Bosch Rexroth IndraDrive C HCS03.1 Technical manual

Rexroth IndraControl VCP 20
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
Rexroth IndraDrive C
Drive Controllers
Power Sections HCS03.1
R911307049
Edition 02
Project Planning Manual

About this Documentation Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR02-EN-P
Rexroth Indra Drive C
Drive Controllers
Power Sections HCS03.1
Project Planning Manual
DOK-INDRV*-HCS03.1****-PR02-EN-P
•Box:M8*-01VRS
•Document Number 120-2400-B316-02/EN
This documentation provides information on …
•how to design the control cabinet
•how to mount the drive controllersin the control cabinet
•how to install the drive system
Description Release
Date Notes
DOK-INDRV*-HCS03.1****-PR01-EN 03.2004 First Edition
DOK-INDRV*-HCS03.1****-PR02-EN 02.2005 Second Edition
•technical data updated
•preliminary data added (sound
pressure level, mains supply)
•further load and current profiles
added
•structure of manual has been
adapted to structure of Project
Planning Manual "Rexroth
IndraDrive Drive System"
Bosch Rexroth AG, 2005
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
The specified data only serve to describe the product. No statements
concerning a certain condition or suitability for a certain application can be
derived from our information. The given information does not release the
user from the obligation of own judgement and verification. It must be
remembered that our products are subject to a natural process of wear
and aging.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.com/
Dept. EDY/EDY1 (rr/hp/bb)
This document has been printed on chlorine-free bleached paper.
Title
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Record of Revisions
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Note

Rexroth IndraDrive C HCS03.1 Contents I
DOK-INDRV*-HCS03.1****-PR02-EN-P
Contents
1 Indroduction 1-1
1.1 Documentation.............................................................................................................................. 1-1
About this Documentation ....................................................................................................... 1-1
Documentations - Overview .................................................................................................... 1-2
1.2 Basic Design of a Drive Controller................................................................................................ 1-3
1.3 General Information on How to Install the Drive Controller .......................................................... 1-5
2 Important Directions for Use 2-1
2.1 Appropriate Use............................................................................................................................ 2-1
Introduction .............................................................................................................................. 2-1
Areas of Use and Application .................................................................................................. 2-2
2.2 Inappropriate Use ......................................................................................................................... 2-2
3 Safety Instructions for Electric Drives and Controls 3-1
3.1 Introduction ................................................................................................................................... 3-1
3.2 Explanations ................................................................................................................................. 3-1
3.3 Hazards by Improper Use............................................................................................................. 3-2
3.4 General Information ...................................................................................................................... 3-3
3.5 Protection Against Contact with Electrical Parts........................................................................... 3-4
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) ......................................... 3-6
3.7 Protection Against Dangerous Movements .................................................................................. 3-6
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting ....................................................................................................................................... 3-8
3.9 Protection Against Contact with Hot Parts....................................................................................3-9
3.10 Protection During Handling and Mounting.................................................................................... 3-9
3.11 Battery Safety ............................................................................................................................. 3-10
3.12 Protection Against Pressurized Systems.................................................................................... 3-11
4 Identification 4-1
4.1 Device Types ................................................................................................................................ 4-1
Type Code ............................................................................................................................... 4-1
4.2 Type Plates................................................................................................................................... 4-2
Type Plate Power Section (Example)...................................................................................... 4-3
Type Plate Control Section......................................................................................................4-3
4.3 Scope of Delivery.......................................................................................................................... 4-3
Overview.................................................................................................................................. 4-3

II Contents Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR02-EN-P
5 Mechanical Data 5-1
5.1 Dimensions ................................................................................................................................... 5-1
Drive Controller HCS03.1E-W0070......................................................................................... 5-1
Drive Controller HCS03.1E-W0070 with HAS02 ..................................................................... 5-1
Drive Controller HCS03.1E-W0100, -W0150 .......................................................................... 5-2
Drive Controller HCS03.1E-W0100, -W0150 with HAS02 ...................................................... 5-2
Drive Controller HCS03.1E-W0210......................................................................................... 5-3
Drive Controller HCS03.1E-W0210 with HAS02 ..................................................................... 5-3
5.2 Weight........................................................................................................................................... 5-7
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 ............................................................................................................... 6-2
6.3 Power Section - DC Bus Power.................................................................................................... 6-3
Mains Connection Power and DC Bus Continuous Power ..................................................... 6-4
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 - Cooling, Power Dissipation, Insulation Resistance, Sound Pressure.............. 6-10
6.8 Control Voltage ........................................................................................................................... 6-10
Devices with Control Voltage Generation from DC Bus (HCS03.1E-W0xxx-NNxV)............. 6-10
6.9 Connections................................................................................................................................ 6-12
Overall Connection Diagram ................................................................................................. 6-12
6.10 Connections at Power Section HCS03.1.................................................................................... 6-13
Optional Control Voltage ....................................................................................................... 6-16
DC Bus .................................................................................................................................. 6-16
X1, Module Bus ..................................................................................................................... 6-17
X3, Mains Connection ........................................................................................................... 6-18
X5, Motor Connection............................................................................................................6-19
X6, Motor Temperature Monitoring and Motor Holding Brake .............................................. 6-21
X9, Braking Resistor.............................................................................................................. 6-24
XS1, Shield Connection......................................................................................................... 6-25
Ground Connection of Housing ............................................................................................. 6-25
Connection Point of Equipment Grounding Conductor ......................................................... 6-26
7 Touch Guard 7-1
Cutouts .................................................................................................................................... 7-1
Mounting .................................................................................................................................. 7-2

Rexroth IndraDrive C HCS03.1 Contents III
DOK-INDRV*-HCS03.1****-PR02-EN-P
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
Replacing the Motor ................................................................................................................ 8-2
Replacing Cables .................................................................................................................... 8-3
8.3 Fault Report .................................................................................................................................. 8-4
9 Disposal and Environmental Protection 9-1
9.1 Disposal ........................................................................................................................................ 9-1
Products................................................................................................................................... 9-1
Packaging Materials ................................................................................................................ 9-1
9.2 Environmental Protection.............................................................................................................. 9-1
No Release of Hazardous Substances ................................................................................... 9-1
Materials Contained in the Products ....................................................................................... 9-1
Recycling ................................................................................................................................. 9-1
10 Service & Support 10-1
10.1 Helpdesk..................................................................................................................................... 10-1
10.2 Service-Hotline ........................................................................................................................... 10-1
10.3 Internet........................................................................................................................................ 10-1
10.4 Vor der Kontaktaufnahme... - Before contacting us... ................................................................ 10-1
10.5 Kundenbetreuungsstellen - Sales & Service Facilities ............................................................... 10-2
11 Index 11-1

IV Contents Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR02-EN-P

Rexroth IndraDrive C HCS03.1 Indroduction 1-1
DOK-INDRV*-HCS03.1****-PR02-EN-P
1 Indroduction
1.1 Documentation
About this Documentation
This documentation basically contains the technical data of the Rexroth
IndraDrive C HCS03.1 drive controllers.
WARNING
Personal injury and property damage caused by
incorrect 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 you
need, in any case, the Project Planning Manual "Rexroth IndraDrive Drive
System" (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 bus
resistor unit)
•replacing devices

1-2 Indroduction Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR02-EN-P
Documentations - Overview
For project planning of the drive system the following documentations are
available:
Title Kind of documentation Document typecode1)
Rexroth IndraDrive
Drive System
Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P
Rexroth IndraDrive
Drive Controllers
Control Sections CSx
Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P
Rexroth IndraDrive M
Drive Controllers
Power Sections HMx
Project Planning Manual DOK-INDRV*-HMS+HMD****-PRxx-EN-P
Rexroth IndraDrive C
Drive Controllers
Power Sections HCS02.1
Project Planning Manual DOK-INDRV*-HCS02.1****-PRxx-EN-P
Rexroth IndraDrive C
Drive Controllers
Power Sections HCS03.1
Project Planning Manual DOK-INDRV*-HCS03.1****-PRxx-EN-P
Rexroth IndraDrive
Supply Units
Project Planning Manual DOK-INDRV*-HMV-*******-PRxx-EN-P
Rexroth IndraDrive
Additional Components
Project Planning Manual DOK-INDRV*-ADDCOMP****-PRxx-EN-P
Rexroth IndraDrive
Integrated Safety Technology
Functional and Application
Description
DOK-INDRV*-SI*-**VRS**-FKxx-EN-P
Rexroth IndraDrive
Firmware for Drive Controllers
Functional Description DOK-INDRV*-MP*-02VRS**-FKxx-EN-P
Rexroth IndraDrive
Firmware for Drive Controllers
Parameter Description DOK-INDRV*-GEN-**VRS**-PAxx-EN-P
Rexroth IndraDrive
Firmware for Drive Controllers
Troubleshooting Guide DOK-INDRV*-GEN-**VRS**-WAxx-EN-P
Rexroth Connection Cables Selection Data DOK-CONNEC-CABLE*STAND-AUxx-EN-P
Rexroth IndraDyn A
Asynchronous Motors MAD/MAF
Project Planning Manual DOK-MOTOR*-MAD/MAF****-PRxx-EN-P
Rexroth IndraDyn S
Synchronous Motors MSK
Project Planning Manual DOK-MOTOR*-MSK********-PRxx-EN-P
Rexroth IndraDyn T
Synchronous Torque Motors MBT
Project Planning Manual DOK-MOTOR*-MBT********-PRxx-EN-P
Rexroth IndraDyn H
Synchronous Kit –Spindle Motors
MBS-H
Project Planning Manual DOK-MOTOR*-MBS-H******-PRxx-EN-P
Rexroth IndraDyn L
Synchronous 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 edition
of the documentation (example: "PR01" is the first edition of a
Project Planning Manual)
Fig. 1-1: Documentations - overview

Rexroth IndraDrive C HCS03.1 Indroduction 1-3
DOK-INDRV*-HCS03.1****-PR02-EN-P
1.2 Basic Design of a Drive Controller
1
2
1: Power section
2: Control section
Fig. 1-2: Basic design
The drive controller consists of two essential parts:
•Power section
•Control section

1-4 Indroduction Rexroth IndraDrive C HCS03.1
DOK-INDRV*-HCS03.1****-PR02-EN-P
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)
•motor holding brake (optional)
•motor temperature sensor (optional)
•braking resistor (optional)
Control Section
The control section is a separate component that is plugged into the
power section. The drive controller is supplied ex works complete with
control 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 Bb
contacts.
Note: The control sections are described in a separate
documentation (see page 1-2).