Summary of Contents for Bosch Rexroth IndraDrive C HCS03.1
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Industrial Electric Drives Linear Motion and Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth IndraControl VCP 20 Rexroth IndraDrive C R911307049 Edition 02 Drive Controllers Power Sections HCS03.1 Project Planning Manual...
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About this Documentation Rexroth IndraDrive C HCS03.1 Rexroth Indra Drive C Title Drive Controllers Power Sections HCS03.1 Project Planning Manual Type of Documentation DOK-INDRV*-HCS03.1****-PR02-EN-P Document Typecode • Box: M8*-01VRS Internal File Reference • Document Number 120-2400-B316-02/EN This documentation provides information on …...
Rexroth IndraDrive C HCS03.1 Contents Contents Indroduction Documentation..........................1-1 About this Documentation ....................... 1-1 Documentations - Overview ....................1-2 Basic Design of a Drive Controller....................1-3 General Information on How to Install the Drive Controller ............1-5 Important Directions for Use Appropriate Use..........................
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Contents Rexroth IndraDrive C HCS03.1 Mechanical Data 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 Weight............................
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Rexroth IndraDrive C HCS03.1 Contents Replacing Devices General Information ........................8-1 How to Proceed When Replacing Devices................... 8-1 Replacing the Drive Controller....................8-1 Replacing the Motor ........................ 8-2 Replacing Cables ........................8-3 Fault Report ..........................8-4 Disposal and Environmental Protection Disposal ............................
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Contents Rexroth IndraDrive C HCS03.1 DOK-INDRV*-HCS03.1****-PR02-EN-P...
Rexroth IndraDrive C HCS03.1 Indroduction Indroduction Documentation About this Documentation This documentation basically contains the technical data of the Rexroth IndraDrive C HCS03.1 drive controllers. Personal injury and property damage caused by incorrect project planning for applications, machines and installations! ⇒...
Indroduction Rexroth IndraDrive C HCS03.1 Documentations - Overview For project planning of the drive system the following documentations are available: Title Kind of documentation Document typecode Rexroth IndraDrive Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P Drive System Rexroth IndraDrive Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P...
Rexroth IndraDrive C HCS03.1 Indroduction Basic Design of a Drive Controller Power section Control section Fig. 1-2: Basic design The drive controller consists of two essential parts: • Power section • Control section DOK-INDRV*-HCS03.1****-PR02-EN-P...
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Indroduction Rexroth IndraDrive C HCS03.1 Power Section The 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) •...
Rexroth IndraDrive C HCS03.1 Indroduction General Information on How to Install the Drive Controller Damage can be caused to the drive controller or circuit boards if electrostatic charging present in people and/or tools is discharged across them. Therefore, please note the following information:...
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Indroduction Rexroth IndraDrive C HCS03.1 DOK-INDRV*-HCS03.1****-PR02-EN-P...
Rexroth IndraDrive C HCS03.1 Important Directions for Use Important Directions for Use Appropriate Use Introduction Rexroth products represent state-of-the-art developments manufacturing. They are tested prior to delivery to ensure operating safety and reliability. The products may only be used in the manner that is defined as appropriate.
Important Directions for Use Rexroth IndraDrive C HCS03.1 Areas of Use and Application Drive controllers made by Rexroth are designed to control electrical motors and monitor their operation. Control and monitoring of the motors may require additional sensors and actors.
Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls Introduction Read these instructions before the initial startup of the equipment in order to eliminate the risk of bodily harm or material damage. Follow these safety instructions at all times.
Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C HCS03.1 Hazards by Improper Use High voltage and high discharge current! Danger to life or severe bodily harm by electric shock! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by...
Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric Drives and Controls General Information • Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. • Read the operating, maintenance and safety instructions in your language before starting up the machine.
Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C HCS03.1 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 C HCS03.1 Safety Instructions for Electric Drives and Controls To be observed with electrical drive and filter components: High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! ⇒ Connect the electrical equipment, the housings of all...
Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C HCS03.1 Protection Against Electric Shock by Protective Low Voltage (PELV) All connections and terminals with voltages between 0 and 50 Volts on Rexroth products are protective low voltages designed in accordance with international standards on electrical safety.
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Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric Drives and Controls Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! ⇒ Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures DANGER integrated in the installation.
Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C HCS03.1 ⇒ 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 ⇒...
Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric Drives and Controls Protection Against Contact with Hot Parts Housing surfaces could be extremely hot! Danger of injury! Danger of burns! ⇒ Do not touch housing surfaces near sources of heat! Danger of burns! CAUTION ⇒...
3-10 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C HCS03.1 3.11 Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or material damage. Risk of injury by incorrect handling! ⇒ Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and cauterization).
3-11 Rexroth IndraDrive C HCS03.1 Safety Instructions for Electric Drives and Controls 3.12 Protection Against Pressurized Systems Certain motors and drive controllers, corresponding to the information in the respective Project Planning Manual, must be provided with pressurized media, such as compressed air, hydraulic oil, cooling fluid and cooling lubricant supplied by external systems.
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3-12 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C HCS03.1 DOK-INDRV*-HCS03.1****-PR02-EN-P...
Rexroth IndraDrive C HCS03.1 Identification Identification Device Types Type Code Note: The following figure illustrates the basic structure of the type code. Your sales representative will help with the current status of available versions. Abbrev. Column 1 2 3 4...
Identification Rexroth IndraDrive C HCS03.1 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 label indicates the type designation and the length. (The designation of the cable itself - without connector - is printed on the cable sheath.)
Rexroth IndraDrive C HCS03.1 Identification Type Plate Power Section (Example) Device type HCS02.1E-W0012-A-03- NNNN R911298371 Made in Germany FD:04W12 Part number SN: HCS021-00123 0A01 Serial Number Barcode Hardware index Production week Example 04W12 means year 2004 week 12 Producing Country Fig.
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Identification Rexroth IndraDrive C HCS03.1 DOK-INDRV*-HCS03.1****-PR02-EN-P...
Rexroth IndraDrive C HCS03.1 Mechanical Data Mechanical Data Dimensions Drive Controller HCS03.1E-W0070 all dimensions in mm Fig. 5-1: Dimensional drawing HCS03.1E-W0070 Drive Controller HCS03.1E-W0070 with HAS02 Fig. 5-2: Dimensional drawing HCS03.1E-W0070 with HAS02 DOK-INDRV*-HCS03.1****-PR02-EN-P...
Mechanical Data Rexroth IndraDrive C HCS03.1 Drive Controller HCS03.1E-W0100, -W0150 all dimensions in mm Fig. 5-3: Dimensional drawing HCS03.1E-W0100 and HCS03.1E-W150 Drive Controller HCS03.1E-W0100, -W0150 with HAS02 Fig. 5-4: Dimensional drawing HCS03.1E-W0100 and HCS03.1E-W150 with HAS02 DOK-INDRV*-HCS03.1****-PR02-EN-P...
Rexroth IndraDrive C HCS03.1 Mechanical Data Drive Controller HCS03.1E-W0210 all dimensions in mm Fig. 5-5: Dimensional drawing HCS03.1E-W0210 Drive Controller HCS03.1E-W0210 with HAS02 Fig. 5-6: Dimensional drawing HCS03.1E-W0210 with HAS02 DOK-INDRV*-HCS03.1****-PR02-EN-P...
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Mechanical Data Rexroth IndraDrive C HCS03.1 Boring Dimensions all dimensions in mm Fig. 5-7: Boring dimensions HCS03.1E-W0070 DOK-INDRV*-HCS03.1****-PR02-EN-P...
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Rexroth IndraDrive C HCS03.1 Mechanical Data all dimensions in mm Fig. 5-8: Boring dimensions HCS03.1E-W0100 and HCS03.1-W0150 DOK-INDRV*-HCS03.1****-PR02-EN-P...
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Mechanical Data Rexroth IndraDrive C HCS03.1 all dimensions in mm Fig. 5-9: Boring dimensions HCS03.1E-W0210 DOK-INDRV*-HCS03.1****-PR02-EN-P...
Rexroth IndraDrive C HCS03.1 Mechanical Data Weight Device Weight in kg HCS03.1E-W0070 HCS03.1E-W0100 HCS03.1E-W0150 HCS03.1E-W0210 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.
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Mechanical Data Rexroth IndraDrive C HCS03.1 DOK-INDRV*-HCS03.1****-PR02-EN-P...
Rexroth IndraDrive C HCS03.1 Electrical Data Electrical Data Note: The current and power data below apply when the allowed motor cable length is complied with (see data in section "X5, Motor Connection"). They refer to 3AC400 V. Power Section - Mains Supply...
Electrical Data Rexroth IndraDrive C HCS03.1 Power Section - DC Bus Designation Symbol Unit HCS03.1E- HCS03.1E- HCS03.1E- HCS03.1E- W0070 W0100 W0150 W0210 DC bus voltage range uncontrolled (unloaded) * 1,41 internal DC bus 0,94 1,44 1,88 capacitance max. allowed external DC nicht zulässig...
Rexroth IndraDrive C HCS03.1 Electrical Data Power Section - DC Bus Power Designation Symbol Unit HCS03.1E- HCS03.1E HCS03.1E HCS03.1E W0070 -W0100 -W0150 -W0210 profile DC bus power DC_peak overload operation overload capacity: DC_base DC_peak base DC bus peak power DC_peak_1 = 3 x AC 400 V, at Ta=40°C;...
Electrical Data Rexroth IndraDrive C HCS03.1 Damage due to drive controller overload! ⇒ Make sure the specified performance data - peak power and continuous power - are complied with by correct drive dimensioning and selective fusing in the WARNING mains connection.
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Rexroth IndraDrive C HCS03.1 Electrical Data depending on P DC cont for HCS03.1-E-W0150 @3AC400V/4kHz 100,00 80,00 60,00 40,00 20,00 0,00 [kW] DC cont with mains choke without mains choke Fig. 6-6: Interrelation of S for HCS03.1-E-W0150 depending on P DC cont for HCS03.1-E-W0210 @3AC400V/4kHz...
Rexroth IndraDrive C HCS03.1 Electrical Data Power Section - Inverter Designation Symbol Unit HCS03.1E- HCS03.1E- HCS03.1E- HCS03.1E- W0070 W0100 W0150 W0210 output voltage fundamental with open-loop component of UDC * 0,95 / 1,41 U/f ctrl voltage with closed- UDC * 0,9 / 1,41 loop oper.
Electrical Data Rexroth IndraDrive C HCS03.1 Power Section - Examples of Allowed Output Current Profiles The capacity of the drive controllers when operated with mains choke is described below with examples of load profiles. Designation Symbol Unit HCS03.1E- HCS03.1E- HCS03.1E- HCS03.1E-...
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Rexroth IndraDrive C HCS03.1 Electrical Data Designation Symbol Unit HCS03.1E- HCS03.1E- HCS03.1E- HCS03.1E- W0070 W0100 W0150 W0210 maximum output out_peak4 (4 kHz) current t=60s; T=5min out_peak4 (8 kHz) out_peak4 (12 kHz) out_peak4 (16 kHz) base load current out_base4 (4 kHz)
6-10 Electrical Data Rexroth IndraDrive C HCS03.1 Power Section - Cooling, Power Dissipation, Insulation Resistance, Sound Pressure Designation Symbol Unit HCS03.1E- HCS03.1E- HCS03.1E- HCS03.1E- W0070 W0100 W0150 W0210 cooling of power section forced forced forced forced volumetric capacity of m³/h forced cooling max.
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6-11 Rexroth IndraDrive C HCS03.1 Electrical Data Designation Symbol Unit Value HCS03.1E-W0100 approx. 25 HCS03.1E-W0150 approx. 25 HCS03.1E-W0210 approx. 30 internally generated control 24 ±10% voltage (not used for supplying the motor holding brake) data without motor holding brake and control section taken into account Fig.
6-13 Rexroth IndraDrive C HCS03.1 Electrical Data 6.10 Connections at Power Section HCS03.1 Overview 4, 6 Fig. 6-16: Connections at power section HCS03.1 DOK-INDRV*-HCS03.1****-PR02-EN-P...
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6-14 Electrical Data Rexroth IndraDrive C HCS03.1 Designation Design Connection Note on terminal description obligatory? Module bus X1 Ribbon cable The module bus connection is only necessary if a converter of identical rating or an inverter is connected to L+ and L-.
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6-15 Rexroth IndraDrive C HCS03.1 Electrical Data HCS03.1E PE-connection PE-connection power Motor- connection connection APHC0002EN00 Fig. 6-18: Connections at power section (front) HCS03.1E-W0100 ... 210 Mains connection Motor connection Connection of motor temperature, motor holding brake Fig. 6-19: Connections at power section (bottom) HCS03.1E-W0070...
6-16 Electrical Data Rexroth IndraDrive C HCS03.1 Description of the connections: Connection Page Control voltage 6-16 DC bus 6-16 Module bus (X1) 6-17 Mains connection (X3) 6-18 Motor connection (X5) 6-19 Motor temperature monitoring and motor holding brake (X6) 6-21...
6-17 Rexroth IndraDrive C HCS03.1 Electrical Data Damage caused by voltage arcing! ⇒ When electrical lines and not the contact bars are used to connect the converter, the connections must be 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 drive controllers have to be correctly made.
6-18 Electrical Data Rexroth IndraDrive C HCS03.1 X3, Mains Connection Operation in IT mains is possible without restrictions up to a pulse frequency = 8 kHz. Operation at a pulse frequency of > 8 kHz is not allowed. For operation in grounded IT mains take into account that when filter HNK is used, leakage currents can occur which might trigger circuit breakers or earth-leakage monitors.
6-19 Rexroth IndraDrive C HCS03.1 Electrical Data Dangerous movements caused by unbraked coasting to stop of the motor in case supply voltage fails! ⇒ Do not stay within the motional range of the machine. DANGER Possible measures to prevent personnel accidentally...
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6-20 Electrical Data Rexroth IndraDrive C HCS03.1 Tightening Torque HCS03.1E- Tightening torque [Nm] W0070 W0100 W0150 W0210 Fig. 6-29: Tightening torques motor connection Damage to the drive controller! ⇒ Strain relief for the motor power cables cannot be provided at the drive controller. Therefore, make...
6-21 Rexroth IndraDrive C HCS03.1 Electrical Data Note: If greater cable lengths are required, the additional component HMF01.1 must be used. The maximum allowed cable length with HMF01.1 is 200 m, the maximum allowed switching frequency of the drive controller in this case has to be limited to 4 kHz.
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6-22 Electrical Data Rexroth IndraDrive C HCS03.1 A1 A2 A3 shield support motor cable Rexroth AC-Motor holding- brake* PTC / NTC / KTY84 (in depence of motortype) APHC0003EN00.FH9 Holding brake (optional) Fig. 6-36: Connection of motor temperature monitoring and motor holding...
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6-23 Rexroth IndraDrive C HCS03.1 Electrical Data Dangerous movements! Danger to personnel from falling or dropping axes! ⇒ The standard motor holding brake provided or an external motor holding brake controlled directly by DANGER the drive controller are not sufficient on their own to guarantee the safety of personnel! ⇒...
6-25 Rexroth IndraDrive C HCS03.1 Electrical Data XS1, Shield Connection ANHC0002EN00.FH9 Fig. 6-41: Shield connection XS1 Connection for the shields of lines connected to the control section. Note: Always connect shields of control lines with a large metal-to- metal contact surface.
6-26 Electrical Data Rexroth IndraDrive C HCS03.1 Connection Point of Equipment Grounding Conductor Lethal electric shock caused by live parts with more than 50 V! ⇒ Connect the drive controller to the equipment grounding system. DANGER ⇒ Via the joint bar on the front connect the drive controller to the neighboring drive controller.
Rexroth IndraDrive C HCS03.1 Touch Guard Touch Guard Lethal electric shock caused by live parts with more than 50 V! ⇒ The appropriate touch guard must be mounted for each drive controller following connection work. WARNING ⇒ Never mount a damaged touch guard.
Touch Guard Rexroth IndraDrive C HCS03.1 Mounting PZHC0003DE00.FH9 Fig. 7-2: Touch guard The touch guard must always be mounted following connection work. Note: Risk of damage to the touch guard! The maximum tightening torque for the fixing screw for the touch guard is 2.8 Nm.
Rexroth IndraDrive C HCS03.1 Replacing Devices Replacing Devices General Information The diagnostic display enables aimed and effective troubleshooting in order to: • avoid production downtimes due to extensive searches in individual devices and repairs of devices in the installation. • start operating the installation again without extensive assembly and adjustments.
Replacing Devices Rexroth IndraDrive C HCS03.1 Replacing the Motor • open main switch • make sure main switch cannot be switched on again • disconnect plug-in connectors Note: When replacing the motor, cover the open mating sites of power lines with protective caps if sprinkling with cooling liquid/lubricant or soiling may occur (allowed degree of soiling according to EN50178: 2).
Rexroth IndraDrive C HCS03.1 Replacing Devices Replacing Cables Lethal electric shock caused by live parts with more than 50 V! ⇒ Power connectors of the cables may only be separated or connected if the installation has been ATTENTION de-energized! Note: When replacing cables, observe the instructions of the machine manufacturer.
Replacing Devices Rexroth IndraDrive C HCS03.1 Fault Report Fault Report Date: for Drive Systems Report No.: This fault report is intended to help eliminate problems that might possibly be related to drive systems. Please fill it out carefully and send it, together with the parameter file with which the fault occurred, to Bosch Rexroth .
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Rexroth IndraDrive C HCS03.1 Replacing Devices General conditions: Mode at time fault occurred: Parameterization mode Operating mode Switch phase Operating mode active at time fault occurred: Encoder 7-segment display..before fault occurred: ...after fault occurred: Fault status Causes Other defects...
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Replacing Devices Rexroth IndraDrive C HCS03.1 DOK-INDRV*-HCS03.1****-PR02-EN-P...
Rexroth IndraDrive C HCS03.1 Disposal and Environmental Protection Disposal and Environmental Protection Disposal Products Our products can be returned to us free of charge for disposal. However, the products must be free of oil, grease or other dirt. Furthermore, the products returned for disposal must not contain any undue foreign matter or foreign component.
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Disposal and Environmental Protection Rexroth IndraDrive C HCS03.1 DOK-INDRV*-HCS03.1****-PR02-EN-P...
10-1 Rexroth IndraDrive C HCS03.1 Service & Support Service & Support 10.1 Helpdesk Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries.
10-2 Service & Support Rexroth IndraDrive C HCS03.1 10.5 Kundenbetreuungsstellen - Sales & Service Facilities Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen! from abroad: don’t dial (0) after country code! Vertriebsgebiet Mitte Germany Centre S E R V I C E A U T O M A T I O N...
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10-3 Rexroth IndraDrive C HCS03.1 Service & Support Europa (West) - Europe (West) vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen from abroad: don’t dial (0) after country code, Italy: dial 0 after country code Austria - Österreich Austria –...
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10-4 Service & Support Rexroth IndraDrive C HCS03.1 Europa (Ost) - Europe (East) vom Ausland: (0) nach Landeskennziffer weglassen from abroad: don’t dial (0) after country code Czech Republic - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland – Polen DEL a.s.
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10-5 Rexroth IndraDrive C HCS03.1 Service & Support Africa, Asia, Australia – incl. Pacific Rim Australia - Australien Australia - Australien China China AIMS - Australian Industrial Bosch Rexroth Pty. Ltd. Shanghai Bosch Rexroth Shanghai Bosch Rexroth Machinery Services Pty. Ltd.
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Canada West - Kanada West Mexico Mexico Bosch Rexroth Canada Corporation Bosch Rexroth Canada Corporation Bosch Rexroth Mexico S.A. de C.V. Bosch Rexroth S.A. de C.V. Burlington Division 5345 Goring St. Calle Neptuno 72 Calle Argentina No 3913 3426 Mainway Drive Burnaby, British Columbia Unidad Ind.
11-1 Rexroth IndraDrive C HCS03.1 Index Index Appropriate use 2-1 Battery safety 3-10 Bb contact 1-4 Boring dimensions 5-4 braking resistor 6-6 Braking resistor tightening torque 6-24 Cable replace 8-3 Connection braking resistor 6-24 control voltage 6-16 DC bus 6-16...
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11-2 Index Rexroth IndraDrive C HCS03.1 power section - power dissipation 6-10 Environmental protection 9-1 Fault report 8-4 Ground connection 6-25 Hazards by Improper Use 3-2 Holding brake 6-21 Identification of the drive controller 4-1 Improper use hazards 3-2 Inappropriate use 2-2...
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11-3 Rexroth IndraDrive C HCS03.1 Index Safety Instructions for Electric Drives and Controls 3-1 Scope of delivery 4-3 Supply unit connection point of equipment grounding conductor 6-26 Technical data 6-9 Temperature monitoring 6-21 Temperatures above top of device 5-7 Touch guard 7-1...
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11-4 Index Rexroth IndraDrive C HCS03.1 DOK-INDRV*-HCS03.1****-PR02-EN-P...
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Bosch Rexroth AG Electric Drives and Controls P.O. Box 13 57 97803 Lohr, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr, Germany Phone +49 (0)93 52-40-50 60 +49 (0)93 52-40-49 41 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany R911307049 DOK-INDRV*-HCS03.1****-PR02-EN-P...