REXROTH IndraDrive HCQ02 Technical manual

Project Planning Manual
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics
Rexroth IndraDrive
Drive Controllers
HCQ, HCT
R911324185
Edition 03

Rexroth IndraDrive
Drive Controllers
HCQ, HCT
Project Planning Manual
DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
RS-a3a3ad602ba8890e0a6846a00109da40-6-en-US-2
Provides information on the project planning of Rexroth IndraDrive systems
considering the components
● HCQ02
● HCT02
Edition Release Date Notes
DOK-INDRV*-HCQ-T+HMQ-T-PR01 2009/10 See index entry "Docu‐
mentation → Editions"
DOK-INDRV*-HCQ-T+HMQ-T-PR02 2011/07 See index entry "Docu‐
mentation → Editions"
DOK-INDRV*-HCQ-T+HMQ-T-PR03 2012/04 See index entry "Docu‐
mentation → Editions"
Copyright © Bosch Rexroth AG 2012
This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth AG. It may not be re‐
produced or given to third parties without its consent.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this docu‐
mentation and the availability of the product.
Published by Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr a. Main, Germany
Phone [phone] ■ Fax [phone]
http://www.boschrexroth.com/
Dept. DC-IA/EDY1 (RB, US, BB); DC-IA/EDH (TS, MN, GB)
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revision
Bosch Rexroth AG DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT

Table of Contents
Page
1 System Presentation...................................................................................................... 7
1.1 Drive System with Rexroth IndraDrive HCQ02, HCT02 ........................................................................ 7
1.2 Drive Controllers HCQ02, HCT02........................................................................................................... 9
1.3 Type Code............................................................................................................................................ 11
1.3.1 HCQ02............................................................................................................................................... 11
1.3.2 HCT02............................................................................................................................................... 12
1.4 Firmware............................................................................................................................................... 12
1.5 Operator Panels.................................................................................................................................... 13
1.6 About This Documentation................................................................................................................... 13
1.6.1 Purpose............................................................................................................................................. 13
1.6.2 Editions.............................................................................................................................................. 13
1.6.3 Documentations ................................................................................................................................ 14
Drive Systems, System Components............................................................................................. 14
Motors............................................................................................................................................. 14
Cables............................................................................................................................................ 14
Control Unit..................................................................................................................................... 15
1.6.4 Your Feedback.................................................................................................................................. 15
2 Important Directions for Use ....................................................................................... 17
2.1 Appropriate Use ................................................................................................................................... 17
2.1.1 Introduction........................................................................................................................................ 17
2.1.2 Areas of Use and Application............................................................................................................ 17
2.2 Inappropriate Use................................................................................................................................. 18
3 Safety Instructions for Electric Drives and Controls..................................................... 19
3.1 Definitions of Terms.............................................................................................................................. 19
3.2 General Information.............................................................................................................................. 20
3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 20
3.2.2 Requirements for Safe Use............................................................................................................... 20
3.2.3 Hazards by Improper Use.................................................................................................................. 21
3.3 Instructions with Regard to Specific Dangers....................................................................................... 23
3.3.1 Protection Against Contact With Electrical Parts and Housings........................................................ 23
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 24
3.3.3 Protection Against Dangerous Movements....................................................................................... 25
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 26
3.3.5 Protection Against Contact With Hot Parts........................................................................................ 26
3.3.6 Protection During Handling and Mounting......................................................................................... 27
3.3.7 Battery Safety.................................................................................................................................... 27
3.3.8 Protection Against Pressurized Systems........................................................................................... 28
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 28
4 General Data and Specifications................................................................................. 31
4.1 Acceptance Tests and Approvals......................................................................................................... 31
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Table of Contents

Page
4.2 Transport and Storage.......................................................................................................................... 33
4.2.1 Transport of the Components............................................................................................................ 33
4.2.2 Storage of the Components............................................................................................................... 33
4.3 Installation Conditions........................................................................................................................... 34
4.3.1 Ambient and Operating Conditions.................................................................................................... 34
4.3.2 Control Cabinet Design and Cooling................................................................................................. 35
4.3.3 Mounting Position.............................................................................................................................. 38
Mounting Positions of Components................................................................................................ 38
4.3.4 Compatibility With Foreign Matters.................................................................................................... 38
4.4 Voltage Test and Insulation Resistance Test....................................................................................... 38
4.5 Control Voltage (24V Supply) .............................................................................................................. 39
5 Technical Data of the Components.............................................................................. 41
5.1 HCQ02.................................................................................................................................................. 41
5.1.1 Brief Description, Use and Design..................................................................................................... 41
5.1.2 Technical Data................................................................................................................................... 41
Ambient and Operating Conditions................................................................................................. 41
Mechanical System and Mounting.................................................................................................. 42
Basic Data Power Section HCQ02................................................................................................. 44
5.2 HCT02.................................................................................................................................................. 50
5.2.1 Brief Description, Use and Design..................................................................................................... 50
5.2.2 Technical Data................................................................................................................................... 50
Ambient and Operating Conditions................................................................................................. 50
Mechanical System and Mounting.................................................................................................. 51
Basic Data Power Section HCT02.................................................................................................. 53
6 Electrical Connection Points........................................................................................ 61
6.1 Connection Diagrams........................................................................................................................... 61
6.1.1 Connection Diagram HCQ02............................................................................................................. 61
6.1.2 Connection Diagram HCT02............................................................................................................. 62
6.2 Arrangement of the Connection Points................................................................................................. 63
6.3 Connection of Equipment Grounding Conductor.................................................................................. 64
6.4 Ground Connection............................................................................................................................... 64
6.5 X3, Mains Connection........................................................................................................................... 65
6.6 X3L, Interface for Operator Panels....................................................................................................... 65
6.7 X4.1 … X4.4, Encoder Evaluation........................................................................................................ 66
6.8 X5.1 and X5.2, Motor Connection......................................................................................................... 66
6.9 X5.3 and X5.4, Motor Connection......................................................................................................... 67
6.10 X6.1 … X6.4, Motor Temperature Monitoring and Motor Holding Brake ............................................. 68
6.11 X6C, Memory Card............................................................................................................................... 71
6.12 X8, Optional Encoder Evaluation.......................................................................................................... 71
6.13 X9, External Braking and Charging Resistor........................................................................................ 71
6.14 X18, 24V Supply (Control Voltage)....................................................................................................... 72
6.15 X19, Bb Contact, DC Bus Short Circuit Control.................................................................................... 75
6.16 X24 and X25, sercos III Master............................................................................................................ 76
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Table of Contents

Page
6.17 X26, Engineering Interface................................................................................................................... 77
6.18 X81 and X82, Digital Outputs............................................................................................................... 79
6.19 X83 ... X86, Digital Inputs..................................................................................................................... 80
6.20 Shield Connection................................................................................................................................. 82
6.20.1 Shield Connection Motor Cable......................................................................................................... 82
6.20.2 Shield Connection Control Lines....................................................................................................... 83
7 Optional Modules......................................................................................................... 85
7.1 OM1 and OM2...................................................................................................................................... 85
7.2 Digital I/O Extension............................................................................................................................. 86
7.2.1 Interfaces........................................................................................................................................... 86
7.2.2 X70, External 24V Supply.................................................................................................................. 86
7.2.3 X71 … X72, Digital Outputs............................................................................................................... 87
7.2.4 X73 … X76, Digital Inputs................................................................................................................. 88
8 Notes on Project Planning........................................................................................... 91
8.1 Mains Connection................................................................................................................................. 91
8.2 24V Supply........................................................................................................................................... 91
8.3 DC Bus Load........................................................................................................................................ 92
8.3.1 General Information........................................................................................................................... 92
8.3.2 Calculation of Performance Profile ................................................................................................... 93
8.4 External Braking Resistor..................................................................................................................... 94
9 Scope of Supply........................................................................................................... 95
10 Identifying and Checking the Delivered Components.................................................. 97
10.1 Type Plate............................................................................................................................................. 97
10.1.1 Arrangement...................................................................................................................................... 97
10.1.2 Design............................................................................................................................................... 97
11 Mounting and Installation............................................................................................. 99
11.1 Mounting............................................................................................................................................... 99
11.1.1 Dimensional Drawing......................................................................................................................... 99
11.1.2 Distances........................................................................................................................................... 99
11.2 Connection Diagram........................................................................................................................... 100
11.3 EMC Measures for Design and Installation........................................................................................ 103
11.3.1 Rules for Design of Installations With Drive Controllers in Compliance With EMC......................... 103
11.3.2 EMC-Optimal Installation in Facility and Control Cabinet................................................................ 104
General Information...................................................................................................................... 104
Division Into Areas (Zones).......................................................................................................... 105
Control Cabinet Design According to Interference Areas - Exemplary Arrangements................. 106
Design and Installation in Area A - Interference-Free Area of Control Cabinet............................ 107
Design and Installation in Area B - Interference-Susceptible Area of Control Cabinet................. 109
Design and Installation in Area C - Strongly Interference-Susceptible Area of Control Cabinet.. 109
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Table of Contents

Page
11.3.3 Ground Connections........................................................................................................................ 110
11.3.4 Installing Signal Lines and Signal Cables........................................................................................ 111
11.3.5 General Measures of Radio Interference Suppression for Relays, Contactors, Switches, Chokes and
Inductive Loads............................................................................................................................... 112
12 Commissioning, Operation, Diagnostics.................................................................... 113
12.1 Operation and Diagnostics................................................................................................................. 113
12.1.1 Diagnostic LED Displays................................................................................................................. 113
12.1.2 Diagnostic LED Displays with Drive Firmware MPM-16VRS.......................................................... 113
12.1.3 Diagnostic LED Displays with Drive Firmware MPM-17VRS.......................................................... 115
13 Technical Data - Encoder Evaluation......................................................................... 119
13.1 ES - Standard Encoder Evaluation..................................................................................................... 119
13.1.1 Interface Standard Encoder Evaluation ES..................................................................................... 119
13.1.2 Properties of ES.............................................................................................................................. 120
13.1.3 Signal Assignment to the Actual Position Value.............................................................................. 121
13.1.4 Connection for 12V Encoder Systems............................................................................................. 122
Power Supply............................................................................................................................... 122
Allowed Encoder Cable Lengths for 12V Encoder Systems......................................................... 122
Connection Diagrams for 12V Encoder Systems......................................................................... 122
Connection Diagrams for 12V Third-Party Encoder Systems...................................................... 122
13.1.5 Connection for 5V Encoder Systems............................................................................................... 124
Power Supply............................................................................................................................... 124
Allowed Encoder Cable Lengths for 5V Encoder Systems without Sense Evaluation................. 124
Connection Diagrams for 5V Encoder Systems with Third-Party Encoder................................... 125
14 Technical Data - Functions........................................................................................ 129
14.1 Relay Contacts................................................................................................................................... 129
14.1.1 Relay Contact Type 2...................................................................................................................... 129
14.2 Digital Inputs/Outputs......................................................................................................................... 129
14.2.1 General Information......................................................................................................................... 129
14.2.2 Digital Inputs.................................................................................................................................... 129
Digital Inputs Type A (Standard).................................................................................................. 129
Digital Inputs Type B (Probe)....................................................................................................... 130
14.2.3 Digital Outputs................................................................................................................................. 131
15 Accessories................................................................................................................ 133
15.1 HAS09................................................................................................................................................ 133
15.2 CompactFlash Memory Card.............................................................................................................. 134
16 Environmental Protection and Disposal .................................................................... 135
16.1 Environmental Protection.................................................................................................................... 135
16.2 Disposal.............................................................................................................................................. 135
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Table of Contents

Page
17 Service and Support.................................................................................................. 137
Index.......................................................................................................................... 139
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Table of Contents

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1 System Presentation
1.1 Drive System with Rexroth IndraDrive HCQ02, HCT02
Drive System Rexroth IndraDrive C with 4‑Axis Converter HCQ02
1 … 4 Motors (1: Powerful main drive; 2–4: Secondary drives)
24V 24V supply
DST Transformer (optional)
F Fuses
HCQ02 4-axis converter
HMI External operator panel
HNF Mains filter (optional)
HNL Mains choke (optional; you can do without mains choke in the case of
reduced performance)
K1 Mains contactor
RB External charging resistor
Fig.1-1: Drive System Rexroth IndraDrive C with 4‑Axis Converter HCQ02
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System Presentation

Drive System Rexroth IndraDrive C with 3‑Axis Converter HCT02
1 … 4 Motors (1: Powerful main drive; 3–4: Secondary drives)
24V 24V supply
DST Transformer (optional)
F Fuses
HCT02 3-axis converter
HMI External operator panel
HNF Mains filter (optional)
HNL Mains choke (optional; you can do without mains choke in the case of
reduced performance)
K1 Mains contactor
RB External charging resistor
Fig.1-2: Drive System Rexroth IndraDrive C with 3‑Axis Converter HCT02
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System Presentation

1.2 Drive Controllers HCQ02, HCT02
Main Features
Fig.1-3: View of a Drive Controller
● Multi-axis converter (HCQ02, HCT02) in flat type of construction with
forced-ventilated cooling
● Degree of protection IP20
● Voltage range mains connection nominal 3 AC 200 … 500 V
● 4 (HCQ02) or 3 (HCT02) integrated inverters
● Integrated brake chopper to operate an external braking resistor
● External 24V supply
● 2 slots for optional extensions (e.g. digital inputs/outputs)
● Interface to operate external operator panels (HMI)
● Changeable programming module in CompactFlash format with firm‐
ware and parameters
Properties
Property HCQ02 HCT02
Type of drive controller Converter, multi-axis
Number of axes 4 3
Mains connection ■
DC bus connection -
Number of encoder evaluations 5 4
Configurable ■
Number of configurable slots 2
Configurable slots for safety
technology
-
Braking resistor External, required as charging resistor, too
DC bus short circuit input ■
Interface to operator panel
(LVDS + USB)
■
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System Presentation

Property HCQ02 HCT02
EtherNet Engineering Port ■
sercos III Master Port ■
Master communication
Embedded PC ■
Multi-protocol EtherNet -
PROFIBUS -
Inputs / outputs
Digital inputs 1)
Thereof probes
32
4
Digital outputs 1) 16
Analog inputs 0
Analog outputs 0
Relay contacts 1 N/O
Switching frequencies
4 kHz ■
8 kHz ■
■ Available
- Not available
1) On-board connection points; can be extended with optional modules
Fig.1-4: Properties
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System Presentation

1.3 Type Code
1.3.1 HCQ02
Fig.1-5: Type Code HCQ02
The figure illustrates the basic structure of the type code. Our
sales representative will help you with the current status of availa‐
ble versions.
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System Presentation

1.3.2 HCT02
Fig.1-6: Type Code HCT02
The figure illustrates the basic structure of the type code. Our
sales representative will help you with the current status of availa‐
ble versions.
1.4 Firmware
Required Firmware FWA-MICRO*-MTX-12VRS-NN or higher version
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System Presentation

1.5 Operator Panels
Allowed operator panels: VDP80.1
1.6 About This Documentation
1.6.1 Purpose
Personal injury and property damage caused
by incorrect project planning for applications,
machines and installations!
WARNING
Observe the contents of the documentations relevant to your drive system
(see chapter "Documentations").
This documentation provides information on
● the project planning of Rexroth IndraDrive systems
● considering the components
– HCQ02
– HCT02
1.6.2 Editions
Edition Release
date
Notes
01 2009/10 First edition
02 2011/07 Changes
● HCT02.1E-W0020 device removed
● HCT02.1E-W0025 device included
● Technical data and dimensional drawing updated
● Notes on project planning for mains connection included
● Chapter "Environmental Protection and Disposal" revised
● Shield connection of the motor cables updated
● Accessory HAS09 updated
● Cover picture updated
03 2012/04 Changes
● Chapter "Project Planning of Cooling System" removed
● Chapter "General Data and Specifications → Installation Conditions":
New subchapter "Control Cabinet Design and Cooling" included
● Technical data (mains voltage) updated
● New diagnostic displays of drive firmware MPM-17VRS included
● Chapter "Service and Support" revised
● Spelling of "SERCOS" changed to "sercos"
Fig.1-7: Editions
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System Presentation

1.6.3 Documentations
Drive Systems, System Components
Drive Systems with Multi-Axis Drive Controllers
Title Kind of documentation Document typecode1) Part number
R911…
Rexroth IndraDrive
Drive Controllers HCQ02, HCT02
Project Planning Manual DOK-INDRV*-HCQ-T+HMQ-T-
PRxx-EN-P
324185
Rexroth IndraDrive
Additional Components and Accesso‐
ries
Project Planning Manual DOK-INDRV*-ADDCOMP****-
PRxx-EN-P
306140
Rexroth IndraControl VDP 80.1
Machine Operator Panel
Operator Display
Project Planning Manual DOK-SUPPL*-VDP*80.1***-PRxx-
EN-P
329156
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.1-8: Documentations – Drive Systems, System Components
Motors
Title
Rexroth IndraDyn …
Kind of documentation Document typecode1)
DOK-MOTOR*-…
Part number
R911…
A Asynchronous Motors MAD / MAF Project Planning Manual MAD/MAF****-PRxx-EN-P 295781
H Synchronous Kit Spindle Motors Project Planning Manual MBS-H******-PRxx-EN-P 297895
L Synchronous Linear Motors Project Planning Manual MLF********-PRxx-EN-P 293635
L Coreless Linear Motors MCL Project Planning Manual MCL********-PRxx-EN-P 330592
S Synchronous Motors MKE Project Planning Manual MKE*GEN2***-PRxx-EN-P 297663
S Synchronous Motors MSK Project Planning Manual MSK********-PRxx-EN-P 296289
S Synchronous Motors MSM Data Sheet MSM********-DAxx-EN-P 329338
S Synchronous Motors QSK Project Planning Manual QSK********-PRxx-EN-P 330321
T Synchronous Torque Motors Project Planning Manual MBT********-PRxx-EN-P 298798
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.1-9: Documentations – Motors
Cables
Title Kind of documentation Document typecode1)
DOK-CONNEC-…
Part number
R911…
Rexroth Connection Cables Selection Data CABLE*INDRV-CAxx-EN-P 322949
1) In the document typecodes, "xx" is a wild card for the current edition of
the documentation (example: CA02 is the second edition of the docu‐
mentation "Selection Data")
Fig.1-10: Documentations – Cables
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System Presentation

Control Unit
Title
Rexroth IndraMotion MTX micro
Kind of documentation Document typecode1)
DOK-MTXMIC-…
Part number
R911…
Easy setup for Standard Turning and
Milling Machines
Commissioning Manual EASY*******-COxx-EN-P 332281
12VRS
System Description
Manual SYS*DES*V12-RExx-EN-P 334369
12VRS
Functional Description
Manual NC*FUNC*V12-APxx-EN-P 334357
12VRS
Machine Parameters
Reference Book MA*PAR**V12-RExx-EN-P 334365
12VRS
Programming Manual
Manual NC**PRO*V12-RExx-EN-P 334361
1) In the document typecodes, "xx" is a wild card for the current edition of
the documentation (example: RE02 is the second edition of a Refer‐
ence Book)
Fig.1-11: Documentations – Control Unit
1.6.4 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. DC-IA/EDY1
Buergermeister-Dr.-Nebel-Str. 2
97816 Lohr, Germany
E-mail: [email protected]
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System Presentation

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2 Important Directions for Use
2.1 Appropriate Use
2.1.1 Introduction
Rexroth products reflect the state-of-the-art in their development and their
manufacture. They are tested prior to delivery to ensure operating safety and
reliability.
Personal injury and property damage caused
by incorrect use of the products!
WARNING
The products have been designed for use in industrial environments 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
forfeited. The user alone carries all responsibility of the risks.
Before using Rexroth products, the following pre-requisites must be met to
ensure appropriate use of the products:
● Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar with
their appropriate 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.
● Damaged or faulty products may not be installed or put into operation.
● Make sure that the products have been installed in the manner descri‐
bed 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 be used with the accessories and
parts specified in this documentation. If a component has not
been specifically named, then it may neither be mounted nor con‐
nected. 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 Functional Descriptions.
Drive controllers have to be programmed before commissioning to ensure
that the motor executes 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.
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Important Directions for Use

To ensure application-specific use of Drive controllers, device types of differ‐
ent drive power and different interfaces are available.
Typical applications include, for example:
● 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 technical data and specifications given
is defined as "inappropriate use".
Drive controllers may 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
temperatures.
● Furthermore, Drive controllers may not be used in applications which
have not been expressly authorized by Rexroth. Please carefully follow
the specifications outlined in the general Safety Instructions!
Components of the Rexroth IndraDrive system are products of
category C3 (with limited availability) according to IEC 61800‑3.
To ensure that this category (limit values) is maintained, suitable
line filters must be used in the drive system.
These components are not provided for use in a public low-volt‐
age network supplying residential areas with power. If these com‐
ponents are used in such a public network, high-frequency inter‐
ference is to be expected. This can require additional measures
of radio interference suppression.
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Important Directions for Use