Bosch REXROTH IndraDrive Technical manual

R911306140
Edition 02
Rexroth IndraDrive
Additional Components
Project Planning Manual
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics

About this Documentation Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-PR02-EN
Rexroth IndraDrive
Additional Components
Project Planning Manual
DOK-INDRV*-ADDCOMP****-PR02-EN
Document number 120-2400-B315-02
Description Release
Date Notes
DOK-INDRV*-ADDCOMP****-PR01-EN-P 11.04 first edition
DOK-INDRV*-ADDCOMP****-PR02-EN-P 03.05 motor filter HMF01.1 added
 Bosch Rexroth AG 2004 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
Telefon [phone] / 40-0 •Tx 68 94 21 •Fax [phone] / 40-48 85
http://www.boschrexroth.de/
Abt. EDY1
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revisions
Copyright
Validity
Published by
Note

Rexroth IndraDrive Contents I
DOK-INDRV*-ADDCOMP****-PR02-EN-P
Contents
1 Introduction 1-1
1.1 Documentation.............................................................................................................................. 1-1
About this Documentation ....................................................................................................... 1-1
Documentations - Overview .................................................................................................... 1-2
1.2 General Information on How to Install.......................................................................................... 1-3
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........................................................................... 3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)......................................... 3-6
3.7 Protection Against Dangerous Movements.................................................................................. 3-7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting....................................................................................................................................... 3-9
3.9 Protection Against Contact with Hot Parts.................................................................................. 3-10
3.10 Protection During Handling and Mounting.................................................................................. 3-10
3.11 Battery Safety ............................................................................................................................. 3-11
3.12 Protection Against Pressurized Systems.................................................................................... 3-11
4 Transformers 4-1
4.1 Autotransformers.......................................................................................................................... 4-2
Type Code............................................................................................................................... 4-2
Selection.................................................................................................................................. 4-3
Technical Data......................................................................................................................... 4-4
5 Mains Filter 5-1
5.1 Mains Filter NFD / NFE................................................................................................................. 5-1
Type Code NFE / NFD ............................................................................................................ 5-1
Technical Data NFE / NFD...................................................................................................... 5-4
Dimensions NFE / NFD........................................................................................................... 5-5
5.2 Mains Filter HNF01.1.................................................................................................................... 5-8

II Contents Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-PR02-EN-P
Type Code HNF01.1................................................................................................................ 5-8
Data HNF01.1.......................................................................................................................... 5-9
Dimensional Drawings HNF01.1 ........................................................................................... 5-10
5.3 Mains Filter (-Combination) HNK01.1......................................................................................... 5-12
Type Code HNK01.1 ............................................................................................................. 5-12
Type Plate HNK01.1..............................................................................................................5-13
Mechanical Data HNK01.1.................................................................................................... 5-14
Technical Data HNK01.1....................................................................................................... 5-18
Arrangement of Components ................................................................................................ 5-19
6 Mains Choke 6-1
6.1 Identification.................................................................................................................................. 6-1
Type Code............................................................................................................................... 6-1
Type Plate................................................................................................................................ 6-2
6.2 Mains Choke HNL01.1E (feeding)................................................................................................ 6-3
HNL01.1E-1000-N0012-A-500-NNNN, HNL01.1E-1000-N0020-A-500-NNNN,
HNL01.1E-0600-N0032-A-500-NNNN, HNL01.1E-0571-N0050-A-500-NNNN,
HNL01.1E-0400-N0051-A-480-NNNN, HNL01.1E-0362-N0080-A-500-NNNN,
HNL01.1E-0240-N0106-A-500-NNNN, HNL01.1E-0200-N0125-A-480-NNNN,
HNL01.1E-0170-N0146-A-500-NNNN, HNL01.1E-0100-N0202-A-480-NNNN..................... 6-3
6.3 Mains Choke HNL01.1R (regenerating)....................................................................................... 6-6
HNL01.1R-0980-C0026-A-480-NNNN, HNL01.1R-0590-C0065-A-480-NNNN,
HNL01.1R-0540-C0094-A-480-NNNN .................................................................................... 6-6
6.4 Mains Chokes HNL01.1E-****-S (current compensated) ............................................................. 6-7
HNL01.1E-5700-S0051-A-480-NNNN, HNL01.1E-2800-S0125-A-480-NNNN,
HNL01.1E-3400-S0202-A-480-NNNN, HNL01.1R-4200-S0026-A-480-NNNN,
HNL01.1R-6300-S0065-A-480-NNNN, HNL01.1R-3000-S0094-A-480-NNNN...................... 6-7
7 DC Bus Capacitor Unit HLC01.1 7-1
7.1 Application Instructions................................................................................................................. 7-1
7.2 Identification.................................................................................................................................. 7-2
Types....................................................................................................................................... 7-2
7.3 Mounting....................................................................................................................................... 7-3
Details...................................................................................................................................... 7-3
Mechanical Data...................................................................................................................... 7-4
7.4 Installation..................................................................................................................................... 7-6
Electrical Data.......................................................................................................................... 7-6
Connections............................................................................................................................. 7-6
8 DC Bus Resistor Unit HLB01.1C and HLB01.1D 8-1
8.1 Description.................................................................................................................................... 8-1
8.2 Identification.................................................................................................................................. 8-1
Type Code HLB01.1................................................................................................................ 8-1
8.3 Mounting HLB01.1........................................................................................................................ 8-2
Mechanical Data HLB01.1....................................................................................................... 8-2
8.4 Installation HLB01.1...................................................................................................................... 8-5
Electrical Data HLB01.1 .......................................................................................................... 8-5
Connections............................................................................................................................. 8-6

Rexroth IndraDrive Contents III
DOK-INDRV*-ADDCOMP****-PR02-EN-P
8.5 Diagnostic LEDs and Reset-Pushbutton.................................................................................... 8-15
9 Braking Resistors HLR01.1 9-1
9.1 General Information...................................................................................................................... 9-1
9.2 Identification.................................................................................................................................. 9-3
Type Code HLR01.1................................................................................................................ 9-3
Type Plate HLR01.1 ................................................................................................................ 9-4
9.3 Technical Characteristics of the Standard Braking Resistors HLR01.1....................................... 9-4
9.4 Mechanical Data of the Standard Braking Resistors HLR01.1..................................................... 9-5
Dimensioned Drawings............................................................................................................9-5
Arrangement of the Components Device / Braking Resistor HLR01.1N-0300-N17R-
A-007-NNNN............................................................................................................................ 9-7
9.5 Technical Data of the Standard Braking Resistors HLR01.1 ..................................................... 9-10
9.6 Technical Features of the Reinforced Braking Resistors HLR01.1............................................ 9-10
9.7 Technical Data of the Reinforced Braking Resistors HLR01.1................................................... 9-11
Braking Resistors for HCS03.1E-W0070 .............................................................................. 9-11
Braking Resistors for HCS03.1E-W0100 .............................................................................. 9-13
Braking Resistors for HCS03.1E-W0150 .............................................................................. 9-15
Braking Resistors for HCS03.1E-W0210 .............................................................................. 9-17
9.8 Line Cross Sections for Reinforced Braking Resistors HLR01.1 ............................................... 9-18
Requirements for Line Routing.............................................................................................. 9-18
9.9 Mechanical Data of the Reinforced Braking Resistors HLR01.1................................................ 9-19
Fixed Resistors IP 20 Type A................................................................................................ 9-19
Steel Grid Fixed Resistors IP 20 Type B............................................................................... 9-20
Steel Grid Fixed Resistors IP 20 Type C............................................................................... 9-21
10 Motor Filter HMF01.1 10-1
10.1 Type Code .................................................................................................................................. 10-1
10.2 Type Plate................................................................................................................................... 10-2
10.3 Electrical Data............................................................................................................................. 10-2
10.4 Mechanical Data......................................................................................................................... 10-3
Dimensional Drawings........................................................................................................... 10-3
10.5 Arrangement of the Components HCS03.1 / Motor Filter HMF.................................................. 10-5
10.6 Arrangement of the Components HCS03.1 / Motor Filter and Mains Filter................................ 10-7
11 Service & Support 11-1
11.1 Helpdesk..................................................................................................................................... 11-1
11.2 Service-Hotline ........................................................................................................................... 11-1
11.3 Internet........................................................................................................................................ 11-1
11.4 Vor der Kontaktaufnahme... - Before contacting us... ................................................................ 11-1
11.5 Kundenbetreuungsstellen - Sales & Service Facilities............................................................... 11-2
12 Index 12-1

IV Contents Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-PR02-EN-P

Rexroth IndraDrive Introduction 1-1
DOK-INDRV*-ADDCOMP****-PR02-EN-P
1 Introduction
1.1 Documentation
About this Documentation
This documentation contains the technical data of the additional
components of Rexroth IndraDrive drive systems:
•Transformers
•Mains filters
•Mains chokes
•DC bus capacitor units
•DC bus resistor units
•Braking resistors
•Motor filter
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 Introduction Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-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
Electromagnetic Compatibility (EMC) in
Drive and Control Systems Project Planning Manual DOK-GENERAL-EMV********-PRxx-EN-P
Rexroth IndraDrive
Integrated Safety Technology Functional and Application Description DOK-INDRV*-SI*-**VRS**-FKxx-EN-P
Rexroth Connection Cables Selection Data DOK-CONNEC-CABLE*STAND-AUxx-EN-P
Safety Instructions for Electrical Drives Safety Guidelines DOK-GENERAL-DRIVE-******-SVSx-MS-P
Rexroth IndraDrive
Additional Components Project Planning Manual DOK-INDRV*-ADDCOMP****-PRxx-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 IndraDyn S
Synchronous Motors MSK Project Planning Manual DOK-MOTOR*-MSK********-PRxx-EN-P
Rexroth IndraDyn A
Asynchronous Motors MAD/MAF Project Planning Manual DOK-MOTOR*-MAD/MAF****-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
Third Party Motors Project Planning Manual
and Commissioning DOK-DRIVE*-3RDPART*MOT-AWxx-EN-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 Introduction 1-3
DOK-INDRV*-ADDCOMP****-PR02-EN-P
1.2 General Information on How to Install
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:
CAUTION
Electrostatic charges can cause damage to
electronic components and interfere with their
operational safety!
⇒ Exposed conductive parts coming into contact with
components and circuit boards must be discharged by
means of grounding. Otherwise errors may occur
when 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 conductive
packaging.
Note: Rexroth connection diagrams are only to be used for
producing installation connection diagrams. The machine
manufacturer’s installation connection diagrams must be used
for wiring the installation!
•Lay signal lines separately from the load resistance lines because of
the occurrence of interference.
•Transmit analog signals (e.g. command values, actual values) via
shielded lines.
•Do not connect mains, DC bus or power leads to low voltages or allow
them to come into contact with these.
•When carrying out a high voltage test or an applied-overvoltage
withstand test on the machine’s electrical equipment, disconnect all
connections 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 in
accordance with EN 50178.
CAUTION
Risk of damage to the drive controller by
connecting and disconnecting live connections!
⇒ Do not connect and disconnect live connections.

1-4 Introduction Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-PR02-EN-P
Notes

Rexroth IndraDrive Important Directions for Use 2-1
DOK-INDRV*-ADDCOMP****-PR02-EN-P
2 Important Directions for Use
2.1 Appropriate Use
Introduction
Rexroth products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note: Rexroth, as manufacturer, is not liable for any damages
resulting from inappropriate use. In such cases, the guarantee
and the right to payment of damages resulting from
inappropriate use are forfeited. The user alone carries all
responsibility of the risks.
Before using Rexroth products, make sure that all the pre-requisites for
an appropriate use of the products are satisfied:
•Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
•If the product takes the form of hardware, then they must remain in
their original state, in other words, no structural changes are permitted.
It is not permitted to decompile software products or alter source
codes.
•Do not mount damaged or faulty products or use them in operation.
•Make sure that the products have been installed in the manner
described in the relevant documentation.

2-2 Important Directions for Use Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-PR02-EN-P
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.
Note: The drive controllers may only be used with the accessories
and parts specified in this document. If a component has not
been specifically named, then it may not be either mounted or
connected. The same applies to cables and lines.
Operation is only permitted in the specified configurations and
combinations of components using the software and firmware
as specified in the relevant function descriptions.
Every drive controller has to be programmed before starting it up, making
it possible for the motor to execute the specific functions of an application.
The drive controllers are designed for use in single or multiple-axis drive
and control applications.
To ensure an application-specific use, the drive controllers are available
with differing drive power and different interfaces.
Typical applications of drive controllers are:
•handling and mounting systems,
•packaging and foodstuff machines,
•printing and paper processing machines and
•machine tools.
The drive controllers may only be operated under the assembly,
installation and ambient conditions as described here (temperature,
system of protection, humidity, EMC requirements, etc.) and in the
position specified.
2.2 Inappropriate Use
Using the drive controllers outside of the above-referenced areas of
application or under operating conditions other than described in the
document and the technical data specified is defined as “inappropriate
use".
Drive controllers may not be used if
•they are subject to operating conditions that do not meet the above
specified ambient conditions. This includes, for example, operation
under water, in the case of extreme temperature fluctuations or
extremely high maximum temperatures or if
•Rexroth has not specifically released them for that intended purpose.
Please note the specifications outlined in the general safety
instructions!

Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-1
DOK-INDRV*-ADDCOMP****-PR02-EN-P
3 Safety Instructions for Electric Drives and Controls
3.1 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.
Do not attempt to install or start up this equipment without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation of the equipment prior to
working with the equipment at any time. If you do not have the user
documentation for your equipment, contact your local Rexroth
representative to send this documentation immediately to the person or
persons responsible for the safe operation of this equipment.
If the equipment is resold, rented or transferred or passed on to others,
then these safety instructions must be delivered with the equipment.
WARNING
Improper use of this equipment, failure to follow
the safety instructions in this document or
tampering with the product, including disabling
of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
3.2 Explanations
The safety instructions describe the following degrees of hazard
seriousness in compliance with ANSI Z535. The degree of hazard
seriousness informs about the consequences resulting from non-
compliance with the safety instructions.
Warning symbol with signal
word Degree of hazard seriousness according to ANSI
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 Z535)

3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-PR02-EN-P
3.3 Hazards by Improper Use
DANGER
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
unintentional motor movements!
WARNING
High electrical voltage due to wrong
connections! Danger to life or bodily harm by
electric shock!
WARNING
Health hazard for persons with heart
pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
CAUTION
Surface of machine housing could be extremely
hot! Danger of injury! Danger of burns!
CAUTION
Risk of injury due to improper handling! Bodily
harm caused by crushing, shearing, cutting and
mechanical shock or incorrect handling of
pressurized systems!
CAUTION
Risk of injury due to incorrect handling of
batteries!

Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-3
DOK-INDRV*-ADDCOMP****-PR02-EN-P
3.4 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. If you find that you cannot
completely understand the documentation for your product, please ask
your supplier to clarify.
•Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this equipment.
•Only persons who are trained and qualified for the use and operation
of the equipment may work on this equipment or within its proximity.
•The persons are qualified if they have sufficient knowledge of the
assembly, installation and operation of the equipment as well as an
understanding of all warnings and precautionary measures noted in
these instructions.
•Furthermore, they must be trained, instructed and qualified to
switch electrical circuits and equipment on and off in accordance
with technical safety regulations, to ground them and to mark them
according to the requirements of safe work practices. They must
have adequate safety equipment and be trained in first aid.
•Only use spare parts and accessories approved by the manufacturer.
•Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
•The equipment is designed for installation in industrial machinery.
•The ambient conditions given in the product documentation must be
observed.
•Use only safety features and applications that are clearly and explicitly
approved in the Project Planning Manual.
For example, the following areas of use are not permitted: construction
cranes, elevators used for people or freight, devices and vehicles to
transport people, medical applications, refinery plants, transport of
hazardous goods, nuclear applications, applications sensitive to high
frequency, mining, food processing, control of protection equipment
(also in a machine).
•The information given in the documentation of the product with regard
to the use of the delivered components contains only examples of
applications and suggestions.
The machine and installation manufacturer must
•make sure that the delivered components are suited for his
individual application and check the information given in this
documentation with regard to the use of the components,
•make sure that his application complies with the applicable safety
regulations and standards and carry out the required measures,
modifications and complements.
•Startup of the delivered components is only permitted once it is sure
that the machine or installation in which they are installed complies
with the national regulations, safety specifications and standards of the
application.

3-4 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-PR02-EN-P
•Operation is only permitted if the national EMC regulations for the
application are met.
The instructions for installation in accordance with EMC requirements
can be found in the documentation "EMC in Drive and Control
Systems".
The machine or installation manufacturer is responsible for
compliance with the limiting values as prescribed in the national
regulations.
•Technical data, connections and operational conditions are specified in
the product documentation and must be followed at all times.

Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-5
DOK-INDRV*-ADDCOMP****-PR02-EN-P
3.5 Protection Against Contact with Electrical Parts
Note: This section refers to equipment and drive components with
voltages above 50 Volts.
Touching live parts with voltages of 50 Volts and more with bare hands or
conductive tools or touching ungrounded housings can be dangerous and
cause electric shock. In order to operate electrical equipment, certain
parts must unavoidably have dangerous voltages applied to them.
DANGER
High electrical voltage! Danger to life, severe
bodily harm by electric shock!
⇒ Only those trained and qualified to work with or on
electrical equipment are permitted to operate, maintain
or repair this equipment.
⇒ Follow general construction and safety regulations when
working on high voltage installations.
⇒ Before switching on power the ground wire must be
permanently connected to all electrical units according
to the connection diagram.
⇒ Do not operate electrical equipment at any time, even
for brief measurements or tests, if the ground wire is not
permanently connected to the points of the components
provided for this purpose.
⇒ Before working with electrical parts with voltage higher
than 50 V, the equipment must be disconnected from
the mains voltage or power supply. Make sure the
equipment cannot be switched on again unintended.
⇒ The following should be observed with electrical drive
and filter components:
⇒ Wait thirty (30) minutes after switching off power to
allow capacitors to discharge before beginning to work.
Measure the voltage on the capacitors before beginning
to work to make sure that the equipment is safe to
touch.
⇒ Never touch the electrical connection points of a
component while power is turned on.
⇒ Install the covers and guards provided with the
equipment properly before switching the equipment on.
Prevent contact with live parts at any time.
⇒ A residual-current-operated protective device (RCD)
must not be used on electric drives! Indirect contact
must be prevented by other means, for example, by an
overcurrent protective device.
⇒ Electrical components with exposed live parts and
uncovered high voltage terminals must be installed in a
protective housing, for example, in a control cabinet.

3-6 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-PR02-EN-P
To be observed with electrical drive and filter components:
DANGER
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
electrical units and motors permanently with the safety
conductor at the ground points before power is
switched on. Look at the connection diagram. This is
even necessary for brief tests.
⇒ Connect the safety conductor of the electrical
equipment always permanently and firmly to the
supply mains. Leakage current exceeds 3.5 mA in
normal operation.
⇒ Use a copper conductor with at least 10 mm² cross
section over its entire course for this safety conductor
connection! The cross section must not be smaller
than the cross section of a phase of the mains supply
wire.
⇒ Prior to startups, even for brief tests, always connect
the protective conductor or connect with ground wire.
Otherwise, high voltages can occur on the housing
that lead to electric shock.
3.6 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.
WARNING
High electrical voltage due to wrong
connections! Danger to life, bodily harm by
electric shock!
⇒ Only connect equipment, electrical components and
cables of the protective low voltage type (PELV =
Protective Extra Low Voltage) to all terminals and
clamps with voltages of 0 to 50 Volts.
⇒ Only electrical circuits may be connected which are
safely isolated against high voltage circuits. Safe
isolation is achieved, for example, with an isolating
transformer, an opto-electronic coupler or when
battery-operated.

Rexroth IndraDrive Safety Instructions for Electric Drives and Controls 3-7
DOK-INDRV*-ADDCOMP****-PR02-EN-P
3.7 Protection Against Dangerous Movements
Dangerous movements can be caused by faulty control of the connected
motors. Some common examples are:
•improper or wrong wiring of cable connections
•incorrect operation of the equipment components
•wrong input of parameters before operation
•malfunction of sensors, encoders and monitoring devices
•defective components
•software or firmware errors
Dangerous movements can occur immediately after equipment is
switched on or even after an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be sufficient to avoid
faulty operation in the connected drives. Regarding personal safety,
especially the danger of bodily injury and material damage, this alone
cannot be relied upon to ensure complete safety. Until the integrated
monitoring functions become effective, it must be assumed in any case
that faulty drive movements will occur. The extent of faulty drive
movements depends upon the type of control and the state of operation.

3-8 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive
DOK-INDRV*-ADDCOMP****-PR02-EN-P
DANGER
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
integrated in the installation. Unintended machine
motion is possible if monitoring devices are disabled,
bypassed or not activated.
⇒ Pay attention to unintended machine motion or other
malfunction in any mode of operation.
⇒ Keep free and clear of the machine’s range of motion
and moving parts. Possible measures to prevent
people from accidentally entering the machine’s range
of motion:
- use safety fences
- use safety guards
- use protective coverings
- install light curtains or light barriers
⇒ Fences and coverings must be strong enough to
resist maximum possible momentum, especially if
there is a possibility of loose parts flying off.
⇒ Mount the emergency stop switch in the immediate
reach of the operator. Verify that the emergency stop
works before startup. Don’t operate the machine if the
emergency stop is not working.
⇒ Isolate the drive power connection by means of an
emergency stop circuit or use a starting lockout to
prevent unintentional start.
⇒ Make sure that the drives are brought to a safe
standstill before accessing or entering the danger
zone. Safe standstill can be achieved by switching off
the power supply contactor or by safe mechanical
locking of moving parts.
⇒ Secure vertical axes against falling or dropping after
switching off the motor power by, for example:
- mechanically securing the vertical axes
- adding an external braking/ arrester/ clamping
mechanism
- ensuring sufficient equilibration of the vertical axes
The standard equipment motor brake or an external
brake controlled directly by the drive controller are
not sufficient to guarantee personal safety!