

of the standard braking resistors HLR01.

Page 90

6-14 Mounting and Installation Rexroth IndraDrive

Dimensions – Reinforced Braking Resistors HLR01.1

Fixed Resistors IP 20 Type A

Fig. 6-15:Type A5 – A6

Type Dimensions in mm Weight in kg

HBTH1B1D A5 586 185 120 526 150 M6 5,2 A6 686 185 120 626 150 M6 6,2

Fig. 6-16: Dimensions table braking resistor type A

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Page 91

Rexroth IndraDrive Mounting and Installation 6-15

Steel Grid Fixed Resistors IP 20 Type B

Fig.: 6-17 Type B1 – B4

Type Dimensions in mm Weight in kg

BTHB1T1D

B1 490 300 270 380 270 M10 9,5 B2 490 400 270 380 370 M10 13 B3 490 600 270 380 570 M10 22 B4 490 800 270 380 770 M10 33 B5 490 1000 270 380 970 M10 44

Tab.: 6-1 Dimensions table braking resistor type B

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Page 92

6-16 Mounting and Installation Rexroth IndraDrive

Steel Grid Fixed Resistors IP 20 Type C

Fig.: 6-18 Type C1 – C7

Type Dimensions in mm Weight in kg

BTHB1T1D

C2 595 490 710 570 380 M10 56 C3 795 490 710 770 380 M10 80 C4 995 490 710 970 380 M10 93

Tab.: 6-2 Dimensions table braking resistor type C

Note: Under consideration of the technical data for the minimum

braking resistance and the brake chopper, other braking resistors can be used alternatively.

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Page 93

Rexroth IndraDrive Mounting and Installation 6-17

Dimensions – Motor Filt er HMF

U2 V2 W2 PE

104

125

277

305

330

MBZU0064EN00.FH9

Fig. 6-19: Dimens ions motor filter HMF01.1A-N0K2-D0045-A-500-NNNN

270

MBZU0056EN00.fh9

Fig. 6-20: Dimens ions motor filter HMF01.1A-N0K2-D0073-A-500-NNNN,

HMF01.1A-N0K2-D0095-A-500-NNNN and HMF01.1A-N0K2-D0145-A-500-NNNN

Type Dimensions in mm

BHTB1

H1 0073 225 315 270 175 257 0095 225 315 270 175 257 0145 350 400 260 250 310

Fig. 6-21: Dimensions motor filter

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Page 94

6-18 Mounting and Installation Rexroth IndraDrive

Arrangement of the Components HCS03.1 / Motor Filter HMF

U2 V2 W2 PE

770

125

MBZU0066EN00.FH9

Fig. 6-22: Sample mounting HCS03.1E-W0070 / HMF01.1A-N0K2-D0045

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Page 95

Rexroth IndraDrive Mounting and Installation 6-19

MBZU0057EN00.FH9

Fig. 6-23: Sample mounting HCS03.1E-W0100 0150 0210 / motor filter

DOK-INDRV*-FU*********-IB01-EN-P

HCS03.1E- H B B1

W0100 720 225 175 W0150 720 225 175 W0210 780 350 250

Fig. 6-24: Dimensions table for sample mounting HCS03.1E-…/ motor filter

HMF

Page 96

6-20 Mounting and Installation Rexroth IndraDrive

Arrangement of the Components HCS03.1 / Motor Filter and Mains Filter

770

1075

U2 V2 W2 PE

PE L3

L1 L2 L3 PE

125

MBZU0067EN00.FH9

Fig. 6-25: Arrangement HCS03.1E-W0070 / motor filter and mains filter

+ HAS05.1-001 + HAS05.1-002

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Page 97

Rexroth IndraDrive Mounting and Installation 6-21

DOK-INDRV*-FU*********-IB01-EN-P

MBZU0068EN00.FH9

Fig. 6-26: Arrangement of device 0100, 0150, 0210 / motor filter and mains

filter

HCS03.1E- H B1 B

W0100 980 175 225 W0150 980 175 225 W0210 1090 250 350

Fig. 6-27: Dimensions table for sample mounting HCS03.1E-.. / mains filter /

motor filter

Page 98

6-22 Mounting and Installation Rexroth IndraDrive

Combination of Drive Controllers of the Rexroth IndraDrive C Product Range

Fig. 6-28: Rexroth IndraDrive C components

Note: Observe that using HAS04 accessory at the HCS arranged at

the utmost left position requires additional space of 30 mm. Rexroth IndraDrive components are arranged in line to the

right starting from the supplying device. Arrange the drive controllers with high capacity as close to the supplying unit as possible.

The HAS02 accessories in the figure require additional mounting clearance.

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Page 99

Rexroth IndraDrive Mounting and Installation 6-23

Dimension Z is significantly determined by the involved components. The

table below contains the dimensions Z between the component ar ranged to the left and the component arranged to the right.

Component left Component right

HCS02.1E-W0012 HCS02.1E-W0028 HCS02.1E-W0054 HCS02.1E-W0070

HCS02.1E-W0054 HCS02.1E-W0070

HCS02.1E-W0012 HCS02.1E-W0028

HCS02.1E-W0054 HCS02.1E-W0070 HCS03.1E-W0070 HCS03.1E-W0100 HCS03.1E-W0150

HCS03.1E-W0210 HCS03.1E-W0210

HCS03.1E-W0070 HCS03.1E-W0100 HCS03.1E-W0150

HCS03.1E-W0210

HCS02.1E-W0012 HCS02.1E-W0028 HCS02.1E-W0054 HCS02.1E-W0070

HCS02.1E-W0012 HCS02.1E-W0028 HCS03.1E-W0070 HCS03.1E-W0100 HCS03.1E-W0150

HCS03.1E-W0210

HCS03.1E-W0070 HCS03.1E-W0100 HCS03.1E-W0150

Dimension Z

[mm]

(without distance

between the

components)

57,5

(without distance

between the

components)

62,5

(without distance

between the

components)

100

(without distance

between the

components)

(without distance

between the

components)

(without distance

between the

components)

DOK-INDRV*-FU*********-IB01-EN-P

Fig. 6-29: Table for dimension Z

Page 100

6-24 Mounting and Installation Rexroth IndraDrive

unit

Multiple-Line Arrangement of Drive Controllers

Control Cabinet with Multiple-Line Structure

Note: Particular attention should be paid to the maxim um allowed air

intake temperature of components when they are arranged in multiple lines in the control cabinet. Where nec essary, cooling air guides are to be provided with blowers s pecially used for this purpose.

additional blower

conveying direction of heated air

in flow-off area

intake area of cooling air for

upper device line

conveying direction of heated air

in flow-off area

intake area of cooling air for

lower device line

outlet air to cooling unit

air guide

supply air from cooling

Fig. 6-30: Example of arrangement for multiple-line structure with components

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