Bosch Rexroth IndraDrive HMV Technical manual

Rexroth IndraDrive
Supply Units and
Power Sections
R911318790
Edition 02
Project Planning Manual
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics

Rexroth IndraDrive
Supply Units and
Power Sections
Project Planning Manual
DOK-INDRV*-HMV-S-D+HCS-PR02-EN-P
RS-dfb5157c0a6846ac0005d70aedbf4f52-4-en-US-3
Edition Release Date Notes
120-2400-B331-01/EN 2007/03 1st edition
120-2400-B331-02/EN 2007/08 2nd edition
Copyright © 2007 Bosch Rexroth AG
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).
Validity The specified data is for product description purposes only and may not be
deemed to be guaranteed unless expressly confirmed in the contract. All rights
are reserved with respect to the content of this documentation and the availa‐
bility of the product.
Published by Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ D-97816 Lohr a. Main
Telephone [phone] ■ Fax [phone]
http://www.boschrexroth.com/
Dept. BRC/EDY1 (RR/US/BB)
Note This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revision
Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraDrive |Project Planning Manual

Table of Contents
Page
1 Introduction.................................................................................................................... 1
1.1 About this Documentation....................................................................................................................... 1
1.2 Reference Documentations ................................................................................................................... 1
1.2.1 Overview.............................................................................................................................................. 1
1.3 Your Feedback....................................................................................................................................... 3
2 Important Directions for Use ......................................................................................... 5
2.1 Appropriate Use ..................................................................................................................................... 5
2.1.1 Introduction.......................................................................................................................................... 5
2.1.2 Areas of Use and Application.............................................................................................................. 5
2.2 Inappropriate Use .................................................................................................................................. 6
3 Safety Instructions for Electric Drives and Controls ...................................................... 7
3.1 Safety Instructions - General Information............................................................................................... 7
3.1.1 Using the Safety Instructions and Passing them on to Others............................................................ 7
3.1.2 How to Employ the Safety Instructions................................................................................................ 7
3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness.............................................. 8
3.1.4 Hazards by Improper Use.................................................................................................................... 9
3.2 Instructions with Regard to Specific Dangers....................................................................................... 10
3.2.1 Protection Against Contact with Electrical Parts and Housings......................................................... 10
3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage................................................. 11
3.2.3 Protection Against Dangerous Movements....................................................................................... 11
3.2.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 14
3.2.5 Protection Against Contact with Hot Parts......................................................................................... 14
3.2.6 Protection During Handling and Mounting......................................................................................... 14
3.2.7 Battery Safety.................................................................................................................................... 15
3.2.8 Protection Against Pressurized Systems........................................................................................... 15
4 General Specifications of the Devices ........................................................................ 17
4.1 Certifications ........................................................................................................................................ 17
4.2 Transport and Storage.......................................................................................................................... 19
4.2.1 Transporting the Devices .................................................................................................................. 19
4.2.2 Storing the Devices .......................................................................................................................... 19
4.3 Installation Conditions .......................................................................................................................... 19
4.3.1 Ambient and Operating Conditions ................................................................................................... 19
4.3.2 Mounting Position ............................................................................................................................. 21
4.3.3 Compatibility with Foreign Matters ................................................................................................... 21
4.4 Capacity Utilization .............................................................................................................................. 22
4.5 High-Voltage Test ................................................................................................................................ 23
4.6 Control Voltage Specification (24V Supply) ......................................................................................... 23
5 Power Sections for Converters - IndraDrive C............................................................. 27
5.1 Types ................................................................................................................................................... 27
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5.2 HCS02 Power Sections ....................................................................................................................... 27
5.2.1 Brief Description, Usage and Structure............................................................................................. 27
5.2.2 Type Code and Identification............................................................................................................. 31
Type Code ..................................................................................................................................... 31
Identification................................................................................................................................... 33
5.2.3 Scope of Supply ............................................................................................................................... 34
5.2.4 Technical Data .................................................................................................................................. 34
Ambient and Operating Conditions................................................................................................. 34
Mechanical System and Mounting.................................................................................................. 36
Basic Data Power Section HCS02................................................................................................. 42
Exemplary Data for Applications.................................................................................................... 49
5.2.5 Connections and Interfaces............................................................................................................... 57
Overview......................................................................................................................................... 57
Description of the Connection Points............................................................................................. 62
5.3 HCS03 Power Sections ....................................................................................................................... 62
5.3.1 Brief Description, Usage and Structure............................................................................................. 62
5.3.2 Type Code and Identification............................................................................................................. 64
Type Code ..................................................................................................................................... 64
Identification................................................................................................................................... 66
5.3.3 Scope of Supply ............................................................................................................................... 66
5.3.4 Technical Data .................................................................................................................................. 67
Ambient and Operating Conditions................................................................................................. 67
Mechanical System and Mounting.................................................................................................. 68
Basic Data Power Section HCS03................................................................................................. 80
Exemplary Data for Applications.................................................................................................... 87
5.3.5 Connections and Interfaces............................................................................................................... 94
Overview......................................................................................................................................... 94
Description of the Connection Points............................................................................................. 97
6 Power Sections for Inverters - IndraDrive M................................................................ 99
6.1 Overview of Types ............................................................................................................................... 99
6.2 HMS01 Power Sections ....................................................................................................................... 99
6.2.1 Brief Description, Usage and Structure............................................................................................. 99
6.2.2 Type Code and Identification........................................................................................................... 101
Type Code ................................................................................................................................... 101
Identification................................................................................................................................. 103
6.2.3 Scope of Supply ............................................................................................................................. 104
6.2.4 Technical Data ................................................................................................................................ 104
Ambient and Operating Conditions............................................................................................... 104
Mechanical System and Mounting................................................................................................ 106
Basic Data Power Section HMS01............................................................................................... 117
Exemplary Data for Applications.................................................................................................. 123
6.2.5 Connections and Interfaces............................................................................................................. 133
Overview....................................................................................................................................... 133
6.3 HMS02 Power Sections ..................................................................................................................... 141
6.3.1 Brief Description, Usage and Structure........................................................................................... 141
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6.3.2 Type Code and Identification........................................................................................................... 143
Type Code ................................................................................................................................... 143
Identification................................................................................................................................. 144
6.3.3 Scope of Supply ............................................................................................................................. 145
6.3.4 Technical Data ................................................................................................................................ 145
Ambient and Operating Conditions............................................................................................... 145
Mechanical System and Mounting................................................................................................ 146
Basic Data Power Section HMS02............................................................................................... 150
Exemplary Data for Applications.................................................................................................. 153
6.3.5 Connections and Interfaces............................................................................................................. 158
Overview....................................................................................................................................... 158
Description of the Connection Points........................................................................................... 161
6.4 HMD01 Power Sections ..................................................................................................................... 161
6.4.1 Brief Description, Usage and Structure........................................................................................... 161
6.4.2 Type Code and Identification........................................................................................................... 162
Type Code ................................................................................................................................... 162
Identification................................................................................................................................. 164
6.4.3 Scope of Supply ............................................................................................................................. 165
6.4.4 Technical Data ................................................................................................................................ 165
Ambient and Operating Conditions............................................................................................... 165
Mechanical System and Mounting................................................................................................ 166
Basic Data Power Section HMD01............................................................................................... 171
Exemplary Data for Applications.................................................................................................. 174
6.4.5 Connections and Interfaces............................................................................................................. 180
Overview....................................................................................................................................... 180
Description of the Connection Points........................................................................................... 182
7 IndraDrive M Supply Units......................................................................................... 183
7.1 Types ................................................................................................................................................. 183
7.2 HMV01.1E Supply Units, Infeeding ................................................................................................... 183
7.2.1 Brief Description, Usage and Structure........................................................................................... 183
7.2.2 Type Code and Identification........................................................................................................... 184
Type Code ................................................................................................................................... 184
Identification................................................................................................................................. 186
7.2.3 Scope of Supply ............................................................................................................................. 186
7.2.4 Technical Data HMV01.1E ............................................................................................................. 187
Ambient and Operating Conditions............................................................................................... 187
Mechanical System and Mounting................................................................................................ 188
Basic Data Supply Unit HMV01, Infeeding................................................................................... 190
Exemplary Data for Applications.................................................................................................. 195
7.2.5 Connections and Interfaces............................................................................................................. 199
Overview....................................................................................................................................... 199
Description of the Connection Points........................................................................................... 202
7.3 HMV01.1R Supply Units, Regenerative ............................................................................................. 202
7.3.1 Brief Description, Usage and Structure........................................................................................... 202
7.3.2 Type Code and Identification........................................................................................................... 203
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...................................................................................................................................................... 203
Identification................................................................................................................................. 205
7.3.3 Scope of Supply ............................................................................................................................. 205
7.3.4 Technical Data HMV01.1R ............................................................................................................. 206
Ambient and Operating Conditions............................................................................................... 206
Mechanical System and Mounting................................................................................................ 207
Basic Data Supply Unit HMV01, Regenerative............................................................................ 210
Exemplary Data for Applications.................................................................................................. 213
7.3.5 Connections and Interfaces............................................................................................................. 217
Overall Connection Diagram HMV01.1R-W0018, -W0045, -W0065............................................ 217
Overall Connection Diagram HMV01.1R-W0120......................................................................... 218
Connection Diagram with HLB01.1D ........................................................................................... 219
Arrangement of the Connection Points ........................................................................................ 220
Description of the Connection Points........................................................................................... 222
7.4 HMV02.1R Supply Units, Regenerative ............................................................................................. 222
7.4.1 Brief Description, Usage and Structure........................................................................................... 222
7.4.2 Type Code and Identification........................................................................................................... 223
Type Code ................................................................................................................................... 223
Identification................................................................................................................................. 225
7.4.3 Scope of Supply ............................................................................................................................. 225
7.4.4 Technical Data HMV02.1R ............................................................................................................. 226
Ambient and Operating Conditions............................................................................................... 226
Mechanical System and Mounting................................................................................................ 227
Basic Data Supply Unit HMV02, Regenerative............................................................................ 229
Exemplary Data for Applications.................................................................................................. 233
7.4.5 Connections and Interfaces............................................................................................................. 237
Overview....................................................................................................................................... 237
Arrangement of the Connection Points ........................................................................................ 239
Description of the Connection Points........................................................................................... 240
8 Functions and Electrical Connection Points .............................................................. 241
8.1 Overview of Functions, Power Sections and Supply Units................................................................. 241
8.2 Electrical Connection Points – Overview ........................................................................................... 244
8.3 X1, Module Bus ................................................................................................................................. 246
8.4 X2, Serial Interface (RS232) .............................................................................................................. 246
8.4.1 General Information......................................................................................................................... 246
8.4.2 Connection Diagrams Serial Interface to PC .................................................................................. 248
8.5 X3, Mains Connection ........................................................................................................................ 248
8.5.1 Important Notes............................................................................................................................... 248
8.5.2 X3, Mains Connection HMV02.1R-W0015...................................................................................... 250
8.5.3 X3, Mains Connection HCS02.1E-W0012, ‑W0028........................................................................ 250
8.5.4 X3, Mains Connection HCS02.1E-W0054, -W0070 and HCS03.1E-W0070................................... 251
8.5.5 X3, Mains Connection HCS03.1E-W0100…0150 and HMV01.1R-W0018…0065; HMV01.1E-
W0030…0075.................................................................................................................................. 251
8.5.6 X3, Mains Connection HCS03.1E-W0210....................................................................................... 252
8.5.7 X3, Mains Connection HMV01.1E-W0120 and HMV01.1R-W0120................................................ 253
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8.6 X5, Motor Connection ........................................................................................................................ 253
8.6.1 Important Notes............................................................................................................................... 253
8.6.2 X5, Motor Connection HCS02.1E-W0012, -W0028 and HMS01.1N-W0020, -W0036 and HMD01.1N-
W0012…0036 and HMS02.1N-W0028........................................................................................... 255
8.6.3 X5, Motor Connection HCS02.1E-W0054, ‑W0070 and HCS03.1E-W0070 and HMS01.1N-W0054,
‑W0070 and HMS02.1N-W0054...................................................................................................... 256
8.6.4 X5, Motor Connection HMS01.1N-W0110....................................................................................... 257
8.6.5 X5, Motor Connection HCS03.1E-W0100…0150 and HMS01.1N-W0150…0210.......................... 257
8.6.6 X5, Motor Connection HCS03.1E-W0210....................................................................................... 258
8.6.7 X5, Motor Connection HMS01.1N-W0350....................................................................................... 259
8.7 X6, Motor Temperature Monitoring and Motor Holding Brake ........................................................... 259
8.7.1 Important Notes............................................................................................................................... 259
8.7.2 Connection Point............................................................................................................................. 262
8.8 X9, External Braking Resistor ............................................................................................................ 263
8.8.1 Important Notes............................................................................................................................... 263
8.8.2 X9, External Braking Resistor HCS02.1E‑W0054, ‑W0070............................................................ 263
8.8.3 X9, External Braking Resistor HCS03.1E-W0070…0210............................................................... 264
8.9 X13, Control Voltage (24V, 0V) ......................................................................................................... 265
8.10 X13, Supply Blower Unit HAB01 ........................................................................................................ 267
8.11 X14, Mains Voltage Synchronization ................................................................................................. 269
8.11.1 Connection Point............................................................................................................................. 269
8.11.2 Mains Synchronization HMV01 ...................................................................................................... 269
8.11.3 Mains Synchronization HMV02 ...................................................................................................... 270
8.12 X31, Messages Bb1, UD, WARN ...................................................................................................... 271
8.13 X32, Mains Contactor Control and DC Bus Short Circuit .................................................................. 273
8.14 X33, Acknowledge Messages of Integrated Mains Contactor ........................................................... 275
8.15 X34, Contact for Controlling the External Mains Contactor ............................................................... 277
8.16 X40, Acknowledge Messages of External Mains Contactor .............................................................. 278
8.17 Terminal Block, 24V - 0V (24V Supply) ............................................................................................. 280
8.18 Terminal Block L+, L- (DC Bus Connection) ...................................................................................... 281
8.19 XS1, Shield Connection Control Lines ............................................................................................... 283
8.20 XS2, Shield Connection Motor Cable ................................................................................................ 283
8.21 Ground Connection ............................................................................................................................ 284
8.22 Connection Point of Equipment Grounding Conductor, HMV ............................................................ 284
8.23 Connection Point of Equipment Grounding Conductor, HMS, HMD .................................................. 287
9 Touch Guard at Devices ........................................................................................... 291
9.1 Cutouts............................................................................................................................................... 291
9.2 Mounting............................................................................................................................................. 292
10 Operation and Diagnosis........................................................................................... 293
10.1 Supply Units........................................................................................................................................ 293
10.1.1 Control Panel................................................................................................................................... 293
Brief Description........................................................................................................................... 293
Functional Description.................................................................................................................. 293
10.1.2 Diagnostic Messages Displayed at IndraDrive M Supply Units....................................................... 297
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HMV - Diagnostic Messages for Operating States and During the Initialization Phase............... 297
HMV - Diagnostic Warning Messages.......................................................................................... 298
HMV - Diagnostic Error Messages............................................................................................... 298
HMV - Diagnostic Command Messages....................................................................................... 300
10.2 Drive Controllers................................................................................................................................. 301
10.2.1 Control Panel................................................................................................................................... 301
10.2.2 Diagnostic Messages Displayed at Drive Controllers...................................................................... 301
11 Accessories................................................................................................................ 303
11.1 General Information............................................................................................................................ 303
11.2 HAS01 Basic Accessories ................................................................................................................. 303
11.2.1 Type Code....................................................................................................................................... 303
11.2.2 Brief Description.............................................................................................................................. 304
11.2.3 Usage.............................................................................................................................................. 305
11.2.4 Assignment ..................................................................................................................................... 305
11.2.5 Scope of Supply ............................................................................................................................. 306
11.2.6 Mounting the Parts “Bar” and “End Piece” of the Accessories HAS01 ........................................... 331
11.3 HAS02 Shield Connection ................................................................................................................. 331
11.3.1 General Information......................................................................................................................... 331
11.3.2 Type Code....................................................................................................................................... 332
11.3.3 Usage.............................................................................................................................................. 332
11.3.4 Assignment of Accessory HAS02.................................................................................................... 332
11.3.5 Scope of Supply.............................................................................................................................. 333
11.3.6 Mounting the Accessory HAS02...................................................................................................... 348
General Information...................................................................................................................... 348
HAS02.1-001 at HMS01.1N-W0054............................................................................................. 349
HAS02.1-002 at HCS02.1E-W0054............................................................................................. 350
HAS02.1-003 at HMS01.1N-W0210............................................................................................. 351
HAS02.1-004 at HCS03.1E-W0070............................................................................................. 352
HAS02.1-005 at HCS03.1E-W0100 / 150.................................................................................... 353
HAS02.1-008 at HCS03.1E-W0210............................................................................................. 354
HAS02.1-010 at HMS02.1N‑W0028 / 54...................................................................................... 354
HAS02.1-014 at HMS01.1N-W0350............................................................................................. 355
11.3.7 Shield Connection of the Motor Cable via Mains Filter ................................................................... 355
General Information...................................................................................................................... 355
HAS02.1-006 With Motor Cable and Mains Filter......................................................................... 356
HAS02.1-007 With Power Supply Cable and Mains Filter............................................................ 357
HAS02.1-009 With Power Supply Cable and Mains Filter............................................................ 358
12 Environmental Protection and Disposal .................................................................... 359
12.1 Environmental Protection.................................................................................................................... 359
12.1.1 Production Processes ..................................................................................................................... 359
12.1.2 Prohibited Substances .................................................................................................................... 359
12.1.3 No Release of Hazardous Substances ........................................................................................... 359
12.1.4 Principal Components .................................................................................................................... 359
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12.2 Disposal.............................................................................................................................................. 359
12.2.1 Return of Products .......................................................................................................................... 359
12.2.2 Packaging Materials ....................................................................................................................... 359
12.2.3 Recycling ........................................................................................................................................ 360
13 Service and Support.................................................................................................. 361
13.1 Helpdesk............................................................................................................................................. 361
13.2 Service Hotline.................................................................................................................................... 361
13.3 Internet................................................................................................................................................ 361
13.4 Helpful Information.............................................................................................................................. 361
Index.......................................................................................................................... 363
Project Planning Manual |Rexroth IndraDrive Electric Drives
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|Bosch Rexroth AG VII/VII
Table of Contents

Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraDrive |Project Planning Manual

1 Introduction
1.1 About this Documentation
WARNING
Personal injury and property damage caused by incorrect project plan‐
ning for applications, machines and installations!
Observe the contents of the reference documentations relevant to your drive
system (see chapter 1.2 Reference Documentations , page 1).
In particular, take the Project Planning Manual “Rexroth IndraDrive, Drive Sys‐
tem” into account.
Purpose of Documentation This documentation provides information on
● how to configure Rexroth IndraDrive systems
● considering the components
– HMV supply units
– HMS, HMD, HCS02, HCS03 power sections
Changes in Comparison to Previ‐
ous Edition Chapter Changes
Power Sections for Converters HCS02, HCS03: technical data for order code ‑L***
added
Power Sections for Inverters HMS01.1N-W0350: technical data added
IndraDrive M Supply Units separate connection diagram made available for
HMV01.1R-W0120
Functions and Electrical Connec‐
tion Points
X33, Acknowledge messages mains contactor ex‐
tended; differences integrated/external mains con‐
tactor included
X40, Acknowledge messages external mains con‐
tactor added (HMV01.1R-W0120)
Accessories accessories HAS01 and HAS02 added
Fig.1-1: Changes
1.2 Reference Documentations
1.2.1 Overview
The following documentations contain detailed information on the
● allowed applications
● application, ambient and operating conditions
● technical properties of the components
Reference documentations - drive controllers
Title Kind of documentation Document typecode1)
Rexroth IndraDrive – Drive System Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P
Rexroth IndraDrive Supply Units and Pow‐
er Sections
Project Planning Manual DOK-INDRV*-HMV-S-D+HCS-PR01-EN-P
Project Planning Manual |Rexroth IndraDrive Electric Drives
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|Bosch Rexroth AG 1/369
Introduction

Title Kind of documentation Document typecode1)
Rexroth IndraDrive - Drive Controllers
Control Sections
Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P
Rexroth IndraDrive Additional Compo‐
nents
Project Planning Manual DOK-INDRV*-ADDCOMP****-PRxx-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.1-2: Documentations - overview
The following documentations describe the firmware and contain
information on its scope of functions.
Reference documentations - firmware for drive controllers
Title Kind of documentation Document typecode1)
Rexroth IndraDrive Firmware for Drive
Controllers
Functional Description DOK-INDRV*-MP*-02VRS**-FKxx-EN-P
Rexroth IndraDrive Firmware for Drive
Controllers
Functional Description DOK-INDRV*-MP*-03VRS**-FKxx-EN-P
Rexroth IndraDrive Firmware for Drive
Controllers
Functional Description DOK-INDRV*-MP*-04VRS**-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 IndraDrive Integrated Safety
Technology
Functional and Application
Description
DOK-INDRV*-SI*-**VRS**-FKxx-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.1-3: Documentations - overview
Supplementary documentations - motors
Title Kind of documentation Document typecode1)
Rexroth Connection Cables Selection Data DOK-CONNEC-CABLE*STAND-AUxx-EN-P
Rexroth IndraDyn A Asynchronous Motors Project Planning Manual DOK-MOTOR*-MAD/MAF****-PRxx-EN-P
Rexroth IndraDyn H Frameless Synchro‐
nous Spindle Motors
Project Planning Manual DOK-MOTOR*-MBS-H******-PRxx-EN-P
Rexroth IndraDyn L Synchronous Linear
Motors
Project Planning Manual DOK-MOTOR*-MLF********-PRxx-EN-P
Rexroth IndraDyn S Synchronous Motors Project Planning Manual DOK-MOTOR*-MSK********-PRxx-EN-P
Rexroth IndraDyn T Synchronous Torque
Motors
Project Planning Manual DOK-MOTOR*-MBT********-PRxx-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.1-4: Documentations - overview
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Rexroth IndraDrive |Project Planning Manual
Introduction

1.3 Your Feedback
Your experience is important for our improvement processes of
products and documentations.
Inform us about mistakes you discovered in this documentation and changes
you suggest; we would be grateful for your feedback.
Please send your remarks to:
Address for Your Feedback Bosch Rexroth AG
Dept. BRC/EDY1
Bürgermeister-Dr.-Nebel-Str. 2
D-97816 Lohr
e-mail: [email protected]
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Introduction

Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraDrive |Project Planning Manual

2 Important Directions for Use
2.1 Appropriate Use
2.1.1 Introduction
Rexroth products represent state-of-the-art developments and manufacturing.
They are tested prior to delivery to ensure operating safety and reliability.
WARNING
Personal injury and property damage caused by incorrect use of the
products!
The products have been designed for use in the industrial environment and may
only be used in the appropriate way. If they are not used in the appropriate way,
situations resulting in property damage and personal injury can occur.
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 forfei‐
ted. The user alone carries all responsibility of the risks.
Before using Rexroth products, make sure that all the pre-requisites for an ap‐
propriate 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 ap‐
propriate use.
● If the products 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 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.
2.1.2 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 Drive controllers may require additional sensors
and actors.
The drive controllers may only used with the accessories and parts
specified in this documentation. If a component has not been spe‐
cifically named, then it may neither be mounted nor connected. The
same applies to cables and lines.
Operation is only permitted in the specified configurations and com‐
binations of components using the software and firmware as speci‐
fied in the relevant Functional Descriptions.
Drive controllers have to be programmed before commissioning, making it pos‐
sible for the motor to execute the specific functions of an application.
Drive controllers of the Rexroth IndraDrive line have been developed for use in
single- and multi-axis drive and control tasks.
To ensure application-specific use of Drive controllers, device types of different
drive power and different interfaces are available.
Typical applications include:
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|Bosch Rexroth AG 5/369
Important Directions for Use

● handling and mounting systems,
● packaging and food machines,
● printing and paper processing machines and
● machine tools.
Drive controllers may only be operated under the assembly and installation
conditions described in this documentation, in the specified position of normal
use and under the ambient conditions as described (temperature, degree of
protection, humidity, EMC, etc.).
2.2 Inappropriate Use
Using the Drive controllers outside of the operating conditions described in this
documentation and outside of the indicated technical data and specifications is
defined as "inappropriate use".
Drive controllers must not be used, if …
● they are subject to operating conditions that do not meet the specified
ambient conditions. This includes, for example, operation under water,
under extreme temperature fluctuations or extremely high maximum tem‐
peratures.
● Furthermore, Drive controllers must not be used in applications which
have not been expressly authorized by Rexroth. Please carefully follow
the specifications outlined in the general Safety Instructions!
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Rexroth IndraDrive |Project Planning Manual
Important Directions for Use

3 Safety Instructions for Electric Drives and Controls
3.1 Safety Instructions - General Information
3.1.1 Using the Safety Instructions and Passing them on to Others
Do not attempt to install or commission this device without first reading all doc‐
umentation provided with the product. Read and understand these safety
instructions and all user documentation prior to working with the device. If you
do not have the user documentation for the device, contact your responsible
Bosch Rexroth sales representative. Ask for these documents to be sent im‐
mediately to the person or persons responsible for the safe operation of the
device.
If the device is resold, rented and/or passed on to others in any other form,
these safety instructions must be delivered with the device in the official lan‐
guage of the user's country.
WARNING
Improper use of these devices, failure to follow the safety instructions in
this document or tampering with the product, including disabling of safe‐
ty devices, may result in material damage, bodily harm, electric shock
or even death!
Observe the safety instructions!
3.1.2 How to Employ the Safety Instructions
Read these instructions before initial commissioning of the equipment in order
to eliminate the risk of bodily harm and/or material damage. Follow these safety
instructions at all times.
● Bosch Rexroth AG is not liable for damages resulting from failure to ob‐
serve the warnings provided in this documentation.
● Read the operating, maintenance and safety instructions in your language
before commissioning 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 device.
● Only assign trained and qualified persons to work with electrical installa‐
tions:
– Only persons who are trained and qualified for the use and operation
of the device may work on this device or within its proximity. The
persons are qualified if they have sufficient knowledge of the assem‐
bly, installation and operation of the product, as well as an under‐
standing of all warnings and precautionary measures noted in these
instructions.
– Furthermore, they must be trained, instructed and qualified to switch
electrical circuits and devices 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 safe‐
ty equipment and be trained in first aid.
● Only use spare parts and accessories approved by the manufacturer.
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● Follow all safety regulations and requirements for the specific application
as practiced in the country of use.
● The devices have been designed for installation in industrial machinery.
● The ambient conditions given in the product documentation must be ob‐
served.
● Only use safety-relevant applications that are clearly and explicitly ap‐
proved in the Project Planning Manual. If this is not the case, they are
excluded. Safety-relevant are all such applications which can cause dan‐
ger to persons and material damage.
● The information given in the documentation of the product with regard to
the use of the delivered components contains only examples of applica‐
tions 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.
● Commissioning 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.
● Operation is only permitted if the national EMC regulations for the appli‐
cation are met.
● The instructions for installation in accordance with EMC requirements can
be found in the section on EMC in the respective documentation (Project
Planning Manuals of components and system).
The machine or installation manufacturer is responsible for compliance
with the limiting values as prescribed in the national regulations.
● Technical data, connection and installation conditions are specified in the
product documentation and must be followed at all times.
National regulations which the user must take into account
● European countries: according to European EN standards
● United States of America (USA):
– National Electrical Code (NEC)
– National Electrical Manufacturers Association (NEMA), as well as
local engineering regulations
– regulations of the National Fire Protection Association (NFPA)
● Canada: Canadian Standards Association (CSA)
● Other countries:
– International Organization for Standardization (ISO)
– International Electrotechnical Commission (IEC)
3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness
The safety instructions describe the following degrees of hazard seriousness.
The degree of hazard seriousness informs about the consequences resulting
from non-compliance with the safety instructions:
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Warning symbol Signal word
Degree of hazard serious‐
ness acc. to ANSI Z
535.4-2002
Danger Death or severe bodily harm
will occur.
Warning Death or severe bodily harm
may occur.
Caution
Minor or moderate bodily
harm or material damage
may occur.
Fig.3-1: Hazard classification (according to ANSI Z 535)
3.1.4 Hazards by Improper Use
DANGER
High electric voltage and high working current! Risk of death or severe
bodily injury by electric shock!
Observe the safety instructions!
DANGER
Dangerous movements! Danger to life, severe bodily harm or material
damage by unintentional motor movements!
Observe the safety instructions!
WARNING
High electric voltage because of incorrect connection! Risk of death or
bodily injury by electric shock!
Observe the safety instructions!
WARNING
Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electrical equipment!
Observe the safety instructions!
CAUTION
Hot surfaces on device housing! Danger of injury! Danger of burns!
Observe the safety instructions!
CAUTION
Risk of injury by improper handling! Risk of bodily injury by bruising,
shearing, cutting, hitting or improper handling of pressurized lines!
Observe the safety instructions!
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Safety Instructions for Electric Drives and Controls

CAUTION
Risk of injury by improper handling of batteries!
Observe the safety instructions!
3.2 Instructions with Regard to Specific Dangers
3.2.1 Protection Against Contact with Electrical Parts and Housings
This section concerns devices and drive components with voltages
of more than 50 Volt.
Contact with parts conducting voltages above 50 Volts can cause personal
danger and electric shock. When operating electrical equipment, it is unavoid‐
able that some parts of the devices conduct dangerous voltage.
DANGER
High electrical voltage! Danger to life, electric shock and severe bodily
injury!
●Only those trained and qualified to work with or on electrical equipment
are permitted to operate, maintain and repair this equipment.
● Follow general construction and safety regulations when working on pow‐
er installations.
● Before switching on the device, the equipment grounding conductor must
have been non-detachably connected to all electrical equipment in ac‐
cordance with the connection diagram.
● Do not operate electrical equipment at any time, even for brief measure‐
ments or tests, if the equipment grounding conductor is not permanently
connected to the mounting points of the components provided for this
purpose.
● Before working with electrical parts with voltage potentials higher than
50 V, the device must be disconnected from the mains voltage or power
supply unit. Provide a safeguard to prevent reconnection.
● With electrical drive and filter components, observe the following:
Wait 30 minutes after switching off power to allow capacitors to discharge
before beginning to work. Measure the electric 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. Do not remove or plug in connectors when the component
has been powered.
● Install the covers and guards provided with the equipment properly before
switching the device on. Before switching the equipment on, cover and
safeguard live parts safely to prevent contact with those parts.
● A residual-current-operated circuit-breaker or r.c.d. cannot be used for
electric drives! Indirect contact must be prevented by other means, for
example, by an overcurrent protective device according to the relevant
standards.
● Secure built-in devices from direct touching of electrical parts by providing
an external housing, for example a control cabinet.
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