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Rexroth IndraDrive CDrive ControllersPower Sections HCS03.1

R911307049Edition 03

Project Planning Manual

About this Documentation Rexroth IndraDrive C HCS03.1

DOK-INDRV*-HCS03.1****-PR03-EN-P

Rexroth Indra Drive C

Drive Controllers

Power Sections HCS03.1

Project Planning Manual


• Box: M8*-01VRS• Document Number 120-2400-B316-03/EN

This documentation provides information on …

• how to design the control cabinet• how to mount the drive controllers in the control cabinet• how to install the drive system

Description ReleaseDate

Notes

DOK-INDRV*-HCS03.1****-PR01-EN 03.2004 First Edition

DOK-INDRV*-HCS03.1****-PR02-EN 02.2005 Revision

DOK-INDRV*-HCS03.1****-PR03-EN 01.2006 Revision

Bosch Rexroth AG, 2006

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

The specified data only serve to describe the product. No statementsconcerning a certain condition or suitability for a certain application can bederived from our information. The given information does not release theuser from the obligation of own judgement and verification. It must beremembered that our products are subject to a natural process of wearand aging.

Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. MainTelephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85http://www.boschrexroth.com/

Dept. BRC/EDY1 (RR, US)

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

Title

Type of Documentation

Document Typecode

Internal File Reference

Purpose of Documentation

Copyright

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Published by

Note

Rexroth IndraDrive C HCS03.1 Contents I


Contents

1 Indroduction 1-1

1.1 Documentation.............................................................................................................................. 1-1

About this Documentation ....................................................................................................... 1-1

Documentations - Overview .................................................................................................... 1-2

1.2 Basic Design of a Drive Controller................................................................................................ 1-3

1.3 General Information on How to Install the Drive Controller .......................................................... 1-5

2 Important Directions for Use 2-1

2.1 Appropriate Use............................................................................................................................ 2-1

Introduction .............................................................................................................................. 2-1

Areas of Use and Application .................................................................................................. 2-2

2.2 Inappropriate Use ......................................................................................................................... 2-2

3 Safety Instructions for Electric Drives and Controls 3-1

3.1 General Information ...................................................................................................................... 3-1

Using the Safety Instructions and Passing them on to Others................................................ 3-1

Instructions for Use.................................................................................................................. 3-1

Explanation of Warning Symbols and Degrees of Hazard Seriousness ................................. 3-3

Hazards by Improper Use........................................................................................................ 3-4

3.2 Instructions with Regard to Specific Dangers............................................................................... 3-5

Protection Against Contact with Electrical Parts ..................................................................... 3-5

Protection Against Electric Shock by Protective Low Voltage (PELV) .................................... 3-6

Protection Against Dangerous Movements ............................................................................. 3-7

Protection Against Magnetic and Electromagnetic Fields During Operation andMounting .................................................................................................................................. 3-9

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

Protection During Handling and Mounting............................................................................. 3-11

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

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

4 Identification 4-1

4.1 Device Types ................................................................................................................................ 4-1

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

4.2 Type Plates ................................................................................................................................... 4-2

Type Plate Power Section (Example)...................................................................................... 4-3

Type Plate Control Section...................................................................................................... 4-3

4.3 Scope of Delivery.......................................................................................................................... 4-3

Overview.................................................................................................................................. 4-3

II Contents Rexroth IndraDrive C HCS03.1


5 Mechanical Data 5-1

5.1 Dimensions ................................................................................................................................... 5-1

Drive Controller HCS03.1E-W0070......................................................................................... 5-1

Drive Controller HCS03.1E-W0070 with HAS02 ..................................................................... 5-1

Drive Controller HCS03.1E-W0100, -W0150 .......................................................................... 5-2

Drive Controller HCS03.1E-W0100, -W0150 with HAS02 ...................................................... 5-2

Drive Controller HCS03.1E-W0210......................................................................................... 5-3

Drive Controller HCS03.1E-W0210 with HAS02 ..................................................................... 5-3

5.2 Weight........................................................................................................................................... 5-6

Mounting Position .................................................................................................................... 5-7

Temperatures Above the Top of the Device............................................................................ 5-7

6 Electrical Data 6-1

6.1 Power Section - Mains Supply...................................................................................................... 6-1

6.2 Power Section - DC Bus ............................................................................................................... 6-1

6.3 Power Section - DC Bus Power.................................................................................................... 6-2

Mains Connection Power and DC Bus Continuous Power ..................................................... 6-3

6.4 Power Section - Braking Resistor................................................................................................. 6-6

6.5 Power Section - Inverter ............................................................................................................... 6-7

6.6 Power Section - Examples of Allowed Output Current Profiles.................................................... 6-8

6.7 Power Section - Operating Standard Motors.............................................................................. 6-10

6.8 Power Section - Cooling, Power Dissipation, Insulation Resistance, Sound Pressure.............. 6-11

6.9 Control Voltage ........................................................................................................................... 6-12

Devices with Control Voltage Generation from DC Bus (HCS03.1E-W0xxx-NNxV)............. 6-12

6.10 Connections................................................................................................................................ 6-14

Overall Connection Diagram ................................................................................................. 6-14

6.11 Connections at Power Section HCS03.1.................................................................................... 6-15

Optional Control Voltage ....................................................................................................... 6-18

DC Bus .................................................................................................................................. 6-18

X1, Module Bus ..................................................................................................................... 6-19

X3, Mains Connection ........................................................................................................... 6-20

X5, Motor Connection............................................................................................................ 6-21

X6, Motor Temperature Monitoring and Motor Holding Brake .............................................. 6-23

X9, Braking Resistor.............................................................................................................. 6-26

XS1, Shield Connection......................................................................................................... 6-27

Ground Connection of Housing ............................................................................................. 6-27

Connection Point of Equipment Grounding Conductor ......................................................... 6-28

7 Touch Guard 7-1

Cutouts .................................................................................................................................... 7-1

Mounting .................................................................................................................................. 7-2

8 Replacing Devices 8-1

8.1 General Information ...................................................................................................................... 8-1

8.2 How to Proceed When Replacing Devices................................................................................... 8-1

Replacing the Drive Controller................................................................................................. 8-1

Rexroth IndraDrive C HCS03.1 Contents III


Replacing the Motor ................................................................................................................ 8-2

Replacing Cables .................................................................................................................... 8-3

8.3 Fault Report .................................................................................................................................. 8-4

9 Disposal and Environmental Protection 9-1

9.1 Disposal ........................................................................................................................................ 9-1

Products................................................................................................................................... 9-1

Packaging Materials ................................................................................................................ 9-1

9.2 Environmental Protection.............................................................................................................. 9-1

No Release of Hazardous Substances ................................................................................... 9-1

Materials Contained in the Products ....................................................................................... 9-1

Recycling ................................................................................................................................. 9-1

10 Service & Support 10-1

10.1 Helpdesk..................................................................................................................................... 10-1

10.2 Service-Hotline ........................................................................................................................... 10-1

10.3 Internet........................................................................................................................................ 10-1

10.4 Vor der Kontaktaufnahme... - Before contacting us... ................................................................ 10-1

10.5 Kundenbetreuungsstellen - Sales & Service Facilities ............................................................... 10-2

11 Index 11-1

IV Contents Rexroth IndraDrive C HCS03.1


Rexroth IndraDrive C HCS03.1 Indroduction 1-1


1 Indroduction

1.1 Documentation

About this DocumentationThis documentation basically contains the technical data of the RexrothIndraDrive C HCS03.1 drive controllers.

WARNING

Personal injury and property damage caused byincorrect project planning for applications,machines and installations!⇒ Take the content of the Project Planning Manual

"Rexroth IndraDrive Drive System" (DOK-INDRV*-SYSTEM*****-PRxx-EN-P; part no. R911309636)into account.

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

• specifications for the components of the drive system• configuration of the drive system components• arrangement of the components in the control cabinet• electromagnetic compatibility (EMC)• types of mains connection• requirements to the mains connection• control circuits for the mains connection• connections of the components in the drive system• fusing and selecting the mains contactor• accessories in the drive system• calculations (determining appropriate drive controller; mains

connection; leakage capacitance; operating data of mains filters;selecting the 24V supply; braking behavior when using a DC busresistor unit)

• notes on how to replace devices

1-2 Indroduction Rexroth IndraDrive C HCS03.1


Documentations - OverviewFor project planning of the drive system the following documentations areavailable:

Title Kind of documentation Document typecode1)

Rexroth IndraDriveDrive System

Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P

Rexroth IndraDriveDrive ControllersControl Sections CSx

Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P

Rexroth IndraDrive MDrive ControllersPower Sections HMx

Project Planning Manual DOK-INDRV*-HMS+HMD****-PRxx-EN-P


Project Planning Manual DOK-INDRV*-HCS02.1****-PRxx-EN-P


Project Planning Manual DOK-INDRV*-HCS03.1****-PRxx-EN-P

Rexroth IndraDriveSupply Units

Project Planning Manual DOK-INDRV*-HMV-*******-PRxx-EN-P

Rexroth IndraDriveAdditional Components

Project Planning Manual DOK-INDRV*-ADDCOMP****-PRxx-EN-P

Rexroth IndraDriveIntegrated Safety Technology

Functional and ApplicationDescription

DOK-INDRV*-SI*-**VRS**-FKxx-EN-P

Rexroth IndraDriveFirmware for Drive Controllers

Functional Description DOK-INDRV*-MP*-02VRS**-FKxx-EN-P






Parameter Description DOK-INDRV*-GEN-**VRS**-PAxx-EN-P


Troubleshooting Guide DOK-INDRV*-GEN-**VRS**-WAxx-EN-P

Rexroth Connection Cables Selection Data DOK-CONNEC-CABLE*STAND-AUxx-EN-P

Rexroth IndraDyn AAsynchronous Motors MAD/MAF

Project Planning Manual DOK-MOTOR*-MAD/MAF****-PRxx-EN-P

Rexroth IndraDyn SSynchronous Motors MSK

Project Planning Manual DOK-MOTOR*-MSK********-PRxx-EN-P

Rexroth IndraDyn TSynchronous Torque Motors MBT

Project Planning Manual DOK-MOTOR*-MBT********-PRxx-EN-P

Rexroth IndraDyn HSynchronous Kit –Spindle MotorsMBS-H

Project Planning Manual DOK-MOTOR*-MBS-H******-PRxx-EN-P

Rexroth IndraDyn LSynchronous Linear Motors MLF

Project Planning Manual DOK-MOTOR*-MLF********-PRxx-EN-P

Safety Instructions for Electrical Drives Safety Guidelines DOK-GENERAL-DRIVE******-SVSx-MS-P

1) In the document typecodes "xx" is a wild card for the current editionof the documentation (example: "PR01" is the first edition of aProject Planning Manual)

Fig. 1-1: Documentations - overview



1.2 Basic Design of a Drive Controller

�

�

1: Power section2: Control section

Fig. 1-2: Basic design

The drive controller consists of two essential parts:

• Power section• Control section



Power SectionThe following are connected to the power section:

• mains voltage• motor• 24 V power supply (optional)• module bus (for cross communication in the case of DC bus

connection with other devices)

• motor holding brake (optional)• motor temperature sensor (optional)• braking resistor (optional)

Control SectionThe control section is a separate component that is plugged into thepower section. The drive controller is supplied ex works complete withcontrol section.

The control section may only be replaced by qualified personnel.

The contacts X31/1 and X31/2 are connected to the control section as Bbcontacts.

Note: The control sections are described in a separatedocumentation (see page 1-2).



1.3 General Information on How to Install the Drive Controller

Damage can be caused to the drive controller or circuit boards ifelectrostatic charging present in people and/or tools is discharged acrossthem. Therefore, please note the following information:

CAUTION

Electrostatic charges can cause damage toelectronic components and interfere with theiroperational safety!Exposed conductive parts coming into contact with

components and circuit boards must be discharged bymeans of grounding. Otherwise errors may occurwhen triggering motors and moving elements.

Such exposed conductive parts include:

• the copper bit when soldering• the human body (ground connection caused by touching a conductive,

grounded item)

• parts and tools (place them on a conductive support)Endangered components may only be stored or dispatched in conductivepackaging.

Note: Rexroth connection diagrams are only to be used forproducing installation connection diagrams! The machinemanufacturer’s installation connection diagrams must be usedfor wiring the installation!

• Lay signal lines separately from the load resistance lines because ofthe occurrence of interference.

• Transmit analog signals (e.g. command values, actual values) viashielded lines.

• Do not connect mains, DC bus or power leads to low voltages or allowthem to come into contact with these.

• When carrying out a high voltage test or an applied-overvoltagewithstand test on the machine’s electrical equipment, disconnect allconnections to the devices. This protects the electronic components(allowed in accordance with EN 60204-1). During their routine testing,Rexroth drive components are tested for high voltage and insulation inaccordance with EN 50178.

CAUTION

Risk of damage to the drive controller byconnecting and disconnecting live connections!⇒ Do not connect and disconnect live connections.

Rexroth IndraDrive C HCS03.1 Important Directions for Use 2-1


2 Important Directions for Use

2.1 Appropriate Use

IntroductionRexroth products represent state-of-the-art developments andmanufacturing. They are tested prior to delivery to ensure operating safetyand reliability.

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

Note: Rexroth as manufacturer is not liable for any damagesresulting from inappropriate use. In such cases, the guaranteeand the right to payment of damages resulting frominappropriate use are forfeited. The user alone carries allresponsibility of the risks.

Before using Rexroth products, make sure that all the pre-requisites foran appropriate use of the products are satisfied:

• Personnel that in any way, shape or form uses our products must firstread and understand the relevant safety instructions and be familiarwith appropriate use.

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

• Do not mount damaged or faulty products or use them in operation.• Make sure that the products have been installed in the manner

described in the relevant documentation.

2-2 Important Directions for Use Rexroth IndraDrive C HCS03.1


Areas of Use and ApplicationDrive controllers made by Bosch Rexroth are designed to controlelectrical motors and monitor their operation.

Control and monitoring of the motors may require additional sensors andactors.

Note: The drive controllers may only be used with the accessoriesand parts specified in this document. If a component has notbeen specifically named, then it may not be either mounted orconnected. The same applies to cables and lines.

Operation is only permitted in the specified configurations andcombinations of components using the software and firmwareas specified in the relevant Functional Descriptions.

Every drive controller has to be programmed before commissioning,making it possible for the motor to execute the specific functions of anapplication.

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

To ensure an application-specific use, the drive controllers are availablewith different drive power and different interfaces.

Typical applications of the drive controllers include:

• handling and mounting systems,• packaging and food machines,• printing and paper processing machines and• machine tools.The drive controllers may only be operated under the assembly andinstallation conditions described in this documentation, in the specifiedposition of normal use and under the ambient conditions as described(temperature, degree of protection, humidity, EMC, etc.).

2.2 Inappropriate Use

Using the drive controllers outside of the operating conditions described inthis documentation and outside of the indicated technical data andspecifications is defined as "inappropriate use".

Drive controllers must not be used, if…

• …they are subject to operating conditions that do not meet thespecified ambient conditions. This includes, for example, operationunder water, under extreme temperature fluctuations or extremely highmaximum temperatures.

• Furthermore, the drive controllers must not be used in applicationswhich have not been expressly authorized by Rexroth.

• Please carefully follow the specifications outlined in the general SafetyInstructions!

Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric Drives and Controls 3-1


3 Safety Instructions for Electric Drives and Controls

3.1 General Information

Using the Safety Instructions and Passing them on to OthersDo not attempt to install or commission this device without first reading alldocumentation provided with the product. Read and understand thesesafety instructions and all user documentation prior to working with thedevice. If you do not have the user documentation for the device, contactyour responsible Bosch Rexroth sales representative. Ask for thesedocuments to be sent immediately to the person or persons responsiblefor the safe operation of the device.

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

WARNING

Improper use of these devices, failure to followthe safety instructions in this document ortampering with the product, including disablingof safety devices, may result in materialdamage, bodily harm, electric shock or evendeath!

Instructions for UseRead these instructions before the initial startup of the equipment in orderto eliminate the risk of bodily harm or material damage. Follow thesesafety instructions at all times.

• Bosch Rexroth AG is not liable for damages resulting from failure toobserve the warnings provided in this documentation.

• Read the operating, maintenance and safety instructions in yourlanguage before starting up the machine. If you find that you cannotcompletely understand the documentation for your product, pleaseask your supplier to clarify.

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

• Only assign trained and qualified persons to work with electricalinstallations:

• Only persons who are trained and qualified for the use andoperation of the device may work on this device or within itsproximity. The persons are qualified if they have sufficientknowledge of the assembly, installation and operation of theequipment as well as an understanding of all warnings andprecautionary measures noted in these instructions.

• Furthermore, they must be trained, instructed and qualified toswitch electrical circuits and devices on and off in accordance withtechnical safety regulations, to ground them and to mark themaccording to the requirements of safe work practices. They musthave adequate safety equipment and be trained in first aid.

• Only use spare parts and accessories approved by the manufacturer.• Follow all safety regulations and requirements for the specific

application as practiced in the country of use.

3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C HCS03.1


• The devices have been designed for installation in industrialmachinery.

• The ambient conditions given in the product documentation must beobserved.

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

• The information given in the documentation of the product with regardto the use of the delivered components contains only examples ofapplications and suggestions.

The machine and installation manufacturer must

• make sure that the delivered components are suited for hisindividual application and check the information given in thisdocumentation with regard to the use of the components,

• make sure that his application complies with the applicablesafety regulations and standards and carry out the requiredmeasures, modifications and complements.

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

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

• The instructions for installation in accordance with EMC requirementscan be found in the documentation "EMC in Drive and ControlSystems".

• The machine or installation manufacturer is responsible forcompliance with the limiting values as prescribed in the nationalregulations.

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



Explanation of Warning Symbols and Degrees of Hazard SeriousnessThe safety instructions describe the following degrees of hazardseriousness. The degree of hazard seriousness informs about theconsequences resulting from non-compliance with the safety instructions:

Warning symbol with signalword

Degree of hazard seriousness accordingto ANSI Z 535

DANGER

Death or severe bodily harm will occur.

WARNING

Death or severe bodily harm may occur.

CAUTION

Bodily harm or material damage may occur.

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



Hazards by Improper Use

DANGER

High electric voltage and high working current!Risk of death or severe bodily injury by electricshock!

DANGER

Dangerous movements! Danger to life, severebodily harm or material damage byunintentional motor movements!

WARNING

High electric voltage because of incorrectconnection! Risk of death or bodily injury byelectric shock!

WARNING

Health hazard for persons with heartpacemakers, metal implants and hearing aids inproximity to electrical equipment!

CAUTION

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

CAUTION

Risk of injury by improper handling! Risk ofbodily injury by bruising, shearing, cutting,hitting, or improper handling of pressurizedlines!

CAUTION

Risk of injury by improper handling of batteries!



3.2 Instructions with Regard to Specific Dangers

Protection Against Contact with Electrical Parts

Note: This section only concerns devices and drive components withvoltages of more than 50 Volt.

Contact with parts conducting voltages above 50 Volts can causepersonal danger and electric shock. When operating electrical equipment,it is unavoidable that some parts of the devices conduct dangerousvoltage.

DANGER

High electrical voltage! Danger to life, electricshock and severe bodily injury!⇒ Only those trained and qualified to work with or on

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

⇒ Follow general construction and safety regulationswhen working on electrical power installations.

⇒ Before switching on the device, the equipmentgrounding conductor must have been non-detachably connected to all electrical equipment inaccordance with the connection diagram.

⇒ Do not operate electrical equipment at any time,even for brief measurements or tests, if theequipment grounding conductor is not permanentlyconnected to the mounting points of the componentsprovided for this purpose.

⇒ Before working with electrical parts with voltagepotentials higher than 50 V, the device must bedisconnected from the mains voltage or powersupply unit. Provide a safeguard to preventreconnection.

⇒ With electrical drive and filter components, observethe following:Wait 30 minutes after switching off power to allowcapacitors to discharge before beginning to work.Measure the voltage on the capacitors beforebeginning to work to make sure that the equipment issafe to touch.

⇒ Never touch the electrical connection points of acomponent while power is turned on.

⇒ Install the covers and guards provided with theequipment properly before switching the device on.Before switching the equipment on, cover andsafeguard live parts safely to prevent contact withthose parts.

⇒ A residual-current-operated circuit-breaker or r.c.d.cannot be used for electric drives! Indirect contactmust be prevented by other means, for example, byan overcurrent protective device according to therelevant standards.

⇒ Secure built-in devices from direct touching ofelectrical parts by providing an external housing, forexample a control cabinet.

European countries: according to EN 50178/ 1998,



section 5.3.2.3.

USA: See National Electrical Code (NEC), NationalElectrical Manufacturers' Association (NEMA), as well aslocal engineering regulations. The operator must observeall the above regulations at any time.

With electrical drive and filter components, observe the following:

DANGER

High housing voltage and large leakage current!Risk of death or bodily injury by electric shock!⇒ Before switching on, the housings of all electrical

equipment and motors must be connected orgrounded with the equipment grounding conductor tothe grounding points. This is also applicable beforeshort tests.

⇒ The equipment grounding conductor of the electricalequipment and the units must be non-detachablyand permanently connected to the power supply unitat all times. The leakage current is greater than3.5 mA.

⇒ Over the total length, use copper wire of a crosssection of a minimum of 10 mm2 for this equipmentgrounding connection!

⇒ Before start-up, also in trial runs, always attach theequipment grounding conductor or connect with theground wire. Otherwise, high voltages may occur atthe housing causing electric shock.

Protection Against Electric Shock by Protective Low Voltage (PELV)All connections and terminals with voltages between 5 and 50 Volt atRexroth products are protective extra-low voltage systems which areprovided with touch guard according to the product standards.

WARNING

High electric voltage by incorrect connection!Risk of death or bodily injury by electric shock!⇒ To all connections and terminals with voltages

between 0 and 50 Volt, only devices, electricalcomponents, and conductors may be connectedwhich are equipped with a PELV (Protective Extra-Low Voltage) system.

⇒ Connect only voltages and circuits which are safelyisolated from dangerous voltages. Safe isolation isachieved for example by isolating transformers, safeoptocouplers or battery operation without mainsconnection.



Protection Against Dangerous MovementsDangerous movements can be caused by faulty control of connectedmotors. Some common examples are:

• improper or wrong wiring of cable connections• incorrect operation of the equipment components• wrong input of parameters before operation• malfunction of sensors, encoders and monitoring devices• defective components• software or firmware errorsDangerous movements can occur immediately after equipment isswitched on or even after an unspecified time of trouble-free operation.

The monitoring in the drive components will normally be sufficient to avoidfaulty operation in the connected drives. Regarding personal safety,especially the danger of bodily harm and material damage, this alonecannot be relied upon to ensure complete safety. Until the integratedmonitoring functions become effective, it must be assumed in any casethat faulty drive movements will occur. The extent of faulty drivemovements depends upon the type of control and the state of operation.



DANGER

Dangerous movements! Danger to life, risk ofinjury, severe bodily harm or material damage!⇒ For the above reasons, ensure personal safety by

means of qualified and tested higher-level monitoringdevices or measures integrated in the installation.They have to be provided for by the user accordingto the specific conditions within the installation and ahazard and fault analysis. The safety regulationsapplicable for the installation have to be taken intoconsideration. Unintended machine motion or othermalfunction is possible if safety devices are disabled,bypassed or not activated.

To avoid accidents, bodily harm and/or materialdamage:

⇒ Keep free and clear of the machine’s range ofmotion and moving parts. Possible measures toprevent people from accidentally entering themachine’s range of motion:- use safety fences

- use safety guards

- use protective coverings

- install light curtains or light barriers

⇒ Fences and coverings must be strong enough toresist maximum possible momentum.

⇒ Mount the emergency stop switch in the immediatereach of the operator. Verify that the emergency stopworks before startup. Don’t operate the device if theemergency stop is not working.

⇒ Isolate the drive power connection by means of anemergency stop circuit or use a safety relatedstarting lockout to prevent unintentional start.

⇒ Make sure that the drives are brought to a safestandstill before accessing or entering the dangerzone.

⇒ Additionally secure vertical axes against falling ordropping after switching off the motor power by, forexample:- mechanically securing the vertical axes,

- adding an external braking/ arrester/ clampingmechanism or

- ensuring sufficient equilibration of the verticalaxes.

The standard equipment motor brake or an externalbrake controlled directly by the drive controller arenot sufficient to guarantee personal safety!



⇒ Disconnect electrical power to the equipment using amaster switch and secure the switch againstreconnection for:- maintenance and repair work

- cleaning of equipment

- long periods of discontinued equipment use

⇒ Prevent the operation of high-frequency, remotecontrol and radio equipment near electronics circuitsand supply leads. If the use of such devices cannotbe avoided, verify the system and the installation forpossible malfunctions in all possible positions ofnormal use before initial startup. If necessary,perform a special electromagnetic compatibility(EMC) test on the installation.

Protection Against Magnetic and Electromagnetic Fields DuringOperation and Mounting

Magnetic and electromagnetic fields generated by current-carryingconductors and permanent magnets in motors represent a seriouspersonal danger to those with heart pacemakers, metal implants andhearing aids.

WARNING

Health hazard for persons with heartpacemakers, metal implants and hearing aids inproximity to electrical equipment!⇒ Persons with heart pacemakers and metal implants

are not permitted to enter following areas:- Areas in which electrical equipment and parts are

mounted, being operated or commissioned.

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

⇒ If it is necessary for somebody with a pacemaker toenter such an area, a doctor must be consulted priorto doing so. The interference immunity of present orfuture implanted heart pacemakers differs greatly, sothat no general rules can be given.

⇒ Those with metal implants or metal pieces, as wellas with hearing aids must consult a doctor beforethey enter the areas described above. Otherwisehealth hazards may occur.



Protection Against Contact with Hot Parts

CAUTION

Hot surfaces at motor housings, on drivecontrollers or chokes! Danger of injury! Dangerof burns!⇒ Do not touch surfaces of device housings and

chokes in the proximity of heat sources! Danger ofburns!

⇒ Do not touch housing surfaces of motors! Danger ofburns!

⇒ According to operating conditions, temperatures canbe higher than 60 °C, 140 °F during or afteroperation.

⇒ Before accessing motors after having switched themoff, let them cool down for a sufficiently long time.Cooling down can require up to 140 minutes!Roughly estimated, the time required for coolingdown is five times the thermal time constantspecified in the Technical Data.

⇒ After switching drive controllers or chokes off, wait15 minutes to allow them to cool down beforetouching them.

⇒ Wear safety gloves or do not work at hot surfaces.⇒ For certain applications, the manufacturer of the end

product, machine or installation, according to therespective safety regulations, has to take measuresto avoid injuries caused by burns in the endapplication. These measures can be, for example:warnings, guards (shielding or barrier), technicaldocumentation.



Protection During Handling and MountingIn unfavorable conditions, handling and assembling certain parts andcomponents in an improper way can cause injuries.

CAUTION

Risk of injury by improper handling! Bodilyinjury by bruising, shearing, cutting, hitting!⇒ Observe the general construction and safety

regulations on handling and assembly.⇒ Use suitable devices for assembly and transport.⇒ Avoid jamming and bruising by appropriate

measures.⇒ Always use suitable tools. Use special tools if

specified.⇒ Use lifting equipment and tools in the correct

manner.⇒ If necessary, use suitable protective equipment (for

example safety goggles, safety shoes, safetygloves).

⇒ Do not stand under hanging loads.⇒ Immediately clean up any spilled liquids because of

the danger of skidding.

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

CAUTION

Risk of injury by improper handling!⇒ Do not attempt to reactivate low batteries by heating

or other methods (risk of explosion andcauterization).

⇒ Do not recharge the batteries as this may causeleakage or explosion.

⇒ Do not throw batteries into open flames.⇒ Do not dismantle batteries.⇒ Do not damage electrical parts installed in the

devices.

Note: Environmental protection and disposal! The batteries installedin the product are considered dangerous goods during land,air, and sea transport (risk of explosion) in the sense of thelegal regulations. Dispose of used batteries separate fromother waste. Observe the local regulations in the country ofassembly.



Protection Against Pressurized SystemsAccording to the information given in the Project Planning Manuals,motors cooled with liquid and compressed air, as well as drive controllers,can be partially supplied with externally fed, pressurized media, such ascompressed air, hydraulics oil, cooling liquids, and cooling lubricatingagents. In these cases, improper handling of external supply systems,supply lines, or connections can cause injuries or damages.

CAUTION

Risk of injury by improper handling of pressurizedlines!⇒ Do not attempt to disconnect, open, or cut

pressurized lines (risk of explosion).⇒ Observe the respective manufacturer's operating

instructions.⇒ Before dismounting lines, relieve pressure and

empty medium.⇒ Use suitable protective equipment (for example

safety goggles, safety shoes, safety gloves).⇒ Immediately clean up any spilled liquids from the

floor.

Note: Environmental protection and disposal! The agents used tooperate the product might not be economically friendly.Dispose of ecologically harmful agents separate from otherwaste. Observe the local regulations in the country ofassembly.

Rexroth IndraDrive C HCS03.1 Identification 4-1


4 Identification

4.1 Device Types

Type Code

Note: The following figure illustrates the basic structure of the typecode. Your sales representative will help with the currentstatus of available versions.

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4-2 Identification Rexroth IndraDrive C HCS03.1


4.2 Type Plates

Each drive component is marked by a type designation.

There is a type plate attached to all devices.

A label (cable mark) is wrapped around ready-made cables. This labelindicates the type designation and the length. (The designation of thecable itself - without connector - is printed on the cable sheath.)

The identification of accessories packed in bags is either printed on thebag or indicated in an accompanying note.

Type Plate Arrangement

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Rexroth IndraDrive C HCS03.1 Identification 4-3


Type Plate Power Section (Example)

(-.�/�('�0''��

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Example 04W12 means year 2004 week 12

Production week

Serial Number Barcode Hardware index

Part number

Producing Country

Device type

Fig. 4-3: Type plate power section

Type Plate Control SectionSee Project Planning Manual of the control sections.

4.3 Scope of Delivery

Overview

as standard optional

Power section Control section (with options where required)

Touch guard Accessories HAS02

Connector X6 Accessories HAS01

Connector X3, X5

Connector X9 (forHCS03.1E-W0070)

Accessories HAS01 optional

Further optional accessories

Fig. 4-4: Scope of delivery

4-4 Identification Rexroth IndraDrive C HCS03.1


Rexroth IndraDrive C HCS03.1 Mechanical Data 5-1


5 Mechanical Data

5.1 Dimensions

Drive Controller HCS03.1E-W0070

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all dimensions in mmFig. 5-1: Dimensional drawing HCS03.1E-W0070

Drive Controller HCS03.1E-W0070 with HAS02

Fig. 5-2: Dimensional drawing HCS03.1E-W0070 with HAS02

5-2 Mechanical Data Rexroth IndraDrive C HCS03.1


Drive Controller HCS03.1E-W0100, -W0150

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all dimensions in mmFig. 5-3: Dimensional drawing HCS03.1E-W0100 and HCS03.1E-W150

Drive Controller HCS03.1E-W0100, -W0150 with HAS02

all dimensions in mmFig. 5-4: Dimensional drawing HCS03.1E-W0100 and HCS03.1E-W150 with

HAS02



Drive Controller HCS03.1E-W0210

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all dimensions in mmFig. 5-5: Dimensional drawing HCS03.1E-W0210

Drive Controller HCS03.1E-W0210 with HAS02

all dimensions in mmFig. 5-6: Dimensional drawing HCS03.1E-W0210 with HAS02



Boring Dimensions

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all dimensions in mmFig. 5-7: Boring dimensions HCS03.1E-W0070*



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all dimensions in mmFig. 5-9: Boring dimensions HCS03.1E-W0210

5.2 Weight

Device Weight in kg

HCS03.1E-W0070 13

HCS03.1E-W0100 20

HCS03.1E-W0150 20

HCS03.1E-W0210 38

Fig. 5-10: Weight of the devices

Note: The control section is not contained in the weight data.The weight of the control section is about 0.4 kg.



Mounting PositionDrive controllers and DC bus resistor unit should be mounted in such away that their longitudinal axis corresponds to the natural direction ofconvection (motor and power connections facing downwards).

In this way, natural convection supports the forced cooling air flow. Thisavoids the generation of pockets of heat in the drive controller.

Temperatures Above the Top of the DeviceThe drive controllers have a high efficiency. Outlet temperatures higherthan the ambient temperature are nevertheless produced at the top of thedevices, among other things due to the converted energies. High outlettemperatures are particularly produced in the case of insufficient coolingor when the cooling air current (blower failure) fails.

CAUTION

Risk of damage caused by too high outlettemperatures!⇒ When mounting and installing other components,

make sure the distance to the top of the drivecontrollers is sufficient.

⇒ You have to take into account that higher outlettemperatures can occur when the cooling air currentfails.

Outlet Temperatures

Designation Symbol Unit HCS03.1

temperature risewith distance of10 mm from top ofdevice

∆T K 30

Fig. 5-11: Outlet temperatures

Rexroth IndraDrive C HCS03.1 Electrical Data 6-1


6 Electrical Data

Note: The current and power data below apply when the allowedmotor cable length is complied with (see data in section "X5,Motor Connection"). They refer to 3AC400 V.

6.1 Power Section - Mains Supply

Designation Symbol Unit HCS03.1E-W0070

HCS03.1E-W0100

HCS03.1E-W0150

HCS03.1E-W0210

three-phase mainsconnection allowed

single-phase mainsconnection

not allowed

rotary field no rotary field condition

total power factor TPF atPDC with / without mainschoke

TPF 0,85/0,57 0,83/0,59 0,81/0,61 0,78/0,62

power factor offundamental componentDPF PDC with / withoutmains choke

cosφh1 0,95/0,64 0,95/0,67 0,94/0,70 0,93/0,73

assigned mains chokeHNL01.1E-

0571-N0050-A-500-NNNN

0362-N0080-A-500-NNNN

0240-N0106-A-500-NNNN

0170-N0146-A-500-NNNN

mains input voltage range ULN

V 3AC400…500 +10% -15%

mains frequency fLN

Hz 50…60 ± 2 Hz

mains input continuouscurrent at PDC cont

IL,cont

A 50 80 106 146

maximum inrush current(at max. input voltage)

IL, trans max

(on)

A 2,8 5,7 5,7 17

mains connection powerat PDC_cont;

ULN=AC400V; with

HNL01.1E

SLN

kVA 35 55,2 72,9 99,3

mains connection powerat PDC_cont;

ULN=AC400V; without

HNL01.1E

SLN

kVA 22,6 40,3 54 76

Fig. 6-1: Electrical data: power section - mains supply

6-2 Electrical Data Rexroth IndraDrive C HCS03.1


6.2 Power Section - DC Bus


HCS03.1E-W0100

HCS03.1E-W0150

HCS03.1E-W0210

DC bus voltage range(unloaded)

UDC

V uncontrolledULN * 1,41

internal DC buscapacitance

CDC

mF 0,94 1,44 1,88 4,7

max. allowed external DCbus capacitance

CDCext

mF nicht zulässig 501)

limitation of inrush current charging via resistor;N/O contact: min. 250.000 switching actions

charging bymeans of phase

control1)

storable energy of theinternal DC bus capacitorsat 3AC400V

WDC

Ws 150 230 300 752

braking resistor switch-onthreshold

UDC

(R_DC On)

V 820…850 820…850 820…850 820…850

lower DC bus voltage limit(switch-off threshold)

UDC limit

(min)

V 400 400 400 400

upper DC bus voltage limit(switch-off threshold)

UDC limit

(max)

V 900 900 900 900

capacitance in DC busagainst ground; betweenL+ and L-

CY

nF 100 100 100 100

balancing factor for PDCcont

(for parallel operation withcommon DC bus)with/without mains choke

- 1/0,8 1/0,8 1/0,8 1/0,8

rated power atULN = 400V

without mains chokeminimum inductance ofmains supply

PDC cont

Lmin

kW

µH

13

40

24

40

34

40

47

40

rated power atULN = 400V

with mains choke

PDC cont

kW 25 43 56 85

1): as of hardware index 03 (see type plate)Fig. 6-2: Electrical data: power section - DC bus



6.3 Power Section - DC Bus Power


HCS03.1E-W0100

HCS03.1E-W0150

HCS03.1E-W0210

profile DC bus poweroverload operation

overload capacity:

base DC_

DC_peak

P

P=K

T

PDC_base

t

P

PDC_peak

t

DC bus peak powerULN = 3AC400 V, at Ta=40 °C; t=0,4 s; T=4 swithout mains chokewith mains choke

PDC_peak_1

kW

2040

3359

5489

68124

DC bus powerULN = 3AC400 V, at Ta=40 °C; t=0,4 s; T=4 swithout mains chokewith mains choke

PDC_base_1

kW

1020

1832

2440

3767

DC bus peak powerULN = 3AC400 V, at Ta=40 °C; t=2 s; T=20 swithout mains chokewith mains choke

PDC_peak_3

kW

1836

3053

5387

68124

DC bus powerULN = 3AC400 V, at Ta=40 °C; t=2 s; T=20 swithout mains chokewith mains choke

PDC_base_3

kW

1020

1629

2135

3564

DC bus peak powerULN = 3AC400 V, at Ta=40 °C; t=60 s; T=5 minwithout mains chokewith mains choke

PDC_peak_4

kW

1427

2544

4066

5294

DC bus powerULN = 3AC400 V, at Ta=40 °C; t=60 s; T=5 minwithout mains chokewith mains choke

PDC_base_4

kW

1121

1729

2439

3767

DC bus peak powerULN = 3AC400 V, at Ta=40 °C; t=60 s;T=10 minwithout mains chokewith mains choke

PDC_peak_5

kW

1427

2544

4066

5294

DC bus powerULN = 3AC400 V, at Ta=40 °C; t=60 s;T=10 minwithout mains chokewith mains choke

PDC_base_5

kW

1121

1729

2439

3767

Fig. 6-3: Electrical data: power section - DC bus power



WARNING

Damage due to drive controller overload!⇒ Make sure the specified performance data - peak

power and continuous power - are complied with bycorrect drive dimensioning and selective fusing in themains connection.

Mains Connection Power and DC Bus Continuous PowerThe diagrams below illustrate the interrelation between mains connectionpower (SLN) and DC bus continuous power (PDCcont) with and without theuse of mains chokes.

SLN depending on PDC cont for HCS03.1-E-W0070 @3AC400V/4kHz

0,00

10,00

20,00

30,00

40,00

50,00

2,5 5 7,5 10 12,5 15 17,5 20 22,5 25 27,5 30

PDC cont [kW]

SL

N [

kVA

]

with mains choke without mains choke

Fig. 6-4: Interrelation of SLN / PDC for HCS03.1-E-W0070


0,00

10,00

20,00

30,00

40,00

50,00

60,00

70,00

0 10 20 30 40 50PDC cont [kW]

SL

N [

kVA

]






0,00

20,00

40,00

60,00

80,00

100,00

0 10 20 30 40 50 60 70

PDC cont [kW]

SL

N [

kVA

]




0,00

20,00

40,00

60,00

80,00

100,00

120,00

0 10 20 30 40 50 60 70 80 90 100PDC cont [kW]

SL

N [k

VA

]





6.4 Power Section - Braking Resistor


HCS03.1E-W0100

HCS03.1E-W0150

HCS03.1E-W0210

nominal brakingresistor

RDC(Bleeder) Ohm internally not contained

operating externalbraking resistor(optional)

allowed allowed allowed allowed

braking resistorswitch-on threshold

RDC (R_DC On) V see Functional Description of firmware

balancing factor forPBD(for parallel operationwith common DC bus)

0,8 0,8 0,8 0,8

min. resistance valueof external brakingresistor

RDC(Bleeder) Ohm 17,5 11,7 7 5

allowed continuouspower of externalbraking resistor

Pcontchopper kW 13,2 18,9 25,2 42,6

ext. braking resistorpeak powerat ED=60% andt=120s

PBS kW 22 31,5 42 71

peak power brakechopper for t=1s

Ppeakchopper kW 42 63 97 137

Fig. 6-8: Data power section - braking resistor

60% 72120

peakchoppercontchopper

PP s

s= ×

Pcontchopper: brake chopper continuous powerPpeakchopper: brake chopper peak power

Fig. 6-9: Example for calculating brake chopper continuous power

Example for Calculating BrakeChopper Continuous Power



6.5 Power Section - Inverter


HCS03.1E-W0100

HCS03.1E-W0150

HCS03.1E-W0210

output voltagefundamentalcomponent ofvoltage

Uoutwith open-loop

U/f ctrlwith closed-loop oper.

V

V

UDC * 0,85 / 1,41

UDC * 0,85 / 1,41

output frequencyrange- at fs = 4 kHz– at fs = 8 kHz– at fs = 12 kHz– at fs = 16 kHz

fout Hz

0…4000…800

0…12000…1600

0…4000…800

0…12000…1600

0…4000…800

0…12000…1600

0…4000…800

0…12000…1600

rise of voltage atoutput at ULN=400Vand 15 m motorcable length 1)

dv/dt

10% - 90%

kV/µs

5 5 5 5

maximum outputcurrent

Iout_max (4 kHz)Iout_max (8 kHz)Iout_max (12 kHz)Iout_max (16 kHz)

A 70624734

100866050

15013710586

210190135105

continuous outputcurrent or ratedcurrent

Iout_cont (4 kHz)Iout_cont (8 kHz)Iout_cont (12 kHz)Iout_cont (16 kHz)

A 45332418

73503727

95664837

1451007254

continuous outputcurrent or ratedcurrent

at electric rotationalfrequency 0 Hz

Iout_cont (4 kHz)Iout_cont (8 kHz)Iout_cont (12 kHz)Iout_cont (16 kHz)

A 2918128

47302115

61402720

93583828

1) recommended value; see following noteFig. 6-10: Data power section - inverter

Note: Observe that the load at the motor terminal is almostindependent of the power section used.

Especially when using standard motors, make sure that theycan withstand the voltage load.

Observe section "Using Third-Party Motors in Drive SystemRexroth IndraDrive" of the Project Planning Manual "RexrothIndraDrive Drive System".

Note: Depending on the electric rotational frequency, the outputcurrent is reduced for thermal protection of the power section.

The output current is reduced when the value of the electricrotational frequency falls below 4 Hz.



6.6 Power Section - Examples of Allowed Output CurrentProfiles

The capacity of the drive controllers when operated with mains choke isdescribed below with examples of load profiles.


HCS03.1E-W0100

HCS03.1E-W0150

HCS03.1E-W0210

output current profilefor overloadoperation

overload capacity:

Iout_baseIout_peak

=K

T

Iout_base

t

I

Iout_peak

t

maximum outputcurrentt=400ms; T=4s

Iout_peak1 (4 kHz)

Iout_peak1 (8 kHz)

Iout_peak1 (12 kHz)

Iout_peak1 (16 kHz)

A 70

50

36

28

100

70

50

40

150

100

75

60

210

150

100

75

base load currentavailable atmaximum currentt=400ms; T=4s

Iout_base1 (4 kHz)

Iout_base1 (8 kHz)

Iout_base1 (12 kHz)

Iout_base1 (16 kHz)

A 35

25

18

14

54

37

28

19

67

50

36

26

116

78

59

45

maximum outputcurrentt=2s; T=20s

Iout_peak3 (4 kHz)

Iout_peak3 (8 kHz)

Iout_peak3 (12 kHz)

Iout_peak3 (16 kHz)

A 63

45

32

23

90

65

45

32

147

100

70

50

210

150

100

80

base load currentavailable atmaximum currentt=2s; T=20s

Iout_base3 (4 kHz)

Iout_base3 (8 kHz)

Iout_base3 (12 kHz)

Iout_base3 (16 kHz)

A 35

25

19

15

49

30

25

21

59

44

35

28

109

73

57

41




HCS03.1E-W0100

HCS03.1E-W0150

HCS03.1E-W0210

maximum outputcurrentt=60s; T=5min

Iout_peak4 (4 kHz)

Iout_peak4 (8 kHz)

Iout_peak4 (12 kHz)

Iout_peak4 (16 kHz)

A 47

34

25

19

75

52

38

28

111

80

60

45

160

110

80

60

base load currentavailable atmaximum currentt=60s; T=5min

Iout_base4 (4 kHz)

Iout_base4 (8 kHz)

Iout_base4 (12 kHz)

Iout_base4 (16 kHz)

A 37

23

16

10

50

34

21

19

66

42

28

22

115

80

55

42

maximum outputcurrentt=60s; T=10min

Iout_peak5 (4 kHz)

Iout_peak5 (8 kHz)

Iout_peak5 (12 kHz)

Iout_peak5 (16 kHz)

A 47

34

25

19

75

52

38

28

111

80

60

45

160

110

80

60

base load currentavailable atmaximum currentt=60s; T=10min

Iout_base5 (4 kHz)

Iout_base5 (8 kHz)

Iout_base5 (12 kHz)

Iout_base5 (16 kHz)

A 37

23

16

10

50

34

21

19

66

42

28

22

118

82

56

43

Fig. 6-11: Technical data for power section

Note: The load profiles are characterized by their time flow and thecorresponding currents and represent the output currentcapacity. These profiles are limited by the drive controller viathe thermal effect of the output current. When the currentlimitation is triggered, it is therefore necessary to compare theactual load with the above data and, if necessary,

• reduce the load with Iout_max or• reduce the pulse time or• increase the cycle time or• reduce the switching frequency fs or

• use a device with higher type current(See also Functional Description and Troubleshooting Guideof the firmware.)

Note: The load profiles are available if particularly the maximumcurrent at switching frequencies of 8, 12 and 16 kHz isexternally (e.g. by the control unit) limited to the indicatedvalues.



6.7 Power Section - Operating Standard Motors

The following table specifies the nominal power PNenn of 4-pole standardmotors, which can be operated with the respective drive controller. Thereapply following conditions:

• the dedicated mains choke is used• switching frequency: 4 kHz• output frequency: > 4 Hz• ambient temperature: Ta < Tamax °C

• control factor: a0 > 0,8• relation of overload: K =

peak baseP P

ULN = 3AC400V, 48…62 Hz:

Designation Symbol Unit HCS03.1E-W0070 1)

HCS03.1E-W0100 1)

HCS03.1E-W0150 1)

HCS03.1E-W0210 1)

standard motor nominal power foroverload operation:t=2 s; T=20 s; K=2,0

PNenn kW 15 22 33 55

standard motor nominal power foroverload operation:t=60 s; T=5 min; K=1,5

PNenn kW 15 22 33 55


PNenn kW 18,5 27 35 60

standard motor nominal power forcontinuous operation:t>10 min; K=1,0

PNenn kW 22 37 45 75

1) preliminary dataFig. 6-12: Standard motors 3AC400V, 50 Hz

ULN = 3AC460…480V, 48…62 Hz

Designation Symbol Unit HCS03.1E-W0070 1)

HCS03.1E-W0100 1)

HCS03.1E-W0150 1)

HCS03.1E-W0210 1)

standard motor nominal power foroverload operation:t=2 s; T=20 s; K=2,0

PNenn kW 15 22 33 55


PNenn kW 15 22 33 55


PNenn kW 18,5 27 35 60

standard motor nominal power forcontinuous operation:t>10 min; K=1,0

PNenn kW 22 37 45 75

1) preliminary dataFig. 6-13: Standard motors 3AC460V, 60 Hz



6.8 Power Section - Cooling, Power Dissipation, InsulationResistance, Sound Pressure


HCS03.1E-W0100

HCS03.1E-W0150

HCS03.1E-W0210

cooling of power section forced forced forced forced

volumetric capacity offorced cooling

m³/h 265 367 367 780

max. device powerdissipation at ratedcurrent(with inverter, chopperand rectifier losses;without continuousbraking resistor powerand without controlsection)

PDiss,Drive W 800 950 1150 2000

min. insulationresistance at DC500 V

Ris MOhm 11 11 11 11

capacitance powersection against housing

CKop nF 210 210 210 210

sound pressure level dB(A) 85 80 80 95

Fig. 6-14: Data power section - cooling, power dissipation, insulationresistance, sound pressure



6.9 Control Voltage

Devices with Control Voltage Generation from DC Bus (HCS03.1E-W0xxx-NNxV)

The internally generated control voltage is used for stand-alone supply ofthe drive controller or for buffering in case the external 24V supply fails. Itis not used for supplying motor holding brakes.

(Data based on an ambient temperature of 25 °C)

Designation Symbol Unit Value

external control voltage supply UN3 V 24 ±20%(if no motor holding brake has to be supplied)

If motor holding brakes are to be supplied, observe thedata of the motor documentation. The following valuesare normally sufficient:24 ±5% with motor cable length < 50 m26 ±5% with motor cable length > 50 m

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

max. allowed overvoltage UN3max V 33 (max. 1 ms)

max. inrush current IEIN3 A2,8plus inrush current of control section (see Project PanningManual IndraDrive Control Sections)

max. pulse width of IEIN3 tEIN3Lade ms 5

max. input capacitance CN3 mF 1,2 * 0,47

power consumption (in the case of external supply)*:

HCS03.1E-W0070 PN3 W approx. 22.5

HCS03.1E-W0100 PN3 W approx. 25



internally generated controlvoltage

UN3 V 24 ±10%

(not used for supplying the motor holding brake)

*: data without motor holding brake and control section taken intoaccount

Fig. 6-15: Control voltage

Note: Overvoltage of more than 33V has to be discharged by meansof the appropriate electrical equipment of the machine orinstallation.This includes:

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

• Overvoltage limiters at the control cabinet input that limitexisting overvoltage to the allowed value. This, too,applies to long 24V lines that have been run in parallel topower cables and mains cables and can absorbovervoltages by inductive or capacitive coupling.



Block Diagram of Control Voltage Generation from theDC Bus

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Br: brake circuitLT: power sectionST: control sectionSMPS: internal switching-mode power supplyZK: DC bus

Fig. 6-16: Block diagram of internal control voltage generation



6.10 Connections

Overall Connection Diagram

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Fig. 6-17: Overall connection diagram



6.11 Connections at Power Section HCS03.1

Overview

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No. Designation Design Connectionobligatory?

Note on terminal description

1 Module bus X1 Ribbon cable no The module bus connection is onlynecessary if a converter of identical ratingor an inverter is connected to L+ and L-.

1.1 Park position X1

2 Control voltage; +24 Vand 0 V

Bars yes (forcompliance

with UL termsand utilizationof integrated

safetytechnology)

Connection of an external 24 V supply isonly necessary if an external mainscontactor or a holding brake is used.If connection with bars is not possible,short twisted wires may be used as analternative.

3 DC bus; L+ and L- Bars no Connection is only necessary if twoconverters of identical rating are to belinked via the DC bus or if an inverter isconnected.If connection with bars is impossible, linesmay be used as an alternative.

4 Connection of equipmentgrounding conductor

Joint bar yes If connection with joint bar is impossible,lines may be used as an alternative.

5 Motor (X5) yes 4 connections: A1, A2, A3, PE

6 Shield connection of motorcable

Shielded motorcable

yes Alternatively, shield connection can berealized via the mounting plate availableas an option.

7 Motor temperaturemonitoring and motorholding brake (X6)

Shielded cable orshielded motor

cable withintegrated

connection cablefor X6

no This connection is only required if themotor is equipped with temperaturemonitoring function and/or holding brakeand if these functions are to be used.

8 Mains connection Single cores or4-core non-

metallic-sheathed cable

yes

9 Braking resistor connection Single cores no

Fig. 6-19: Connections at power section (overview)



HCS03.1E

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Fig. 6-20: Connections at power section (front) HCS03.1E-W0100…210�

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X3: Mains connectionX5: Motor connectionX6: Connection of motor temperature, motor holding brake

Fig. 6-21: Connections at power section (bottom) HCS03.1E-W0070



Optional Control VoltageControl voltage is supplied by an external 24V power supply unit.

Note: Technical data of control voltage: See page 6-12

The control voltage supply is connected via contact bars and screws (M6)at the front of the drive controller (cross section of a contact bar:6 x 12 mm). Depending on the width of the drive controllers, there arecontact bars of different lengths.

6 Nm

DC BusBy means of the DC bus connection, the following components are linked:

• the converter to other inverters• external additional capacitors are not allowed (except –W0210)

The DC bus is connected via contact bars and screws (M6) at the front ofthe drive controller (cross section of a contact bar: 6 x 12 mm).Depending on the width of the drive controllers, there are contact bars ofdifferent lengths.

6 Nm

If in special cases it is not possible to use the DC bus rails for connection,connection must be established using the shortest possible twisted wires.

Length of twisted wire max. 4 m

Wire cross section minimum 10 mm2 (AWG 8)but not less than supply feedercross section

Wire protection by means of fuses in the mainssupply

Dielectric strength of single strand againstground

> 750 V DC(e.g.: strand type – H07)

CAUTION

Damage caused by voltage arcing!⇒ When electrical lines and not the contact bars are

used to connect the converter, the connections mustbe executed correctly.

CAUTION

Damage caused by voltage arcing!⇒ If drive controllers are stacked in the control cabinet,

the connections for the DC buses between the drivecontrollers have to be correctly made.

Design

Tightening Torque

Design

Tightening Torque

DC Bus Wiring



CAUTION

Damage due to converter overload!⇒ Only converters of identical DC bus power may be

connected.

X1, Module BusThe module bus is used to exchange data between two converters ofidentical rating or between one converter and inverters connected to theDC bus.

X1f2.FH7

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Fig. 6-22: Graphic representation module bus

Type No. of poles Type of design

Ribbon cable connector 8 Connector at device

Ribbon cable socket 8 Socket at ribbon cable

Fig. 6-23: Design module bus

Note: When extension cables are used for the module bus, theymust be shielded. Their total length must not exceed 40 m.

Graphic Representation

Design



X3, Mains ConnectionOperation in IT mains is possible without restrictions up to a pulsefrequency = 8 kHz. Operation at a pulse frequency of > 8 kHz is notallowed.

For operation in grounded IT mains take into account that when filter HNKis used, leakage currents can occur which might trigger circuit breakers orearth-leakage monitors.

Install an isolating transformer.

HCS03.1E- Type No. of poles Type of design

W0070 Connector 4 Screw connection

W0100 Terminal block 3 Screw connection for M6 ringcable lugs


W0210 Terminal block 3 Screw connection for M10 ringcable lug

Fig. 6-24: Design mains connection

Identification of the individual connections:

Identification Significance

L1 phase 1

L2 phase 2

L3 phase 3

(PE) equipment grounding conductor

Fig. 6-25: Identification of the individual connections mains connection

HCS03.1E- Cross section

[mm²]

Cross sectionflexible[mm²]

Cross section

AWG

W0070 16 - 6

W0100 35 - 2

W0150 50 2*25 0

W0210 95 2*50 4/0

Fig. 6-26: Connection cross sections mains connection

HCS03.1E- Tightening torque [Nm]

W0070 1.5

W0100 6

W0150 6

W0210 18

Fig. 6-27: Tightening torques mains connection

Remedy

Design

Connection Cross Section

Tightening Torque



DANGER

Dangerous movements caused by unbrakedcoasting to stop of the motor in case supplyvoltage fails!⇒ Do not stay within the motional range of the machine.

Possible measures to prevent personnel accidentallyaccessing the machine:- protective fencing- protective grid- protective cover- light barrier.

⇒ Fencing and covers must be adequately securedagainst the maximum possible force of movement.

X5, Motor Connection

HCS03.1E- Type No. ofpoles

Type of design

W0070 Connector 4 Screw connection




Fig. 6-28: Design motor connection

Identification of the individual connections:

Identification Significance

A1 phase 1

A2 phase 2

A3 phase 3

(PE) equipment grounding conductor

Fig. 6-29: Identification of the individual connections motor connection

HCS03.1E- Cross section

[mm²]

Cross sectionflexible[mm²]

Cross section

in AWG

W0070 16 - 6

W0100 35 - 2

W0150 50 2*25 0

W0210 95 2*50 4/0

Fig. 6-30: Connection cross sections motor connection

Design

Connection Cross Section



HCS03.1E- Tightening torque [Nm]

W0070 1.5

W0100 6

W0150 6

W0210 18

Fig. 6-31: Tightening torques motor connection

CAUTION

Damage to the drive controller!⇒ Strain relief for the motor power cables cannot be

provided at the drive controller. Therefore, makesure strain relief of the motor power cables isprovided in the control cabinet.

For the connection between drive controller and motor, use Rexroth motorpower cables.

The Rexroth motor power cable comprises:

• three conductors for motor power connection• one conductor for equipment grounding connection• a separately shielded pair of conductors for motor temperature

monitoring

• a separately shielded pair of conductors for motor holding brake• an overall shield to be applied to shield contact.

Alternatively the cable can be composed of four twisted single wires(3 phases, 1 equipment grounding conductor) with separately guided,shielded wires for temperature monitoring and connecting the brake.

Note: For more details on the technical data, connection and crosssection, please refer to the respective motor description.

To avoid overload of the drive controller the motor cable length is limitedat a switching frequency > 4 kHz.

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

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

Drive controller switchingfrequency

Max. length for 2nd environment(industrial area), EN61800-3

4 kHz 75 m

8 kHz 50 m

12 kHz 25 m

16 kHz 18

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