Bosch REXROTH IndraDrive User manual

IndraDrive
Drive Controllers
Power Sections HCS02
Instruction Manual
R911319657
Edition 09

IndraDrive
Drive Controllers
Power Sections HCS02
Instruction Manual
DOK-INDRV*-HCS02*UL***-IB09-EN-P
RS-b0429bdd416152660a6846a000582523-12-en-US-3
Edition Release Date Notes
DOK-INDRV*-HCS02*UL***-IB01-EN-P 2007-01 Unpublished edition
DOK-INDRV*-HCS02*UL***-IB02-EN-P 2009-09 Corrected edition
DOK-INDRV*-HCS02*UL***-IB03-EN-P 2010-10 Corrected edition
DOK-INDRV*-HCS02*UL***-IB04-EN-P 2012-01 Corrected edition
DOK-INDRV*-HCS02*UL***-IB05-EN-P 2012-01 Corrected edition
DOK-INDRV*-HCS02*UL***-IB06-EN-P 2012-05 Included safety instruc‐
tions in further languag‐
es
DOK-INDRV*-HCS02*UL***-IB07-EN-P 2014-10 Corrected edition
DOK-INDRV*-HCS02*UL***-IB08-EN-P 2016-02 Corrected edition
DOK-INDRV*-HCS02*UL***-IB09-EN-P 2019-07 Corrected edition
Purpose of Documentation This documentation provides information on the installation and operation of
the described products, by persons trained and qualified to work with
electrical installations.
Copyright © Bosch Rexroth AG 2019
All rights reserved, also regarding any disposal, exploitation, reproduction,
editing, distribution, as well as in the event of applications for industrial
property rights.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this
documentation and the availability of the product.
Published by Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr a. Main, Germany
Phone [phone] ■ Fax [phone]
http://www.boschrexroth.com/
DC-AE/EPI2 (CR)
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revision
IndraDrive Drive Controllers Power Sections HCS02

Table of Contents
Page
1 Important notes.............................................................................................................. 1
1.1 Safety instructions.................................................................................................................................. 1
1.1.1 General information............................................................................................................................. 1
1.1.2 Protection against contact with electrical parts and housings............................................................. 2
1.1.3 Battery safety....................................................................................................................................... 3
1.2 Intended use........................................................................................................................................... 4
2 Ratings and dimensions................................................................................................. 5
2.1 HCS02.................................................................................................................................................... 5
2.2 China RoHS 2....................................................................................................................................... 10
3 Overview of documentations........................................................................................ 11
3.1 Motors................................................................................................................................................... 11
4 Instructions for use....................................................................................................... 13
4.1 Overcurrent protection.......................................................................................................................... 13
4.2 Connection............................................................................................................................................ 14
4.2.1 Connection diagram.......................................................................................................................... 14
4.2.2 Connection points.............................................................................................................................. 15
5 Service and support..................................................................................................... 17
Index............................................................................................................................ 19
IndraDrive Drive Controllers Power Sections HCS02 I
Table of Contents
R911319657_Edition 09 Bosch Rexroth AG

II IndraDrive Drive Controllers Power Sections HCS02
Bosch Rexroth AG R911319657_Edition 09

1 Important notes
1.1 Safety instructions
1.1.1 General information
● Do not attempt to install and operate the components of the electric
drive and control system without first reading all documentation provided
with the product. Read and understand these safety instructions and all
user documentation prior to working with these components. If you do
not have the user documentation for the components, contact our
Rexroth sales representative. Ask for these documents to be sent
immediately to the person or persons responsible for the safe operation
of the components.
● If the supplied documents contain some information you do not
understand, it is absolutely necessary that you ask Rexroth for
explanation before you start working at or with the components.
● If the component is resold, rented and/or passed on to others in any
other form, these safety instructions must be delivered with the
component in the official language of the user's country.
● Only qualified persons may work with components of the electric drive
and control system or within its proximity.
In terms of this Instruction Manual, qualified persons are those persons
who are familiar with the installation, mounting, commissioning and
operation of the components of the electric drive and control system, as
well as with the hazards this implies, and who possess the qualifications
their work requires. To comply with these qualifications, it is necessary,
among other things,
– to be trained, instructed or authorized to switch electric circuits and
components safely on and off, to ground them and to mark them,
– to be trained or instructed to maintain and use adequate safety
equipment,
– to attend a course of instruction in first aid.
● The technical data, connection and installation conditions of the
components are specified in the respective application documentations
and must be followed at all times.
● If the components take the form of hardware, then they must remain in
their original state, in other words, no structural changes are permitted.
It is not permitted to decompile software components or alter source
codes.
● Do not mount damaged or faulty components or use them in operation.
● Only use accessories and spare parts approved by Rexroth.
● Follow the safety regulations and requirements of the country in which
the electric components of the electric drive and control system are
operated.
● Proper and correct transport, storage, mounting and installation, as well
as care in operation and maintenance, are prerequisites for optimal and
safe operation of the component.
Improper use of these components, failure to follow the safety instructions in
this document or tampering with the product, including disabling of safety
devices, could result in property damage, injury, electric shock or even death.
IndraDrive Drive Controllers Power Sections HCS02 1/21
Important notes
R911319657_Edition 09 Bosch Rexroth AG

1.1.2 Protection against contact with electrical parts and housings
This section concerns components of the electric drive and
control system with voltages of more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal
danger and electric shock. When operating components of the electric drive
and control system, it is unavoidable that some parts of these components
conduct dangerous voltage.
High electrical voltage! Danger to life, risk of injury by electric shock or
serious injury!
● Only qualified persons are allowed to operate, maintain and/or repair the
components of the electric drive and control system.
● Follow the general installation and safety regulations when working on
power installations.
● Before switching on, the equipment grounding conductor must have
been permanently connected to all electric components in accordance
with the connection diagram.
● Even for brief measurements or tests, operation is only allowed if the
equipment grounding conductor has been permanently connected to the
points of the components provided for this purpose.
● Before accessing electrical parts with voltage potentials higher than
50 V, you must disconnect electric components from the mains or from
the power supply unit. Secure the electric component from
reconnection.
● With electric components, observe the following aspects:
Always wait 30 minutes after switching off power to allow live capacitors
to discharge before accessing an electric component. Measure the
electrical voltage of live parts before beginning to work to make sure
that the equipment is safe to touch.
● Install the covers and guards provided for this purpose before switching
on.
● Never touch any electrical connection points of the components while
power is turned on.
● Do not remove or plug in connectors when the component has been
powered.
● Under specific conditions, electric drive systems can be operated at
mains protected by residual-current-operated circuit-breakers sensitive
to universal current (RCDs/RCMs).
● Secure built-in devices from penetrating foreign objects and water, as
well as from direct contact, by providing an external housing, for
example a control cabinet.
High housing voltage and high leakage current! Danger to life, risk of injury
by electric shock!
● Before switching on and before commissioning, ground or connect the
components of the electric drive and control system to the equipment
grounding conductor at the grounding points.
2/21
Important notes
IndraDrive Drive Controllers Power Sections HCS02
Bosch Rexroth AG R911319657_Edition 09

● Connect the equipment grounding conductor of the components of the
electric drive and control system permanently to the main power supply
at all times. The leakage current is greater than 3.5 mA.
● Establish an equipment grounding connection with a minimum cross
section according to the table below. With an outer conductor cross
section smaller than 10 mm2 (8 AWG), the alternative connection of two
equipment grounding conductors is allowed, each having the same
cross section as the outer conductors.
Cross section outer
conductor
Minimum cross section equipment grounding conductor
Leakage current ≥ 3.5 mA
1 equipment grounding
conductor
2 equipment grounding
conductors
1.5 mm2 (16 AWG)
10 mm2 (8 AWG)
2 × 1.5 mm2 (16 AWG)
2.5 mm2 (14 AWG) 2 × 2.5 mm2 (14 AWG)
4 mm2 (12 AWG) 2 × 4 mm2 (12 AWG)
6 mm2 (10 AWG) 2 × 6 mm2 (10 AWG)
10 mm2 (8 AWG) -
16 mm2 (6 AWG)
16 mm2 (6 AWG)
-
25 mm2 (4 AWG) -
35 mm2 (2 AWG) -
50 mm2 (1/0 AWG) 25 mm2 (4 AWG) -
70 mm2 (2/0 AWG) 35 mm2 (2 AWG) -
... ... ...
Tab. 1-1: Minimum cross section of the equipment grounding connection
1.1.3 Battery safety
Batteries consist of active chemicals in a solid housing. Therefore, improper
handling can cause injury or property damage.
Risk of injury by improper handling!
● Do not attempt to reactivate low batteries by heating or other methods
(risk of explosion and cauterization).
● Do not attempt to recharge the batteries as this may cause leakage or
explosion.
● Do not throw batteries into open flames.
● Do not dismantle batteries.
● When replacing the battery/batteries, do not damage the electrical parts
installed in the devices.
● Only use the battery types specified for the product.
IndraDrive Drive Controllers Power Sections HCS02 3/21
Important notes
R911319657_Edition 09 Bosch Rexroth AG

Environmental protection and disposal! The batteries contained in
the product are considered dangerous goods during land, air, and
sea transport (risk of explosion) in the sense of the legal
regulations. Dispose of used batteries separately from other
waste. Observe the national regulations of your country.
1.2 Intended use
This product may only be used for the mentioned applications under the
specified application, ambient and operating conditions.
This product is exclusively intended for use in machines and systems in an
industrial environment. This is to be understood as applications according to
IEC 60204-1 "Safety of machinery, Electric equipment of machines" and
NFPA 79 "Electrical Standard for Industrial Machinery".
Components of the Rexroth IndraDrive system are products of
Category C3 (with restricted distribution) in accordance with
IEC 61800‑3. This Category comprises EMC limit values for line-
based and radiated noise emission. Compliance with this
Category (limit values) requires the appropriate measures of
interference suppression to be used in the drive system (e.g.,
mains filters, shielding measures).
These components are not provided for use in a public low-
voltage mains supplying residential areas. If these components
are used in such a mains, high-frequency interference is to be
expected. This can require additional measures of interference
suppression.
4/21
Important notes
IndraDrive Drive Controllers Power Sections HCS02
Bosch Rexroth AG R911319657_Edition 09

2 Ratings and dimensions
2.1 HCS02
UL ratings and dimensions
Description Symbol Unit HCS02.1E-
W0012-_-03
HCS02.1E-
W0028-_-03
HCS02.1E-
W0054-_-03
HCS02.1E-
W0070-_-03
Listing in accordance with UL
standard UL 508C
Listing in accordance with CSA
standard C22.2 No. 274-13
UL files E134201
Pollution degree 2
Ambient temperature range with
nominal data Tamax °C 40
Ambient temperature range with
reduced nominal data Tamax_red °C 55
Mass m kg 2.90 3.80 6.70 6.80
Device height1) H mm 290 352
Device depth2) T mm 206
Device width3) B mm 65 105
Minimum distance on the top of
the device4) dtop mm 80
Minimum distance on the bottom
of the device5) dbot mm 80
Horizontal spacing at the device6) dhor mm 5
Rated control voltage input7) UN3 V 24 ± 20%
Rated power consumption control
voltage input at UN38) PN3 W 12 14 23
Short circuit current rating SCCR A rms 42000
Rated input voltage, power9) ULN_nom V 3 x AC 200...500
Tolerance rated input voltage ULN % ± 10
Mains frequency fLN Hz 50...60
Tolerance input frequency Hz ± 2
Rated input current ILN A 6.0 13.0 20.0 30.0
Branch circuit protection fuse10) 20 25 40
Required wire size in accordance
with NFPA 79 and UL 508 A
(internal wiring);11)
ALN AWG 14 AWG 12 AWG 10 AWG
Latest amendment: 2019-02-20
IndraDrive Drive Controllers Power Sections HCS02 5/21
Ratings and dimensions
R911319657_Edition 09 Bosch Rexroth AG

Description Symbol Unit HCS02.1E-
W0012-_-03
HCS02.1E-
W0028-_-03
HCS02.1E-
W0054-_-03
HCS02.1E-
W0070-_-03
Field wiring material (material;
conductor temperature; class) Cu; 60/75 °C; 1
Output voltage Uout V 3 x AC 0...530
Output current Iout A 4.5 12.0 20.6 28.0
Output frequency range12) fout Hz 0...1600
Power dissipation at continuous
current and continuous DC bus
power respectively13)
PDiss_cont W 80.00 130.00 270.00 300.00
Latest amendment: 2019-02-20
1) 2) 3) Housing dimension; see also related dimensional drawing
4) 5) 6) See fig. "Air intake and air outlet at device"
7) Observe supply voltage for motor holding brake
8) See information on "Rated power consumption control voltage
input at UN3"
9) Mains input L1, L2, L3 (for HMV and HCS only); For use on a
solidly grounded wye source only.
10) Use listed AC input line fuses (class J; 600 V AC). Suitable for
use on a circuit capable of delivering not more than 42000 Aeff
symmetrical amperes, 500 Volts maximum (HMV, HCS02,
HCS04.2 480 Volts maximum). If using inverse-time circuit
breakers or type E combination motor controllers instead of
recommended fuses, see UL 508C section 45.8.2.
11) Copper wire; PVC-insulation (conductor temperature 90 °C;
Ta ≤ 40 °C) in accordance with NFPA 79 chapter 12 and
UL 508A chapter 28
12) Depending on switching frequency which was set in parameter
P‑0‑0001
13) Plus dissipation of braking resistor and control section
Tab. 2-1: HCS - UL ratings and dimensions
Rated power consumption control voltage input at UN3
Plus motor holding brake and control section, plus safety option
6/21
Ratings and dimensions
IndraDrive Drive Controllers Power Sections HCS02
Bosch Rexroth AG R911319657_Edition 09

Distances
AAir intake
BAir outlet
CMounting surface in control cabinet
dtop Distance top
dbot Distance bottom
dhor Distance horizontal
Fig. 2-1: Air intake and air outlet at device
IndraDrive Drive Controllers Power Sections HCS02 7/21
Ratings and dimensions
R911319657_Edition 09 Bosch Rexroth AG

Dimensional drawing HCS02.1E-W0012
AMinimum mounting clearance (when using accessory
HAS02.1); plus additional space for cable
BMinimum mounting clearance; plus additional space for cable
Fig. 2-2: Dimensional drawing HCS02.1E-W0012
8/21
Ratings and dimensions
IndraDrive Drive Controllers Power Sections HCS02
Bosch Rexroth AG R911319657_Edition 09

Dimensional drawing HCS02.1E-W0028
AMinimum mounting clearance (when using accessory
HAS02.1); plus additional space for cable
BMinimum mounting clearance; plus additional space for cable
Fig. 2-3: Dimensional drawing HCS02.1E-W0028
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Ratings and dimensions
R911319657_Edition 09 Bosch Rexroth AG

Dimensional drawing HCS02.1E-W0054/70
AMinimum mounting clearance (when using accessory
HAS02.1); plus additional space for cable
BMinimum mounting clearance; plus additional space for cable
Fig. 2-4: Dimensional drawing HCS02.1E-W0054 and HCS02.1E-W0070
2.2 China RoHS 2
www.boschrexroth.com.cn/zh/cn/home_2/china_rohs2
10/21
Ratings and dimensions
IndraDrive Drive Controllers Power Sections HCS02
Bosch Rexroth AG R911319657_Edition 09

3 Overview of documentations
3.1 Motors
Title Type of documentation Document typecode1)
DOK-MOTOR*-…
Material number
R911…
MAD / MAF
Asynchronous Motors MAD / MAF
Project Planning Manual MAD/MAF****-PRxx-EN-P 295781
MBS-H
Synchronous Kit Spindle Motors
Project Planning Manual MBS-H******-PRxx-EN-P 297895
MLF
Synchronous Linear Motors
Project Planning Manual MLF********-PRxx-EN-P 293635
MCL
Ironless Linear Motors MCL
Project Planning Manual MCL********-PRxx-EN-P 330592
MKE Synchronous Motors
Synchronous Servo Motors
for Potentially Explosive Areas
acc. to ATEX and UL / CSA
Project Planning Manual MKE*GEN2***-PRxx-EN-P 297663
MSK
Synchronous Servo Motors
Project Planning Manual MSK********-PRxx-EN-P 296289
MSK
Synchronous Servo Motors
for Potentially Explosive Areas
Project Planning Manual MSK*EXGIIK3-PRxx-EN-P 312709
MSM
Synchronous Servo Motors
Data Sheet MSM********-DAxx-EN-P 329338
MS2E
Synchronous Servo Motors
acc. to ATEX Directive 2014/34/EU
Project Planning Manual MS2E*******-PR01-EN-P 394140
MS2N
Synchronous Servo Motors
Project Planning Manual MS2N*******-PRxx-EN-P 347583
MBT
Synchronous Torque Motors
Project Planning Manual MBT********-PRxx-EN-P 298798
1) In the documentation typecodes, "xx" is a placeholder for the
current edition of the documentation (e.g.: PR01 is the first edi‐
tion of a Project Planning Manual)
Tab. 3-1: Documentations – motors
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Overview of documentations
R911319657_Edition 09 Bosch Rexroth AG

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Bosch Rexroth AG R911319657_Edition 09

4 Instructions for use
4.1 Overcurrent protection
Protect the components against overcurrent:
● Branch circuit protection has to be provided externally
● Dimension the branch circuit protection according to the data "Branch
circuit protection fuse" (see Ratings and dimensions)
IndraDrive Drive Controllers Power Sections HCS02 13/21
Instructions for use
R911319657_Edition 09 Bosch Rexroth AG

4.2 Connection
4.2.1 Connection diagram
X1, L+/L- Not available for HCS02.1E-W0012
X9 Not available for HCS02.1E-W0012 and –W0028
Fig. 4-1: Overall Connection Diagram
14/21
Instructions for use
IndraDrive Drive Controllers Power Sections HCS02
Bosch Rexroth AG R911319657_Edition 09

Apart from the indicated connections, it is necessary to wire the
Bb contact at the control section for signaling the readiness for
operation of the drive controller (see Project Planning Manual
"Rexroth IndraDrive Drive Controllers Control Sections").
For proper function of the motor thermal management connect the motor
thermal sensor as described in the wiring diagram. Otherwise motor
overtemperature sensing is not provided by the drive.
For Rexroth motors with data memory in the motor encoder, such as MSK,
the motor overload protection level is set automatically while connecting the
motor to the drive. There is no adjustment necessary. Otherwise refer to the
Rexroth firmware documentation.
4.2.2 Connection points
Symbols used to describe the connection points
Screw terminal block Spring terminal Thread Max. connection cross
section
Max. tightening torque
Tab. 4-1: Symbols
Connection point HCS02
mm2 (AWG) Nm
X3, X5, A, B 1) 2) 4,0 (10) 0,6
C 3) 16,0 (6) 1,7
X6 A, B, C 1,5 (16) -
X9 B, C 4,0 (10) 1,7
X13 A, B, C 1,5 (16) -
L+, L- B, C M6 6,5
1) A: HCS02.1E-W0012
2) B: HCS02.1E-W0028
3) C: HCS02.1E-W0054, -W0070
Tab. 4-2: Connection points
IndraDrive Drive Controllers Power Sections HCS02 15/21
Instructions for use
R911319657_Edition 09 Bosch Rexroth AG

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Bosch Rexroth AG R911319657_Edition 09