Hcs02.1e WW012

Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
Rexroth IndraControl VCP 20

Rexroth IndraDrive C R911306138
Edition 01
Drive Controllers
Power Sections HCS02.1
Project Planning Manual
About this Documentation IndraDrive C
Title Rexroth IndraDrive C

Drive Controllers
Type of Documentation Project Planning Manual
Document Typecode DOK-INDRV*-HCS02.1****-PR01-EN
Internal File Reference Document number 120-2400-B314-01/EN
Record of Revisions Description Release Notes

Date
DOK-INDRV*-HCS02.1****-PR01-EN 04.2004 First Edition
Copyright  Bosch Rexroth AG 2004

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 only serve to describe the product. No statements
concerning a certain condition or suitability for a certain application can be
derived from our information. The given information does not release the
user from the obligation of own judgement and verification. It must be
remembered that our products are subject to a natural process of wear
and aging.
Published by Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telefon +49 (0)93 52 / 40-0 • Tx 68 94 21 • Fax +49 (0)93 52 / 40-48 85
http://www.boschrexroth.de/
Abt. EDY/EDY1 (RR/US)
Note This document has been printed on chlorine-free bleached paper.
DOK-INDRV*-HCS02.1****-EN-P
Rexroth IndraDrive C Contents I
Contents
1 Introduction 1-1
1.1 Documentation .............................................................................................................................. 1-1
Purpose of this Documentation................................................................................................ 1-1
Documentations - Overview..................................................................................................... 1-1
1.2 Introducing the Devices................................................................................................................. 1-2
Basic Structure......................................................................................................................... 1-2
Drive System............................................................................................................................ 1-3
Drive Controllers - Block Diagram ........................................................................................... 1-4
Tests and Certifications ........................................................................................................... 1-7
2 Important Directions for Use 2-1

2.1 Appropriate Use ............................................................................................................................ 2-1
Introduction .............................................................................................................................. 2-1
Areas of Use and Application................................................................................................... 2-2
2.2 Inappropriate Use.......................................................................................................................... 2-2
3 Safety Instructions for Electric Drives and Controls 3-1

3.1 Introduction ................................................................................................................................... 3-1
3.2 Explanations.................................................................................................................................. 3-1
3.3 Hazards by Improper Use ............................................................................................................. 3-2
3.4 General Information ...................................................................................................................... 3-3
3.5 Protection Against Contact with Electrical Parts ........................................................................... 3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) ......................................... 3-6
3.7 Protection Against Dangerous Movements .................................................................................. 3-7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting ....................................................................................................................................... 3-9
3.9 Protection Against Contact with Hot Parts .................................................................................. 3-10
3.10 Protection During Handling and Mounting .................................................................................. 3-10
3.11 Battery Safety.............................................................................................................................. 3-11
3.12 Protection Against Pressurized Systems .................................................................................... 3-11
4 Identifying and Checking the Delivered Components 4-1

4.1 Delivery of Components................................................................................................................ 4-1
Packaging ................................................................................................................................ 4-1
Accompanying Documents ...................................................................................................... 4-1
4.2 Scope of Delivery .......................................................................................................................... 4-1
Overview .................................................................................................................................. 4-1
Checking the Delivered Components ...................................................................................... 4-1
4.3 Type Plates ................................................................................................................................... 4-2
DOK-INDRV*-HCS02.1****-PR01-EN-P
II Contents Rexroth IndraDrive C
Type Plates on the Drive Controller ......................................................................................... 4-2

4.4 Device Types ................................................................................................................................ 4-4
Type Code................................................................................................................................ 4-4
5 Transport and Storage 5-1

5.1 Transporting the Devices .............................................................................................................. 5-1
Conditions ................................................................................................................................ 5-1
5.2 Storing the Devices ....................................................................................................................... 5-1
Conditions ................................................................................................................................ 5-1
In Case of Long Storage Periods............................................................................................. 5-1
6 Mechanical Mounting 6-1

6.1 Mounting Conditions ..................................................................................................................... 6-1
Ambient and Operating Conditions .......................................................................................... 6-1
Duty Capacity........................................................................................................................... 6-3
6.2 Mechanical Technical Data........................................................................................................... 6-4
Dimensions .............................................................................................................................. 6-4
Weight ...................................................................................................................................... 6-7
Installation Orientation ............................................................................................................. 6-7
Separation Distance between Drive Controllers ...................................................................... 6-7
Temperatures Above the Top of the Device ............................................................................ 6-8
Arrangement of Components in the Control Cabinet............................................................. 6-12
6.3 Cooling and Cooling Units .......................................................................................................... 6-14
Power Dissipation .................................................................................................................. 6-14
Mounting Cooling Units.......................................................................................................... 6-19
7 Electrical Installation 7-1

7.1 General Information ...................................................................................................................... 7-1
7.2 10 rules for EMC-correct installation of drives .............................................................................. 7-2
Optimal EMC Installation ......................................................................................................... 7-4
7.3 Electrical Data HCS02.1E-W0012, -W0028, -W0054, -W0070 .................................................... 7-5
Power Section– Mains Supply ................................................................................................. 7-5
Power Section – DC Bus ......................................................................................................... 7-6
Power Section – Braking Resistor ........................................................................................... 7-9
Power Section – Inverter........................................................................................................ 7-10
Power Section – Cooling, Power Dissipation, Insulation ....................................................... 7-13
Control Voltage ...................................................................................................................... 7-14
7.4 Complete Connection Diagram................................................................................................... 7-17
7.5 Connecting Cables and Rails...................................................................................................... 7-18
Connections at HCS02.1E-W0012 ........................................................................................ 7-18
Connections at HCS02.1E-W0028, -W0054, -W0070........................................................... 7-20
X1, Module Bus...................................................................................................................... 7-23
X3, Mains Connection............................................................................................................ 7-24
X5, Motor Connection ............................................................................................................ 7-26
X6, Motor Temperature Monitoring and Motor Holding Brake............................................... 7-30
X9, Connection of Braking Resistor ....................................................................................... 7-33
Rexroth IndraDrive C Contents III
X13, Control Voltage (+24 V, 0 V) ......................................................................................... 7-34

DC Bus (L+, L-) ...................................................................................................................... 7-37
Ground Connection................................................................................................................ 7-38
XS1, Shield Connection (Control Wires)................................................................................ 7-39
XS2, Shield Connection (Motor Cable).................................................................................. 7-40
7.6 Touch Guard ............................................................................................................................... 7-41
Cutouts................................................................................................................................... 7-41
Mounting ................................................................................................................................ 7-42
8 Mains Connections 8-1

8.1 General.......................................................................................................................................... 8-1
8.2 The Ground Conditions of the Supply Mains ................................................................................ 8-1
8.3 Mains Supply Options ................................................................................................................... 8-2
Single Source Supply............................................................................................................... 8-2
Group Supply ........................................................................................................................... 8-3
Central Supply.......................................................................................................................... 8-5
Energy Circuit HCS02.1E-W0070 Using "Central Supply" as an Example ............................. 8-6
8.4 Number of Drive Controllers and Auxiliary Components on one DC bus ..................................... 8-7
Number of IndraDrive C Components ..................................................................................... 8-7
Number of IndraDrive M Components ..................................................................................... 8-8
Allowed DC Bus Continuous Power without Mains Choke for Three-Phase Mains
Connection ............................................................................................................................. 8-10
Allowed DC Bus Continuous Power with Single-Phase Mains Connection .......................... 8-12
8.5 Fusing via Earth-Leakage Circuit Breakers ................................................................................ 8-15
8.6 Control Circuits for the Mains Connection .................................................................................. 8-16
8.7 Mains Contactor / Fuses ............................................................................................................. 8-19
Calculating Phase Current on the Mains ............................................................................... 8-19
Calculating Charging Current Inrush ..................................................................................... 8-20
Q1 Fuse and K1 Contactor .................................................................................................... 8-21
Mains Connection Power and DC Bus Continuous Power.................................................... 8-22
9 Additional Components 9-1

9.1 Mains Choke ................................................................................................................................. 9-1
Identification ............................................................................................................................. 9-1
Technical Data ......................................................................................................................... 9-3
10 Replacing Devices 10-1

10.1 General Information .................................................................................................................... 10-1
10.2 How to Proceed When Replacing Devices ................................................................................. 10-1
Replacing the Drive Controller ............................................................................................... 10-1
Replacing the Motor............................................................................................................... 10-2
Replacing Cables................................................................................................................... 10-2
10.3 Fault Report ................................................................................................................................ 10-4
11 Disposal and Environmental Protection 11-1

11.1 Disposal ...................................................................................................................................... 11-1
IV Contents Rexroth IndraDrive C
Products ................................................................................................................................. 11-1

Packaging Materials............................................................................................................... 11-1
11.2 Environmental Protection ............................................................................................................ 11-1
No Release of Hazardous Substances.................................................................................. 11-1
Materials Contained in the Products...................................................................................... 11-1
Recycling................................................................................................................................ 11-2
12 Service & Support 12-1

12.1 Helpdesk ..................................................................................................................................... 12-1
12.2 Service-Hotline............................................................................................................................ 12-1
12.3 Internet ........................................................................................................................................ 12-1
12.4 Vor der Kontaktaufnahme... - Before contacting us.................................................................... 12-1
12.5 Kundenbetreuungsstellen - Sales & Service Facilities ............................................................... 12-2
13 Appendix 13-1
13.1 Accessories................................................................................................................................. 13-1
Overview ................................................................................................................................ 13-1
HAS01.1 (Accessories for Installation of Drive Controllers in Combination) ......................... 13-2
HAS02.1 (Accessories for Shield Connection of Motor Cable) ............................................. 13-6
Mounting Depth Adapter ........................................................................................................ 13-8
13.2 Determination of Appropriate Drive Controllers .......................................................................... 13-9
Introduction ............................................................................................................................ 13-9
DC Bus Continuous Power .................................................................................................... 13-9
DC Bus Peak Power ............................................................................................................ 13-12
Regenerated Energy............................................................................................................ 13-13
Calculation with Regard to Reduction of Resulting Power Dissipation ............................... 13-14
Continuous Regenerated Power.......................................................................................... 13-15
Peak Regenerated Power.................................................................................................... 13-16
Calculating Allowed Continuous Braking Resistor and DC Bus Power ............................... 13-17
13.3 Use of the Connections for Looping Through the Control Voltage ........................................... 13-18
13.4 Stacked Drive Controllers ......................................................................................................... 13-19
Anticlockwise Cable Routing................................................................................................ 13-19
Clockwise Cable Routing ..................................................................................................... 13-20
14 Index 14-1
Rexroth IndraDrive C Introduction 1-1
1 Introduction
1.1 Documentation
Purpose of this Documentation

This documentation describes ...
• planning the mechanical control cabinet construction
• planning the electrical control cabinet construction
• logistical handling of the equipment
Documentations - Overview
1)
Title Type of Documentation Document Typecode
Rexroth IndraDrive Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P
Drive Controllers
Control Sections
Rexroth IndraDrive M Project Planning Manual DOK-INDRV*-HMS+HMD****-PRxx-EN-P
Drive Controllers
Power Sections
Rexroth IndraDrive C Project Planning Manual DOK-INDRV*-HCS02.1****-PRxx-EN-P
Drive Controllers
Rexroth IndraDrive C Project Planning Manual DOK-INDRV*-HCS03.1****-PRxx-EN-P
Drive Controllers
Rexroth IndraDrive Project Planning Manual DOK-INDRV*-HMV-*******-PRxx-EN-P
Supply Units
Electromagnetic Compatibility (EMC) in Project Planning Manual DOK-GENERAL-EMV********-PRxx-EN-P
Drive and Control Systems
Safety Instructions for Electrical Drives Safety Guidelines DOK-GENERAL-DRIVE-******-SVSx-MS-P
Connecting cables Selection Data DOK-CONNEC-CABLE*STAND-AUxx-EN-P
1) in the document type codes "xx" designates replacement characters for
the update edition of the documentation (Example: "PR01" is the first
edition of a project planning manual)
Fig. 1-1: Documentations - Overview
1-2 Introduction Rexroth IndraDrive C
1.2 Introducing the Devices
Basic Structure
hcs_lt_rt.fh7
1: Power section
2: Control section
Fig. 1-2: Basic structure
The drive controller consists of two essential parts:

• Power section
• Control section
Power Section
The following are connected to the power section:
• mains
• motor (with optional motor holding brake and motor temperature
monitoring)
• 24 V power supply
• DC bus (not for HCS02.1-W0012)
• module bus (for cross communication in the case of DC bus

connection with other devices; not for HCS02.1-W0012)
• braking resistor (optional; not for HCS02.1-W0012 and –W0028)
Control Section
The control section is a separate section which is inserted into the power
section. The drive controller is supplied ex works complete with control
section. The control section must only be replaced by a trained person.
The contacts X31/1 and X31/2 are connected to the control section as Bb
contacts.
Note: The control sections are described in a separate

documentation (see page 1-1).
Drive System
The following figure shows the components of the drive system.
power section
firmware
DC bus resistor unit
DC bus capacitor unit
control section
24 V supply unit 1)
battery
braking resistor
mains supply
output filter
encoder cable
transformer mains filter mains choke motor cable
mains contactor motor antriebssystem_c_v1.fh7
Components shown in gray are absolutely necessary

1) necessary for devices without internal 24 V power supply only
Fig. 1-3: Drive system
Drive Controllers - Block Diagram

HCS02.1E-W0012-NNNN
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
line input with braking resistor DC bus converter

bridge circuit circuit capacitance bridge circuit
rectifier charging with output to
current limit the motor
hcs_block_12n.FH7
Fig. 1-4: HCS02.1E-W0012-NNNN - Block diagram
HCS02.1E-W0012-NNNV
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
line input with optional braking resistor DC bus converter

bridge circuit integrated circuit capacitance bridge circuit
rectifier control with output to
voltage charging the motor
supply current limit
hcs_block_12v.FH7
Fig. 1-5: HCS02.1E-W0012-NNNV - Block diagram
HCS02.1E-W0028-NNNN
L+
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
L-
line input with braking resistor DC bus converter DC bus
bridge circuit circuit capacitance bridge circuit connection
rectifier with output to
charging the motor
current limit
hcs_block_28n.FH7
Fig. 1-6: HCS02.1E-W0028-NNNN - Block diagram
HCS02.1E-W0028-NNNV
L+
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
L-
line input with optional braking resistor DC bus converter DC bus
bridge circuit integrated circuit capacitance bridge circuit connection
hcs_block_28v.FH7
Fig. 1-7: HCS02.1E-W0028-NNNV - Block diagram
HCS02.1E-W0054/70-NNNN
L+
optional
external
braking
resistor
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
L-
line input with braking resistor DC bus converter DC bus
bridge circuit circuit capacitance bridge circuit connection
rectifier with output to
charging the motor
current limit
hcs_block_54_70n.FH7
Fig. 1-8: HCS02.1E-W0054/70-NNNN - Block diagram
HCS02.1E-W0054/70-NNNV
L+
optional
external
braking
resistor
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
L-
line input with optional braking resistor DC bus converter DC bus
bridge circuit integrated circuit capacitance bridge circuit connection
hcs_block_54_70v.FH7
Fig. 1-9: HCS02.1E-W0054/70-NNNV - Block diagram
Tests and Certifications
Note: Your sales representative will help with the current status of
certifications.
CE Mark
CEf1.fh7
Fig. 1-10: CE mark
C-UL-US Listing In accordance with UL508 C.

The devices are C-UL-US listed under the item "Rexroth".
Note: Observe the C-UL limit values according to C-UL when

operating the drive controllers (see "Electrical Data").
c_ul_us.tif
Fig. 1-11: C-UL-US label
Tests High voltage test in Routine testing with DC 2230 V, 1 s

accordance with EN50178
Insulation voltage test in Routine testing with DC 500 V, 1 s
accordance with EN50178
Separation between control Safe separation in accordance with
and power voltage circuits EN50178
Air gaps and leakage According to EN50178
distances
Fig. 1-12: Tests
Notes
Rexroth IndraDrive C Important Directions for Use 2-1
2 Important Directions for Use
2.1 Appropriate Use
Introduction
Rexroth products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note: Rexroth, as manufacturer, is not liable for any damages

resulting from inappropriate use. In such cases, the guarantee
and the right to payment of damages resulting from
inappropriate use are forfeited. The user alone carries all
responsibility of the risks.
Before using Rexroth products, make sure that all the pre-requisites for
an appropriate use of the products are satisfied:
• Personnel that in any way, shape or form uses our products must first
read and understand the relevant safety instructions and be familiar
with appropriate use.
• If the product takes the form of hardware, then they must remain in
their original state, in other words, no structural changes are permitted.
It is not permitted to decompile software products or alter source
codes.
• Do not mount damaged or faulty products or use them in operation.
• Make sure that the products have been installed in the manner
described in the relevant documentation.
2-2 Important Directions for Use Rexroth IndraDrive C
Areas of Use and Application

Drive controllers made by Rexroth are designed to control electrical
motors and monitor their operation.
Control and monitoring of the motors may require additional sensors and
actors.
Note: The drive controllers may only be used with the accessories
and parts specified in this document. If a component has not
been specifically named, then it may not be either mounted or
connected. The same applies to cables and lines.
Operation is only permitted in the specified configurations and
combinations of components using the software and firmware
as specified in the relevant function descriptions.
Every drive controller has to be programmed before starting it up, making

it possible for the motor to execute the specific functions of an application.
The drive controllers are designed for use in single or multiple-axis drive
and control applications.
To ensure an application-specific use, the drive controllers are available
with differing drive power and different interfaces.
Typical applications of drive controllers are:
• handling and mounting systems,
• packaging and foodstuff machines,
• printing and paper processing machines and
• machine tools.
The drive controllers may only be operated under the assembly,
installation and ambient conditions as described here (temperature,
system of protection, humidity, EMC requirements, etc.) and in the
position specified.
2.2 Inappropriate Use

Using the drive controllers outside of the above-referenced areas of
application or under operating conditions other than described in the
document and the technical data specified is defined as “inappropriate
use".
Drive controllers may not be used if
• they are subject to operating conditions that do not meet the above
specified ambient conditions. This includes, for example, operation
under water, in the case of extreme temperature fluctuations or
extremely high maximum temperatures or if
• Rexroth has not specifically released them for that intended purpose.
Please note the specifications outlined in the general safety
instructions!
Rexroth IndraDrive C Safety Instructions for Electric Drives and Controls 3-1
3 Safety Instructions for Electric Drives and Controls
3.1 Introduction
Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these
safety instructions at all times.
Do not attempt to install or start up this equipment without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation of the equipment prior to
working with the equipment at any time. If you do not have the user
documentation for your equipment, contact your local Rexroth
representative to send this documentation immediately to the person or
persons responsible for the safe operation of this equipment.
If the equipment is resold, rented or transferred or passed on to others,
then these safety instructions must be delivered with the equipment.
Improper use of this equipment, failure to follow

the safety instructions in this document or
tampering with the product, including disabling
WARNING of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
3.2 Explanations
The safety instructions describe the following degrees of hazard
seriousness in compliance with ANSI Z535. The degree of hazard
seriousness informs about the consequences resulting from non-
compliance with the safety instructions.
Warning symbol with signal Degree of hazard seriousness according
word to ANSI
Death or severe bodily harm will occur.
DANGER
Death or severe bodily harm may occur.
WARNING
Bodily harm or material damage may occur.
CAUTION
Fig. 3-1: Hazard classification (according to ANSI Z535)
3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C
3.3 Hazards by Improper Use
High voltage and high discharge current!

Danger to life or severe bodily harm by electric
shock!
DANGER
Dangerous movements! Danger to life, severe

bodily harm or material damage by
unintentional motor movements!
DANGER
High electrical voltage due to wrong

connections! Danger to life or bodily harm by
electric shock!
WARNING
Health hazard for persons with heart

pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING
Surface of machine housing could be extremely

hot! Danger of injury! Danger of burns!
CAUTION
Risk of injury due to improper handling! Bodily

harm caused by crushing, shearing, cutting and
mechanical shock or incorrect handling of
CAUTION pressurized systems!
Risk of injury due to incorrect handling of

batteries!
CAUTION
3.4 General Information

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

application are met.
The instructions for installation in accordance with EMC requirements
can be found in the documentation "EMC in Drive and Control
Systems".
The machine or installation manufacturer is responsible for
compliance with the limiting values as prescribed in the national
regulations.
• Technical data, connections and operational conditions are specified in
the product documentation and must be followed at all times.
3.5 Protection Against Contact with Electrical Parts
Note: This section refers to equipment and drive components with

voltages above 50 Volts.
Touching live parts with voltages of 50 Volts and more with bare hands or
conductive tools or touching ungrounded housings can be dangerous and
cause electric shock. In order to operate electrical equipment, certain
parts must unavoidably have dangerous voltages applied to them.
High electrical voltage! Danger to life, severe

bodily harm by electric shock!
⇒ Only those trained and qualified to work with or on
DANGER electrical equipment are permitted to operate, maintain
or repair this equipment.
⇒ Follow general construction and safety regulations when
working on high voltage installations.
⇒ Before switching on power the ground wire must be
permanently connected to all electrical units according
to the connection diagram.
⇒ Do not operate electrical equipment at any time, even
for brief measurements or tests, if the ground wire is not
permanently connected to the points of the components
provided for this purpose.
⇒ Before working with electrical parts with voltage higher
than 50 V, the equipment must be disconnected from
the mains voltage or power supply. Make sure the
equipment cannot be switched on again unintended.
⇒ The following should be observed with electrical drive
and filter components:
⇒ Wait five (5) minutes after switching off power to allow
capacitors to discharge before beginning to work.
Measure the voltage on the capacitors before beginning
to work to make sure that the equipment is safe to
touch.
⇒ Never touch the electrical connection points of a
component while power is turned on.
⇒ Install the covers and guards provided with the
equipment properly before switching the equipment on.
Prevent contact with live parts at any time.
⇒ A residual-current-operated protective device (RCD)
must not be used on electric drives! Indirect contact
must be prevented by other means, for example, by an
overcurrent protective device.
⇒ Electrical components with exposed live parts and
uncovered high voltage terminals must be installed in a
protective housing, for example, in a control cabinet.
To be observed with electrical drive and filter components:
High electrical voltage on the housing!

High leakage current! Danger to life, danger of
injury by electric shock!
DANGER ⇒ Connect the electrical equipment, the housings of all
electrical units and motors permanently with the safety
conductor at the ground points before power is
switched on. Look at the connection diagram. This is
even necessary for brief tests.
⇒ Connect the safety conductor of the electrical
equipment always permanently and firmly to the
supply mains. Leakage current exceeds 3.5 mA in
normal operation.
⇒ Use a copper conductor with at least 10 mm² cross
section over its entire course for this safety conductor
connection! The cross section must not be smaller
than the cross section of a phase of the mains supply
wire.
⇒ Prior to startups, even for brief tests, always connect
the protective conductor or connect with ground wire.
Otherwise, high voltages can occur on the housing
that lead to electric shock.
3.6 Protection Against Electric Shock by Protective Low

Voltage (PELV)
All connections and terminals with voltages between 0 and 50 Volts on
Rexroth products are protective low voltages designed in accordance with
international standards on electrical safety.
High electrical voltage due to wrong

connections! Danger to life, bodily harm by
electric shock!
WARNING ⇒ Only connect equipment, electrical components and
cables of the protective low voltage type (PELV =
Protective Extra Low Voltage) to all terminals and
clamps with voltages of 0 to 50 Volts.
⇒ Only electrical circuits may be connected which are
safely isolated against high voltage circuits. Safe
isolation is achieved, for example, with an isolating
transformer, an opto-electronic coupler or when
battery-operated.
3.7 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of the connected
motors. Some common examples are:
• improper or wrong wiring of cable connections
• incorrect operation of the equipment components
• wrong input of parameters before operation
• malfunction of sensors, encoders and monitoring devices
• defective components
• software or firmware errors
Dangerous movements can occur immediately after equipment is
switched on or even after an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be sufficient to avoid
faulty operation in the connected drives. Regarding personal safety,
especially the danger of bodily injury and material damage, this alone
cannot be relied upon to ensure complete safety. Until the integrated
monitoring functions become effective, it must be assumed in any case
that faulty drive movements will occur. The extent of faulty drive
movements depends upon the type of control and the state of operation.
Dangerous movements! Danger to life, risk of

injury, severe bodily harm or material damage!
⇒ Ensure personal safety by means of qualified and
DANGER tested higher-level monitoring devices or measures
integrated in the installation. Unintended machine
motion is possible if monitoring devices are disabled,
bypassed or not activated.
⇒ Pay attention to unintended machine motion or other
malfunction in any mode of operation.
⇒ Keep free and clear of the machine’s range of motion

and moving parts. Possible measures to prevent
people from accidentally entering the machine’s range
of motion:
- use safety fences
- use safety guards
- use protective coverings
- install light curtains or light barriers
⇒ Fences and coverings must be strong enough to
resist maximum possible momentum, especially if
there is a possibility of loose parts flying off.
⇒ Mount the emergency stop switch in the immediate
reach of the operator. Verify that the emergency stop
works before startup. Don’t operate the machine if the
emergency stop is not working.
⇒ Isolate the drive power connection by means of an
emergency stop circuit or use a starting lockout to
prevent unintentional start.
⇒ Make sure that the drives are brought to a safe
standstill before accessing or entering the danger
zone. Safe standstill can be achieved by switching off
the power supply contactor or by safe mechanical
locking of moving parts.
⇒ Secure vertical axes against falling or dropping after
switching off the motor power by, for example:
- mechanically securing the vertical axes
- adding an external braking/ arrester/ clamping
mechanism
- ensuring sufficient equilibration of the vertical axes
The standard equipment motor brake or an external
brake controlled directly by the drive controller are
not sufficient to guarantee personal safety!
⇒ Disconnect electrical power to the equipment using a

master switch and secure the switch against
reconnection for:
- maintenance and repair work
- cleaning of equipment
- long periods of discontinued equipment use
⇒ Prevent the operation of high-frequency, remote
control and radio equipment near electronics circuits
and supply leads. If the use of such equipment cannot
be avoided, verify the system and the installation for
possible malfunctions in all possible positions of
normal use before initial startup. If necessary, perform
a special electromagnetic compatibility (EMC) test on
the installation.
3.8 Protection Against Magnetic and Electromagnetic Fields

During Operation and Mounting
Magnetic and electromagnetic fields generated near current-carrying
conductors and permanent magnets in motors represent a serious health
hazard to persons with heart pacemakers, metal implants and hearing
aids.
Health hazard for persons with heart

pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING ⇒ Persons with heart pacemakers, hearing aids and
metal implants are not permitted to enter the following
areas:
- Areas in which electrical equipment and parts are
mounted, being operated or started up.
- Areas in which parts of motors with permanent
magnets are being stored, operated, repaired or
mounted.
⇒ If it is necessary for a person with a heart pacemaker
to enter such an area, then a doctor must be
consulted prior to doing so. Heart pacemakers that
are already implanted or will be implanted in the
future, have a considerable variation in their electrical
noise immunity. Therefore there are no rules with
general validity.
⇒ Persons with hearing aids, metal implants or metal
pieces must consult a doctor before they enter the
areas described above. Otherwise, health hazards will
occur.
3.9 Protection Against Contact with Hot Parts
Housing surfaces could be extremely hot!

Danger of injury! Danger of burns!
⇒ Do not touch housing surfaces near sources of heat!
CAUTION Danger of burns!
⇒ After switching the equipment off, wait at least ten (10)
minutes to allow it to cool down before touching it.
⇒ Do not touch hot parts of the equipment, such as
housings with integrated heat sinks and resistors.
Danger of burns!
3.10 Protection During Handling and Mounting

Under certain conditions, incorrect handling and mounting of parts and
components may cause injuries.
Risk of injury by incorrect handling! Bodily

harm caused by crushing, shearing, cutting and
mechanical shock!
CAUTION ⇒ Observe general installation and safety instructions
with regard to handling and mounting.
⇒ Use appropriate mounting and transport equipment.
⇒ Take precautions to avoid pinching and crushing.
⇒ Use only appropriate tools. If specified by the product
documentation, special tools must be used.
⇒ Use lifting devices and tools correctly and safely.
⇒ For safe protection wear appropriate protective
clothing, e.g. safety glasses, safety shoes and safety
gloves.
⇒ Never stand under suspended loads.
⇒ Clean up liquids from the floor immediately to prevent
slipping.
3.11 Battery Safety

Batteries contain reactive chemicals in a solid housing. Inappropriate
handling may result in injuries or material damage.
Risk of injury by incorrect handling!

⇒ Do not attempt to reactivate discharged batteries by
heating or other methods (danger of explosion and
cauterization).
CAUTION
⇒ Never charge non-chargeable batteries (danger of
leakage and explosion).
⇒ Never throw batteries into a fire.
⇒ Do not dismantle batteries.
⇒ Do not damage electrical components installed in the
equipment.
Note: Be aware of environmental protection and disposal! The

batteries contained in the product should be considered as
hazardous material for land, air and sea transport in the sense
of the legal requirements (danger of explosion). Dispose
batteries separately from other waste. Observe the legal
requirements in the country of installation.
3.12 Protection Against Pressurized Systems

Certain motors and drive controllers, corresponding to the information in
the respective Project Planning Manual, must be provided with
pressurized media, such as compressed air, hydraulic oil, cooling fluid
and cooling lubricant supplied by external systems. Incorrect handling of
the supply and connections of pressurized systems can lead to injuries or
accidents. In these cases, improper handling of external supply systems,
supply lines or connections can cause injuries or material damage.
Danger of injury by incorrect handling of

pressurized systems!
⇒ Do not attempt to disassemble, to open or to cut a
CAUTION pressurized system (danger of explosion).
⇒ Observe the operation instructions of the respective
manufacturer.
⇒ Before disassembling pressurized systems, release
pressure and drain off the fluid or gas.
⇒ Use suitable protective clothing (for example safety
glasses, safety shoes and safety gloves)
⇒ Remove any fluid that has leaked out onto the floor
immediately.
Note: Environmental protection and disposal! The media used in the

operation of the pressurized system equipment may not be
environmentally compatible. Media that are damaging the
environment must be disposed separately from normal waste.
Observe the legal requirements in the country of installation.
Notes
Rexroth IndraDrive C Identifying and Checking the Delivered Components 4-1
4 Identifying and Checking the Delivered

Components
4.1 Delivery of Components
Packaging
Packaging Units The components are supplied in separate packaging units.
Packaging Labels The content of the packed components and the order number may be
identified using the adhesive barcode label on the packaging.
Disposal of Packaging Material See chapter 9
Accompanying Documents
A delivery note in duplicate can be found in an envelope on one of the
packages supplied. No other accompanying documents are provided.
The total number of containers supplied is recorded on the delivery note
or consignment note.
4.2 Scope of Delivery
Overview
as standard optional
Power section Control section
Touch guard Accessory for shield connection of motor
cable
Connectors X3, X5, X6, X13 DC bus rails
Connector X9 (HCS02.1E-W0054
and HCS02.1E-W0070 only)
Fig. 4-1: Scope of delivery
Checking the Delivered Components

Please immediately check whether the delivered components are:
• complete
• correct
• intact
4-2 Identifying and Checking the Delivered Components Rexroth IndraDrive C
4.3 Type Plates

Each drive component is identified by a type designation.
A type plate is attached to all units, including the motor.
A label (cable marker) is wrapped round the ready-made cable. The type
designation and length are indicated on this label. (The designation for the
cable itself, without connector, is printed on the cable sheath.)
The identification of accessories packed in bags is either printed on the
bag or indicated in an accompanying note.
Type Plates on the Drive Controller
hcs_lt_rt_typenschildert.fh7
1: Power section type plate

2: Control section type plate
Fig. 4-2: Type plate arrangement
Rexroth IndraDrive C Identifying and Checking the Delivered Components 4-3
Type Plate Power Section
Device type
HCS02.1E-W0012-A-03-
NNNN
R911298371 Made in Germany FD:04W12
Part number
SN: HCS021-00123 0A01
Serial Number Barcode Hardware index
Production week
Example 04W12 means year 2004 week 12
Producing Country
Fig. 4-3: Type plate power section
Type Plate Control Section

See project planning manual of the control sections.
4-4 Identifying and Checking the Delivered Components Rexroth IndraDrive C
4.4 Device Types
Type Code
Note: The following figure illustrates the basic structure of the type
code. Your sales representative will help with the current
status of available versions.
Abbrev. 1 2 3 4
Column 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
Example: H C S 0 2 . 1 E - W 0 0 1 2 - A - 0 3 - N N N N
1. Product
1.1 HCS. . . . . . . . = HCS
2. Line
2.1 1.5 to 11 kW. . . . . . . . = 02
3. Design
3.1 1......................=1
4. Power supply
4.1 feeded . . . . . . . . . . . . . . . . . . . = E
5. Cooling mode
5.1 Air, internal (through integrated blower) = W
6. Maximum current
6.1 12 A . . . . . . . . . . . . . . . . . . . . . . . . . = 0012
6.2 28 A . . . . . . . . . . . . . . . . . . . . . . . . . = 0028
6.3 54 A . . . . . . . . . . . . . . . . . . . . . . . . . = 0054
6.4 70 A . . . . . . . . . . . . . . . . . . . . . . . . . = 0070
7. Protection mode
7.1 IP 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = A
8. Mains connecting voltage

8.1 AC 200 to 500V ±10% . . . . . . . . . . . . . . . . . . . . . . . . . = 03
9. Other design
9.1 none. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN
9.2 with integrated 24 V power supply . . . . . . . . . . . . . . . . . . . .= NNNV
10. Standard reference

Standard Title Edition
DIN EN 60529 Degrees of protection provided 2000-09
by enclosures (IP-Code)
Fig. 4-4: Type code (power section)
Rexroth IndraDrive C Transport and Storage 5-1
5 Transport and Storage
5.1 Transporting the Devices
Conditions
temperature -25 ... 70 °C
relative humidity 5 ... 95%;
climatic category 2K3
3
absolute humidity 1 ... 60 g/m
moisture condensation slight moisture condensation allowed
icing not allowed
Shock check not in operation Halve sine in 3 axis:
according to EN 60068-2-27 10g / 11ms
Fig. 5-1: Conditions for transport
5.2 Storing the Devices
Conditions
temperature -25 ... 55 °C
relative humidity 5 ... 95%;
3
absolute humidity 1 ... 29 g/m
moisture condensation not allowed
icing not allowed
Fig. 5-2: Conditions for storage
In Case of Long Storage Periods

The devices contain sensitive electrolytic capacitors. Therefore, in the
case of long storage periods, operate the devices once a year for at least
1 hour with power on (DC bus voltage must be applied).
5-2 Transport and Storage Rexroth IndraDrive C
Notes
Rexroth IndraDrive C Mechanical Mounting 6-1
6 Mechanical Mounting
6.1 Mounting Conditions
Ambient and Operating Conditions
Note: The drive controllers and their additional components are

designed to be built into control cabinets.
Note: The user must check that the ambient conditions, and in
particular the temperature of the control cabinet, are complied
with by calculating the heat levels in the control cabinet.
Designation Information
Degree of protection IP 20 according to IEC529
Ambient temperature 0 to +40 °C
Ambient temperature with derating 0 °C to +55 °C; see characteristic in Fig. 6-2
Temperature in storage see chapter 5
Temperature during transportation see chapter 5
Mounting altitude at rating < 1000 m above sea level
Mounting altitude with derating* see characteristic in Fig. 6-3
Maximum mounting altitude* 4000 m
(upper temperature limit falls to 40 °C instead of 55 °C)
Relative humidity 5% to 95%
(operation) Cl.3K5 with reservation, as not –5 °C
3
Absolute humidity 1 to 29 g/m
Climatic class Cl.3K5
Contamination level Contamination level 2 in accordance with EN50178
Vibration sinus in operation according to EN Amplitude and frequency: 0.15 mm (peak-peak)
60068-2-6 at 10 ... 57 Hz
Acceleration and frequency: 1 g at 57 ... 150 Hz
Tolerance: ±15 %
Vibration distortion (Random) in operation Frequency: 20 ... 150 Hz
according to IEC 68-2-36 2
Spectral acceleration density amplitude: 0.005 g /Hz
Tolerance: ± 3 dB
Virtual value (rms) of the total acceleration: 1.0 g
* For mounting altitudes of more than 2000 m, an overvoltage limiter for
transient overvoltage 1.2/50 µs must be installed in the installation or
building in order to limit the voltage to 1.0 kV between the outer
conductors and to 2.5 kV between conductor-ground.
Fig. 6-1: Ambient and operating conditions
6-2 Mechanical Mounting Rexroth IndraDrive C
Compatibility with Foreign All Rexroth controls and drives are developed and tested according to the
Matters state-of-the-art of technology.
As it is impossible to follow the continuing development of all materials
(e.g. lubricants in machine tools) which may interact with our controls and
drives, it cannot be completely ruled out that any reactions with the
materials used by Bosch Rexroth might occur.
For this reason, before using the respective material a compatibility test
has to be carried out for new lubricants, cleaning agents etc. and our
housings/our housing materials.
Duty Capacity
Where conditions differ, the following performance data diminish in
accordance with the diagrams (see below):
• Drive controllers:
• Permitted DC bus continuous output
• Continuous output of the braking resistor
• Continuous current
• Motor:
• Power
• Continuous torque at standstill
• S1 continuous torques
• Short-time service MKB
If differing ambient temperatures and higher mounting altitudes occur
simultaneously, both duty factors must be multiplied. The mounting
altitude must be taken into account just once, differing ambient
temperatures must be considered separately for the motor and drive
controller.
Degree of utilization at higher

ambient temperatures
1
0,7
Load factor
5 40 45 50 55
Ambient temperature in °C
DG0006F1.FH7
Fig. 6-2: Duty capacity at higher ambient temperature
Degree of utilization at higher installation altitudes

1
0,8
0,6
Load factor
0,4
0,2
0 1000 2000 3000 4000

Installation altitude above sea level in meters
DG0007F1.FH7
Fig. 6-3: Duty capacity at higher mounting altitude
6.2 Mechanical Technical Data
Dimensions
Dimensional Drawing for HCS02.1E-W0012
A: minimum mounting clearance (when using accessories HAS02.1);

plus space for cables
B: minimum mounting clearance; plus space for cables
Fig. 6-4: Dimensional drawing HCS02.1E-W0012
Dimensional Drawing for HCS02.1E-W0028

Fig. 6-5: Dimensional drawing HCS02.1E-W0028
Dimensional Drawing for HCS02.1E-W0054 and

HCS02.1E-W0070

Fig. 6-6: Dimensional drawing HCS02.1E-W0054 and HCS02.1E-W0070
Weight
Drive controller Weight [kg]

HCS02.1E-W0012 2.9
HCS02.1E-W0028 3.8
HCS02.1E-W0054 6.7
HCS02.1E-W0070 6.8
Fig. 6-7: Weight of drive controllers (without control section and accessories)
The weight of devices with integrated 24V power supply (-NNNV) is 0.2 kg
higher.
Note: Weight of control section: 0.42 kg.
Installation Orientation
Install drive controllers, DC bus resistor units and DC bus capacitor units
in such a way that their longitudinal axis corresponds to the natural
direction of convection (connections for motor and power downwards).
In this way the natural convection supports the forced cooling air current.
This avoids the generation of pockets of heat.
Separation Distance between Drive Controllers

When mounting drive controllers in a row there must be a minimum
separation distance of 5 mm to each drive controller.
Temperatures Above the Top of the Device

The drive controllers have a high efficiency. Outlet temperatures higher
than the ambient temperature are nevertheless produced at the top of the
devices, among other things due to the converted energies. High outlet
temperatures are particularly produced in the case of insufficient cooling
or when the cooling air current (blower failure) fails.
Risk of damage caused by too high outlet

temperatures!
⇒ When mounting and installing other components,
CAUTION make sure the distance to the top of the drive
controllers is sufficient.
⇒ You have to take into account that the indicated
temperature rise can occur when the cooling air
current fails.
Outlet Temperatures when Cooling Air Current Fails

Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E-
W0012 W0028 W0054 W0070
temperature rise
with distance of 40 mm from 7 K 110 150 250 280
top of device
temperature rise
with distance of 80 mm from 7 K 80 90 100 110
top of device
Fig. 6-8: Outlet temperatures when cooling air current fails
Outlet Temperatures in Normal Operation

The diagrams below show the temperature rise of the air from air intake
at the bottom of the device to air outlet at the top of the device, depending
on the average continuous power at the breaking resistor. The values "d"
are representing different distances from the top of the device:
d air outlet
control cabinet mounting plate

air inlet
kuehlluft.FH7
Fig. 6-9: Air inlet and outlet of drive controller
HCS02.1E-W0012
40
35
30
25
20
7>.@
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50
PBD [W]
7#GaPP
7#GaPP
7#GaPP
7#GaPP
Fig. 6-10: HCS02.1E-W0012
HCS02.1E-W0028
100
90
80
70
60
50
7>.@
40
30
20
10
0
0 15 30 45 60 75 90 105 120 135 150
PBD [W]
7#GaPP
7#GaPP
7#GaPP
7#GaPP
Fig. 6-11: HCS02.1E-W0028
HCS02.1E-W0054
90
80
70
60
50
7>.@
40
30
20
10
0
0 35 70 105 140 175 210 245 280 315 350
PBD [W]
7#GaPP
7#GaPP
7#GaPP
7#GaPP
Fig. 6-12: HCS02.1E-W0054
HCS02.1E-W0070
120
100
80
60
7>.@
40
20
0
0 50 100 150 200 250 300 350 400 450 500
PBD [W]
7#GaPP
7#GaPP
7#GaPP
7#GaPP
Fig. 6-13: HCS02.1E-W0070
Arrangement of Components in the Control Cabinet

Power-Dependent Arrangement
• Arrange the drive controllers according to their power.
drive
controllers
low power high power low power
anordnung_leistungabh.FH7
Fig. 6-14: Example of an arrangement
• Position DC bus capacitor unit next to drive with the greatest DC bus
continuous output.
• Position DC bus resistor unit next to drive with the greatest negative
feed power.
Control Cabinet with Multiple Line Structure
Note: Particular attention should be paid to the maximum

permissible air intake temperature of components when they
are arranged in multiple lines in the control cabinet. Where
necessary, cooling air guides are to be allowed for with
ventilators specially inserted for this purpose.
Discharge direction of the

warmed air in the flow-off area Exhaust air
from the air
conditioner
Entry area of the cooling air

for the upper device line
For
example: air
Additional
baffle
fan
Discharge direction of the
warmed air in the flow-off area
Entry area of the cooling air Supply air

for the lower device line from the air
conditioner
Fig. 6-15: Example of arrangement for multiple line structure with components
6.3 Cooling and Cooling Units
Power Dissipation
The power dissipation of a drive system radiated to the control cabinet is
calculated from the sum of the power dissipation of the supply unit, the
power dissipation of the mains connecting unit, the power dissipation of
each drive controller, and the power dissipation of additional units (e.g.
DC bus resistor unit or DC bus capacitor unit).
To determine the power dissipation of the supply unit, the mains

connecting unit, and the additional units please observe the
corresponding documentation of these units.
The power dissipation of a drive controller is composed of

• power dissipation of optional modules
• power dissipation of control section
• basic power dissipation of power section
• current-related power dissipation of power section
The current-depending power dissipation of the power sections illustrated

in the following diagrams is composed of
• the losses of the mains-supply rectifier
• the switching losses of the inverter
HCS02.1E-W0012
16 kHz 12 kHz 10 kHz 8 kHz 4 kHz
y-axis: Power dissipation [W]

x-axis: Current (rms value) [A]
Fig. 6-16: Power dissipation power section HCS02.1E-W0012
HCS02.1E-W0028
Pv vs Iout for HCS02.1-W0028
130 130 16 kHz 12 kHz 10 kHz 8 kHz 4 kHz
120
110
(
P V4kHz i out_4kHz ) 100
90
(
P V8kHz i out_8kHz )
80
(
(
(
40
30
20
0 10
0
0 2 4 6 8 10 12
0 i out_4kHz , i out_8kHz , i out_10kHz , i out_12kHz , i out_16kHz 12

HCS02.1E-W0054

300 300
16 kHz 12 kHz 10 kHz 8 kHz 4 kHz
270
240
( )
P V4kHz i out_4kHz
210
( )
P V8kHz i out_8kHz
180
(
150
(
120
(
90
60
30
0
0
0 2 4 6 8 10 12 14 16 18 20 22 24

HCS02.1E-W0070

300 300 16 kHz 12 kHz 10 kHz 8 kHz 4 kHz
270
240
( )
P V4kHz i out_4kHz
210
( )
P V8kHz i out_8kHz
180
(
150
(
120
(
90
60
30
0
0
0 3 6 9 12 15 18 21 24 27 30 33 36

Mounting Cooling Units

Unless the ratings are reduced the drive controller may only be operated
up to an specified ambient temperature (see chapter 6.1). It is therefore
possible that a cooling unit will be required.
Possible damage to the drive controller

Operational safety of the machine endangered
⇒ Note the following instructions
CAUTION
Avoiding Dripping or Sprayed As a matter of principle condensation water is formed when cooling units
Water are used. For this reason, please observe the following information:
• Always position cooling units in such a way that condensation water
cannot drip onto electrical equipment in the control cabinet.
• Position the cooling unit so that the ventilator for the cooling unit does
not spray accumulated condensation water onto electrical equipment.
correct incorrect
Cooling system Cooling system
warm cold warm cold
Air duct
electronic electronic
equipment equipment
Cabinet Cabinet
Eb0001f1.fh7
Fig. 6-20: Arrangement of the cooling unit on the control cabinet
correct incorrect
control cabinet control cabinet

air inflow air inflow
air air outflow

duct
cooling cooling
unit unit
electronic electronic
equip. equip.
Eb0002f1.fh7
Fig. 6-21: Arrangement of the cooling unit on the front of the control cabinet
Avoiding Condensation Condensation occurs when the temperature of the unit is lower than the
ambient temperature.
• Set cooling units with temperature adjustment to the maximum
surrounding temperature and no lower.
• Set cooling units with traced temperature so that the interior
temperature of the control cabinet is no lower than the temperature of
the surrounding air. Set the temperature delimitation to the maximum
surrounding temperature.
• Only use well-sealed control cabinets so that condensation cannot
arise as a result of warm and moist external air entering the cabinet.
• In the event that control cabinets are operated with the doors open
(start-up, servicing etc.) it is essential to ensure that after the doors are
closed the drive controllers cannot at any time be cooler than the air in
the control cabinet, as otherwise condensation can occur. For this
reason ample circulation must be provided inside the control cabinet to
avoid pockets of heat.
Rexroth IndraDrive C Electrical Installation 7-1
7 Electrical Installation

Damage can be caused to the drive controller or circuit boards if
electrostatic charging present in people and/or tools is discharged across
them. Therefore, please note the following information:
Electrostatic charges can cause damage to

electronic components and interfere with their
operational safety!
CAUTION ⇒ Objects coming into contact with components and
circuit boards must be discharged by means of
grounding. Otherwise errors may occur when
triggering motors and moving elements.
Such objects include:

• the copper bit when soldering
• the human body (ground connection caused by touching a conductive,
grounded item)
• parts and tools (placing on a conductive support)
Endangered components may only be stored or dispatched in conductive
packaging.
Note: Rexroth connection diagrams are only to be used for

producing installation connection diagrams. The machine
manufacturer’s installation connection diagrams must be used
for wiring the installation!
• Lay signal lines separately from the load resistance lines because of
the occurrence of interference.
• Feed analog signals (e.g., command values, actual values) via
sheathed lines.
• Do not connect mains, DC bus or power leads to low voltages or allow
them to come into contact.
• When carrying out a high voltage test or insulation withstand test on
the machine’s electrical equipment, disconnect all connections to the
units. This protects the electronic components (permitted in
accordance with EN 60204-1). During their routine check test, Rexroth
drive components are tested for high voltage and insulation in
accordance with EN 50178.
Plugging and unclamping live connections can

damage the controller.
⇒ Do not plug in or unclamp live connections.
CAUTION
7-2 Electrical Installation Rexroth IndraDrive C
7.2 10 rules for EMC-correct installation of drives
Note: Detailed information is available in the instructions in the

Project Planning Manual "Electromagnetic Compatibility (EMC)
in Drive and Control Systems", document typecode DOK-
GENERL-EMV********-PRxx-xx-P.
The following 10 rules are the basics for designing drive systems in
compliance with EMC.
Rules 1 to 7 are generally valid. Rules 8 to 10 are especially important to
limit noise emission.
Rule 1 All metal parts of the cabinet should be connected with one another
through the largest possible surface area so that the best electrical
connection is established (not paint on paint!). If required, use serrated
washers which cut through the paint surface. The cabinet door should be
connected to the cabinet using the shortest possible grounding straps.
Rule 2 Signal, line supply, motor and power cables should be routed away from
another (this eliminates mutual interference!). The minimum clearance is:
10 cm. Barriers should be provided between power- and signal cables.
These barriers should be grounded at several locations.
Rule 3 Contactors, relays, solenoid valves, electromechanical operating hour
counters etc. in the cabinet must be provided with noise suppression
devices. These devices must be connected directly at the coil.
Rule 4 Non-shielded cables belonging to the same circuit (feeder and return
cables) should be twisted with the smallest possible distance between
them. Cores which are not used must be grounded at both ends.
Rule 5 Generally, interference injection can be reduced by routing cables as
close as possible to grounded sheet steel panels. For this reason, cables
and wires should not be routed freely in the cabinet, but as close as
possible to the cabinet itself and the mounting panels. This is also true for
reserve cables.
Rule 6 Incremental encoders must be connected using shielded cables. The
shield must be connected at the incremental encoder and at the drive
controller through the largest possible surface area. The shield may not
be interrupted, e.g. using intermediate terminals.
Rule 7 The shields of signal cables must be connected to ground at both ends
through the largest possible surface area to establish a good electrical
connection (transmitter and receiver). If the potential bonding between the
screen connections is poor, to reduce the shield current, an additional
potential bonding conductor with a cross-section of at least 10 mm²
should be connected in parallel with the shield. The shield can be
connected to ground (=cabinet housing) at several locations. This is also
true outside the cabinet. Foil shields are not recommended. Braided
screens provide a better shielding effect (factor of 5).
If the potential bonding is poor, analog signal cables may only be
grounded at one end to the drive controller in order to prevent low-
frequency noise being injected into the screen (50 Hz).
Rule 8 Always locate a radio interference suppression filter close to the noise
source. The filter should be connected through the largest possible
surface area with the cabinet housing, mounting panel etc. The best
solution is a bare metal mounting panel (e.g. manufactured from stainless
steel, galvanized steel), as the complete mounting surface can be used to
establish good electrical contact.
The incoming and outgoing cables of the radio interference suppression
filter should be separated.
Rule 9 All variable-speed motors should be connected using shielded cables,

whereby the shield is connected at both ends to the housings through the
largest possible surface area to minimize the inductance. The motor
feeder cables should also be shielded outside the cabinet, or at least
screened using barriers.
Cables with steel shield are not suitable.
To connect the shield at the motor, a suitable PG gland with shield
connection can be used (e.g. "SKINDICHT SHV/SRE/E" from the Lapp
Company, Stuttgart). It should be ensured that the connection between
the motor terminal box and the motor housing has a low impedance.
Otherwise, use an additional grounding strap between them. Never use
plastic motor terminal boxes!
Rule 10 The shield between the motor and drive controller may not be interrupted
by installing components such as output reactors, sinusoidal filters, motor
filters, fuses, contactors. The components must be mounted on mounting
panels which also simultaneously serve as shield connection for the
incoming and outgoing motor cables. If required, metal barriers may be
required to shield the components.
Optimal EMC Installation

With regard to an optimal EMC installation, a spatial separation of the
interference-free area (mains connection) and the interference-
susceptible area (drive components) is advisable. See the next figure in
this respect.
shielded control cabinet

compartment or intermediate
mains PE panel
control
cabinet
connecting
clamps
drive controller
main
switch
distributor
clamps
fuse
mains
to the motors
mains
filter
load earth rail
mains
choke
power connection
mains
contactor
HCS02_emv.fh7
Fig. 7-1: Separation of interference-free area and interference-susceptible

area
7.3 Electrical Data

HCS02.1E-W0012, -W0028, -W0054, -W0070
Note: The current and power data below apply when the allowed
motor cable length is complied with (see data in section "X5,
Motor Connection").
Power Section– Mains Supply

W0012 W0028 W0054 W0070
operating mode on the
allowed
three-phase mains
1)
operating mode on the allowed
single-phase mains
phase rotation
no condition for phase rotation
total power factor TPF at cosϕ = 0.4 0.4 0.4 0.4
PDC (single-phase) 1/λL
total power factor TPF at cosϕ = 0.59 / -- 0.59 / 0.83 0.55 / 0.77 0.58 / 0.66
PDC without / with mains 1/λL
choke
h1
power factor of cosϕ 0.97 / -- 0.97 / -- -- / -- -- / --
fundamental component
DPF PDC without / with
mains choke
assigned mains choke 1000-N0012- 1000-N0012- 1000-N0020- 0600-N0032-
HNL01.1E A-500 A-500 A-500 A-500
assigned mains filters length of

2)
NFD03.1-480 motor cable
with single source supply l < 75 m -007 -016 -075 -075
l < 40 m -007 -016 -055 -055
mains input voltage ULN V 1 * AC (200..250) +-10%
3 * AC (200..500) +-10%
mains frequency fLN Hz
(50 .. 60) +-2
transient overvoltage limit kV • 1 (between the conductors within the circuit)
values between circuits:
impulse withstand voltage
• 2 (against environment and ground)
(1.2/ 50us and 8/ 20 µs);
mains connection:
230...480 V
mains input continuous IL,cont Aeff
6 13 19 30
current at PDcmax
maximum allowed fusing Aeff
10 20 20 32
acc. to C-UL
nominal inrush current IL trans max (on) A 1.4 ... 4.3 3.5 ... 10.7 6.3 ... 19.3 9.9 ... 27.5
(depending on mains
input voltage)
connected load SLN kVA see diagrams on page 8-22 onwards
1) See chapter "Mains Connection"
2) When NFD03.1 mains filters are used, the allowed mains input
voltage is limited to 3*AC480V
Fig. 7-2: Data power section– mains supply
Power Section – DC Bus

W0012 W0028 W0054 W0070
DC bus voltage (range) (depending UDC V uncontrolled
on mains input voltage) 250 ... 770
soft-start resistor RDC(Start) Ohm 180 72 40 28
continuous power soft-start resistor PDC(Start) kW 0.05 0.15 0.35 0.5
max. DC bus charging energy W MAX kWs 1 5 9 13
nominal DC bus capacity CDC mF 0.135 0.270 0.405 0.675
storable energy of the W DC Ws see diagram on page 7-7
DC bus capacitors
lower DC bus voltage limit UDC limit (min) V 200
see also Functional Description of firmware
upper DC bus voltage limit (cut-off UDC limit (max) V 900
threshold)
max. DC bus continuous power PDC cont kW 2.1 5.1 7.0 9
ULN = AC400 V
min. inductance
of mains supply for
1) Lmin uH 200 150 100 80
operation without mains choke
(line value)
max. DC bus continuous power PDC cont kW 2.1 5.1 10 14
ULN = AC400 V
with mains choke

DC bus peak power PDCpeak kW
UN1 = 3 x AC 400 V, at Ta<40 °C;
t=0.4 s; T=4 s
without mains choke 5 8 12 14
with mains choke 5 10 16 19
nom. Y-capacitance (DC bus CY nF 2 * 100 2 * 100 2 * 100 2 * 100
against ground)
2)
k-factor (leakage behavior) - tbd tbd tbd tbd
balancing factor for PDC cont - -
(for parallel operation with common
DC bus)
with / without mains choke: 0.8 / 0.5 0.8 / 0.5 0.8 / 0.5
1) if inductance of mains supply is lower, use mains chokes

2) tbd = in preparation
Fig. 7-3: Data power section – DC bus
Storable Energy in the Bus
Note: The higher the connection voltage the lower the energy that
can be stored in the DC bus as the differential voltage
between braking resistor threshold and DC bus voltage
(threshold value of connecting voltage) decreases.
Further information regarding the braking resistor threshold:
See Functional Description of firmware.
HCS02.1E-W0012
35
30
25
W ZW [Ws]
20
15
10
0
180 230 280 330 380 430 480 530
UN1 [V]
Fig. 7-4: Storable energy in the bus for HCS02.1E-W0012
HCS02.1E-W0028
70
60
50
W ZW [Ws]
40
30
20
10
0
180 230 280 330 380 430 480 530
UN1 [V]
HCS02.1E-W0054
120
100
80
W ZW [Ws]
60
40
20
0
180 230 280 330 380 430 480 530
UN1 [V]
HCS02.1E-W0070
180
160
140
120
W ZW [Ws]
100
80
60
40
20
0
180 230 280 330 380 430 480 530
UN1 [V]
Damage to the drive controller!

In the case of machining cycles of high frequency (more
than 30 cycles per minute), the DC bus capacitors in the
drive controller can be overloaded with decreasing mains
CAUTION connection voltage.
⇒ Operate additional capacities at the DC bus.
Power Section – Braking Resistor

W0012 W0028 W0054 W0070
nominal braking resistor RDC(Bleeder) Ohm 180 72 40 28
(internal)
max. regenerative power W R,MAX kWs 1 5 9 13

braking resistor threshold RDC (R_DC On) V see Functional Description of firmware
cooling of braking resistor forced forced forced forced
braking resistor peak power PBS kW 4 10 18 25
at UDC = 850 V
(allowed load cycle) (0.25s ON; (0.5s ON; 33s (0.5s ON; 26s (0.5s ON; 25s
20s OFF) OFF) OFF) OFF)
braking resistor continuous PBD KW 0.05 0.15 0.35 0.5
power, at Ta<40 °C
under max. temperature 7 K 12 40 40 50
range with distance from d mm 80 80 80 80
1)
top side of housing
balancing factor for PBD - 0.8 0.8 0.8
(for parallel operation with
common DC bus)
operation external braking -- -- allowed allowed
resistor (optional)
min. resistance of external RDC(Bleeder) Ohm -- -- 40 28
braking resistor
allowed continuous power kW -- -- 3.8 5.5
of external braking resistor
ext. braking resistor peak PBS kW -- -- 18 25
power
at UDC = 850 V (5.5s ON; 26s (5.5s ON; 25s
(allowed load cycle)
2) OFF) OFF)
1) see also section Temperatures Above the Top of the Device" on

page6-8
2) take energy absorption capacity of external braking resistor into
account
Fig. 7-8: Data power section – braking resistor
Power Section – Inverter

Note: The adjustable pulse frequency (4, 8, 10, 12 resp. 16 kHz)
depends on the firmware and the control section.

W0012 W0028 W0054 W0070
output voltage Uout eff V
fundamental voltage at UDC = 475 V 335 335 335 335
UDC = 750 V 530 530 530 530
output frequency range fout Hz 400 400 400 400
- at fs = 4 kHz
- at fs = 8 kHz 800 800 800 800
- at fs = 10 kHz 1000 1000 1000 1000
- at fs = 12 kHz
- at fs = 16 kHz 1200 1200 1200 1200
1600 1600 1600 1600
rise of voltage at output at du/dt kV/µs
400V and 10m motor
cable length 10% - 90%
phase-phase: 6 5 5 4
phase-ground: 6 6 5 4
minimum load inductance Lloadmin µH tbd* tbd tbd tbd

maximum output current Iout_eff max (4 kHz) A 11.5 28.3 54 70.8
Iout_eff max (8 kHz) 11.5 28.3 54 70.8
Iout_eff max(10 kHz) 11.5 28.3 54 70.8
Iout_eff max(12 kHz) 11.5 28.3 54 70.8
Iout_eff max(16 kHz) 11.5 28.3 54 70.8
continuous output current Iout_eff cont2 (4 kHz) A 4.5 11.3 20.6 28.3
(effective value)
or rated current Iout_eff cont2 (8 kHz) 4.5 9.2 20.6 21.5
Iout_eff cont2 (10 kHz) 4.5 6.9 17.5 17.2
Iout_eff cont2 (12 kHz) 4.1 5.1 13.8 14.2
Iout_eff cont2 (16 kHz) 2.9 4.4 11.2 10.5
* tbd = in preparation
Fig. 7-9: Data – inverter
Power Section - Examples of Allowed Load Profiles

The capacity of the drive controllers is described below with examples of
load profiles. The examples are distinguishing applications for servo
operation (400 ms) and main spindle operation (2 s resp. 60 s).

W0012 W0028 W0054 W0070
Iout_eff max
output current profile for
overload operation
overload capacity: Iout_eff_cont1
Iout_eff_m ax
K= t
Iout_eff_c ont1 @fs t
T
maximum output current Iout_eff max (4 kHz) A 11.5 28.3 54.0 70.8
(effective value at Iout_eff max (8 kHz) 10 15.6 35.1 35.8
operation at overload)
Iout_eff max (10 kHz) 8.1 11.7 28.7 28.3
t=400ms; T=4s
Iout_eff max (12 kHz) 6.3 8.7 23.0 23.5
Iout_eff max (16 kHz) 4.4 7.7 18.8 17.0
base load current Iout_eff cont1 (4 kHz, Iout_eff max) A 2.7 7.2 12.1 14.0
available at maximum
current (effective value) Iout_eff cont1 (8 kHz, Iout_eff max) 3.0 5.7 13 13.4
T=4s; t=400ms Iout_eff cont1 (10 kHz, Iout_eff max) 3.0 4.3 10.6 10.5
Iout_eff cont1 (12 kHz, Iout_eff max) 2.3 3.2 8.5 8.6
Iout_eff cont1 (16 kHz, Iout_eff max) 1.6 2.8 7 6.4
maximum output current Iout_eff_max (4 kHz) A 5.8 15 27 34
t=2s; T=20s; Iout_eff_max (8 kHz) tbd* tbd tbd tbd
Iout_eff _cont1=0A
Iout_eff_max (10 kHz) tbd tbd tbd tbd
(effective value at
operation at overload) Iout_eff_max (12 kHz) tbd tbd tbd tbd
Iout_eff_max (16 kHz) tbd tbd tbd tbd
maximum output current Iout_eff max (4 kHz) A 4.5 11.3 20.6 28.3
t=60s; T=5min; Iout_eff max (8 kHz) tbd tbd tbd tbd
Iout_eff _cont1=0A
Iout_eff max (10 kHz) tbd tbd tbd tbd
(effective value at
operation at overload) Iout_eff max (12 kHz) tbd tbd tbd tbd
Iout_eff max (16 kHz) tbd tbd tbd tbd
Fig. 7-10: Data load profiles – inverter
Note: The load profiles are characterized by their time flow and the
corresponding currents and are representing the output
current capacity. These profiles are limited by the drive
controller via the thermal effect of the output current. When
the current limitation is triggered, it is therefore necessary to
• reduce the load with Iout_eff max or
• reduce the pulse time or
• increase the cycle time or
• use a device with higher type current
(See also Functional Description and Troubleshooting Guide
of the firmware.)
Note: The load profiles are available if particularly the maximum

current at switching frequencies of 8, 10, 12 and 16 kHz is
externally (e.g. by the NC) limited to the indicated values.
Power Section – Cooling, Power Dissipation, Insulation

W0012 W0028 W0054 W0070
cooling power section forced forced forced forced
volumetric capacity of the m³/h approx. 24 approx. 24 approx. 40 approx. 40
forced cooling
cooling air flow together for braking resistor and power section
max. device power PDiss,Drive W 120 120 270 300
dissipation (with inverter,
chopper and rectifier losses;
without internal continuous
braking resistor power)
insulation resistance at Ris MOhm >1 >8 >8 >8
DC500V
coupling capacitance power CKop nF 210 210 210 210
section against housing
Fig. 7-11: Data power section - cooling, power dissipation, insulation
Control Voltage
Devices without Internal Control Voltage Supply
(HCS02.1E-W00xx-NNNN)
Note: The data below apply to the control sections.

The data are referring to an ambient temperature of 25 °C.
Designation Symbol Unit Value

control voltage UN3 V • 24 ±20%
(when no motor holding brake is used)
• If motor holding brakes are to be supplied, observe the
data of the motor documentation. The following values are
normally sufficient:
24 ±5% with motor cable length <50 m
26 ±5% with motor cable length >50 m
max. ripple content w - mustn’t exceed the control voltage range
max. allowed overvoltage UN3max V 33 (max. 1 ms)
max. charging current IEIN3 A 2.8
plus charging current of control section (see Project Panning
Manual IndraDrive Control Sections)
max. pulse duration of IEIN3 tEIN3Lade ms 15
max. input capacity CN3 mF 1.2 * 0.47
power consumption:
HCS02.1E-W0012 PN3 W 12
HCS02.1E-W0028 PN3 W 14
HCS02.1E-W0054 PN3 W 23
HCS02.1E-W0070 PN3 W 23
* data without motor holding brake and control section CS* taken into account
Fig. 7-12: Control voltage
Devices with Internal Control Voltage Supply Generation

from DC bus (HCS02.1E-W00xx-NNNV)
The internally generated control voltage is used for stand-alone supply of
the drive controller or buffering in case the external 24V supply fails. It is
not used for supplying motor holding brakes.
(Information at ambient temperature of 25 °C)
Designation Symbol Unit Value

control voltage UN3 V • 24 ±20%
(when no motor holding brake is used)
• If motor holding brakes are to be supplied, observe
the data of the motor documentation. The following
values are normally sufficient:
24 ±5% with motor cable length <50 m
26 ±5% with motor cable length >50 m
max. ripple content w - mustn't exceed the control voltage range
max. allowed overvoltage UN3max V 33 (max. 1 ms)
max. charging current IEIN3 A 2.8
plus charging current of control section (see Project
Planning Manual IndraDrive Control Sections)
max. pulse duration of IEIN3 tEIN3Lade ms 15
max. input capacity CN3 mF 1.2 * 0.47
power consumption*:
HCS02.1E-W0012 PN3 W 12
HCS02.1E-W0028 PN3 W 14
HCS02.1E-W0054 PN3 W 23
HCS02.1E-W0070 PN3 W 23
internally generated control UN3 V 24 ±10%
voltage
(not used for supplying the motor holding brake)
output power W 70
for required power of control
section CS* and power section
power dissipation W 25
short-circuit strength present
overload withstand capability present
overtemperature protection present
Fig. 7-13: Control voltage -***V
Block diagram of control voltage generation from the DC bus:
int.
24 V Br LT ST SMPS ZK
(optional)
hcs_block_steuerspg.fh7
Br: brake circuit

LT: power section
ST: control section
int. SMPS: internal switching-mode power supply
ZK: DC bus
Fig. 7-14: Block diagram of internal control voltage generation
7.4 Complete Connection Diagram
XS1 shield connection
X1out
X1:Out bus connection OUT
1-8
X1in
1-8 X1:In bus connection IN
X13:1 0V control voltage

X13:2 0V
X13:3 +24V
X13:4 +24V
L+ DC bus
L+
L-
L-
X3
L1 mains connection
L1
L2
L2
L3
L3
X5
A1 motor connection
A1
A2
A2
A3
A3
X6
MotTemp+ motor temperature monitoring

1
MotTemp-
2
+24VBr motor holding brake

3
0VBr
4
X9
1 external braking resistor

1
2
2
XS2 shield connection
anschlussplan_w0054u70.fh7
X1, L+/L not available for HCS02.1E-W0012

X9 not available for HCS02.1E-W0012 and –W0028
Fig. 7-15: Complete connection diagram
7.5 Connecting Cables and Rails
Note: Apart from the connections listed below, it is necessary to wire

the Bb contact at the control section for signaling the
readiness for operation of the drive controller (see Project
Planning Manual for Control Section).
Connections at HCS02.1E-W0012
Front
XS1
1 2 3 4
X13
hcs0012_front.fh7
Fig. 7-16: HCS02.1E-W0012 power section connections (front)
Description of connections:
Connection Page
X13, Control voltage 7-34
XS1, Shield connection (control wires) 7-39
7-38
Ground connection
Bottom
1 2 3 4
X6
XS2
X5
X3
hcs0028_x3_x5_x6.fh7
Fig. 7-17: HCS02.1E-W0012 power section connections (bottom)
Connection Page
X3, Mains connection 7-24
X5, Motor connection 7-26
X6, Motor temperature monitoring, motor holding brake 7-30
XS2, Shield connection (motor cable) 7-40
Connections at HCS02.1E-W0028, -W0054, -W0070

Front
XS1
X1 out X1 in
1 2 3 4
X13
L+
L-
hcs0028_front.fh7
Fig. 7-18: HCS02.1E-W0028, -W0054, -W0070 power section connections

(front)
Connection Page
X1, Module bus 7-23
X13, Control voltage 7-34
XS1, Shield connection (control wires) 7-39
L+/L-, DC bus 7-37
7-38
Ground connection
Bottom (HCS02.1E-W0028)
1 2 3 4
X6
XS2
X5
X3
hcs0028_x3_x5_x6.fh7
Fig. 7-19: HC02.1E-W0028 power section connections (bottom)
Connection Page
Bottom (HCS02.1E-W0054, -W0070)
1 2 3 4
X9
X6
XS2
X3 X5
hcs0054_x3_x5_x6_x9.fh7
Fig. 7-20: HC02.1E-W0054, -W0070 power section connections (bottom)
Connection Page
X9, External braking resistor 7-33
X1, Module Bus

The module bus permits data exchange between the drive controllers.
Graphic Representation
X1 out X1 in
X1f2.FH7
Fig. 7-21: X1
Design Type Number of Type of design

poles
Flat line connector 8 Connector on device
Flat line bushing 8 Bushing on flat line
Fig. 7-22: Design
Note: Extending the module bus by more than the maximum allowed
number of devices is not allowed!
Maximum allowed number of devices: see section 8.4.
X3, Mains Connection

⇒ Always operate the drive controller with plugged on
DANGER connector!
Design HCS02.1E- Type Number of Type of design

poles
W0012 Terminal screw 4 Pins on device
Fig. 7-23: Design
Identification of the individual connections:

Identification Significance
L1 phase 1
L2 phase 2
L3 phase 3
ground wire
Fig. 7-24: Identification of the individual connections
Note: Only with single-phase operation: connect the connecting lines

of the mains voltage supply L1 and N with the connections L1
and L2.
Connection Cross Section HCS02.1E- Cross section Cross section Cross section
single-wire multi-wire in AWG
[mm²] [mm²]
W0012 0,2-4 0,2-4 24-10
W0028 0,2-4 0,2-4 24-10
W0054 0,5-10 0,5-10 20-8
W0070 0,5-10 0,5-10 20-8
Fig. 7-25: Connection cross section
Tightening Torque HCS02.1E- Tightening torque [Nm]

W0012 0,5 – 0,6
W0028 0,5 – 0,6
W0054 1,2 – 1,5
W0070 1,2 – 1,5
Fig. 7-26: Tightening torque
Damage to the drive controller

⇒ Strain relief for the motor power cable must be
provided within the control cabinet, or you can use
the optionally available connection accessory
CAUTION
HAS02.1.
Note: Observe the following for use within the scope of C-UL:
• Use 60/75°C copper wire only
• Use Class 1 wire only or equivalent
• Suitable for use on a circuit capable of delivering not more
than 8 kA (10 kA) rms symmetrical amperes for a
maximum voltage of 500 V (400 V)
X5, Motor Connection

DANGER connector!
Design HCS02.1E- Type Number of Type of design

poles

W0070 Terminal block 4 Pins on device
Fig. 7-27: Design

A1 phase 1
A2 phase 2
A3 phase 3
ground wire
Short Circuit Protection The outputs A1, A2, A3 are short-circuit proof at the device output against
each other and against ground.
Connection Cross Section HCS02.1N- Cross section Cross section Cross section
[mm²] [mm²]
W0012 0,2-4 0,2-4 24-10
W0028 0,2-4 0,2-4 24-10
W0054 0,5-10 0,5-10 20-8
W0070 0,5-10 0,5-10 20-8
Tightening Torque HCS02.1N- Tightening Torque [Nm]

W0012 0,5 – 0,6
W0028 0,5 – 0,6
W0054 1,2 – 1,5
W0070 1,2 – 1,5
Fig. 7-30: Tightening Torque
Damage to the drive controller

⇒ Strain relief cannot be provided for the motor power
cable at the drive controller. Strain relief for the
motor power cable must therefore be provided within
CAUTION
the control cabinet.
Connecting the Motor Power Rexroth motor power cables must be used for connections between the
Cable drive controller and motor.
The Rexroth motor power cable consists of
• three wires for the motor power connection
• one wire for the grounded wire connection
• a separately shielded pair of wires for monitoring the motor
temperature
• a separately shielded pair of wires for monitoring the motor holding
brake
• a total shield to be put on the shield retainer.
Note: For optimum shield contact of the motor power cable use our
special shielding plate HAS02.1, where possible (see
Appendix -> Accessories).
Shield Contact of the Motor If you do not use the shielding plate you have to provide good shield
Cable without Shielding Plate contact for the motor power cable by other means.
Variant 1:
This variant provides good shield contact and strain relief for the motor
cable at the same time. In this case the ground bus must be in immediate
vicinity of the motor connection (X5) of the drive controller. If you use a
ready-made motor cable, bear in mind the length of the litz wires at the
end of the cable.
6 5
2
4 3
motorkabel_schirmauflage_b.fh7
1: drive controller
2: clip for shield contact
3: overall shield of the motor power cable folded back
4: ground bus in the control cabinet
5: litz wires of the motor cable
6: cable for connecting ground bus and drive controller
Fig. 7-31: Shield contact without shielding plate (variant 1)
• By means of a clip (2) put the overall shield of the motor power
cable (3) on the ground bus (4).
(If you use your own cable make sure the shields of the two inner pairs
of wires are in contact with the overall shield.)
• Connect the ground bus to the ground connection of the drive
2
controller by means of a cable (6) (cross section at least 10 mm ).
Variant 2:
A 7
4 5
motorkabel_schirmauflage_a.fh7
1: drive controller
2: cable tie
3: overall shield of the motor power cable folded back
4: earth-circuit connector in the control cabinet
5: bare overall shield of the motor power cable
6: cable for connecting ground bus and supply unit
7: strain relief (as near to the drive-side cable end as possible)
A: A<1m
Fig. 7-32: Shield contact without shielding plate (variant 2)
• With a cable tie (2) press the drive-side cable end in such a way that
the shields of the two inner pairs of wires (motor temperature, holding
brake) have good contact with the overall shield (3) of the motor power
cable.
(If you use your own cable make sure the shields of the two inner pairs
of wires are in contact with the overall shield.)
• On the level of the earth-circuit connector (4) in the control cabinet
remove a piece of the cable sheath from the motor power cable in
order to lay bare the overall shield (5). The distance between drive
controller and bare overall shield must not be more than a maximum
of 1 m. The smaller the distance, the higher the noise immunity of the
drive system.
• Put the overall shield (5) on the earth-circuit connector (4) in the
control cabinet with an appropriate connection. The connection must
2
have a cross section of at least 10 mm .
• Connect the earth-circuit connector to the ground connection of the
drive controller by means of a cable (6) (cross section at least
2
10 mm ). Make sure there is sufficient strain relief (7) for the motor
power cable as near to the drive-side cable end as possible.
If you do not use a ready-made Rexroth motor power cable, the cable can
alternatively be composed of four stranded single wires (3 phases,
1 ground wire) with separately guided, shielded wires for temperature
monitoring and connecting the brake.
Note: Please refer to the relevant motor description for more detailed
information concerning technical data, connection and cross
sections.
Length of Motor Cable In order to comply with the EMC limit values, the length of the motor cable
is limited at a switching frequency > 4 kHz.
The lengths given in the following table are recommended as a guide (at
an ambient temperature of ≤ 40 °C in accordance with EN 60 204):
Allowed motor cable length without filter at the motor:
Drive controller Cable length [m]

switching frequency shielded unshielded
[kHz]
4 < 75 < 150
8 < 38 < 150
10 < 32 not allowed
12 < 25 not allowed
16 < 18 not allowed
Fig. 7-33: Cable length
Operation with unshielded motor cables of up to 150 m

• aims at applications with "operation without encoder"
• does not include the control voltage lines to the motor
• requires additional measures with regard to EMC on the part of the
operating company
Third-Party Motor Power Cables Requirements on third-party motor power cables:

• Maximum allowed capacitance per unit length at A1, A2, A3:
• against ground: 0.5 nF/m
• against each other: 0.5 nF/m
Maximum allowed inductance per unit length at A1, A2, A3:
• 100 nH/m
Note: No warranty!
If cables manufactured by a company other than Rexroth are
used, the Rexroth warranty for the entire drive system
becomes invalid.
Use ready-made Rexroth cables.
X6, Motor Temperature Monitoring and Motor Holding Brake

DANGER connector, because high voltages can occur at the
connector at the end of the cable (coming from
motor)!
Design Type Number of poles Type of design

Spring power 4 Pins on device
Fig. 7-34: Design

1 MotTemp+
Monitoring the motor temperature
2 MotTemp-
3 +24 V
Motor holding brake
4 0V
Connection Cross Section HCS02.1N-W0012, -W0028, -W0054, -W0070:

Cross section Cross section Cross section
[mm²] [mm²]
0.14-1.5 0.14-1.5 28-16
Note: Make sure the voltage supply for the motor holding brake is
sufficient. In this respect observe the lengths and cross
sections of the cables used.
MotTemp+
MotTemp-
+24VBr
0VBr
1
4
X6
A1 A2 A3
shield for
motor cable
G
H
C
E
A
F
U AC motor
M
3
holding
brake
PTC /
NTC /
KTY84
(depends on motor type)
x6_kabel_anschluss.FH7
Fig. 7-37: Motor cable, temperature monitor and holding brake connection
Maximum permitted braking current:

• HCS02.1N-W0012: 2,0 Aeff
• HCS02.1N-W0028: 2,0 Aeff
CAUTION
• HCS02.1N-W0054: 2,0 Aeff
• HCS02.1N-W0070: 2,0 Aeff
Where braking currents are higher, the motor holding
brake must be activated by means of an external
switching mechanism.
The switching elements used in the drive controller are
subject to wear. Guaranteed number of switching
actions at max. time constant of load < 50 ms
(LBrake/(24V/IBrake)): 250.000
Dangerous movements! Danger to personnel

from falling or slipping axes!
⇒ The standard motor holding brake provided or an
DANGER external motor holding brake controlled directly by
the drive controller are not sufficient on their own to
guarantee the safety of personnel!
⇒ Personnel safety must be achieved using higher-
ranking, fail-safe procedures:
Dangerous areas should be blocked off with
protective fences or grids.
Secure vertical axes against falling or slipping after
switching off the motor power by, for example:
- mechanically locking the vertical axis
- providing external brake/catching/clamping
mechanisms
- adequately counterbalancing the axis
Power consumption levels for the holding rate can be found in the project
planning documents for AC motors.
The holding brake for AC motors is not designed as a service brake. After
approximately 20,000 motor revolutions against the closed brake disc it is
worn out.
Controlling the Motor Holding The drive controller assumes the control of the motor holding brake.
Brake
X9, Connection of Braking Resistor
Lethal electric shock caused by live parts with

more than 50 V!
⇒ Exclusively operate the drive controller with plugged
DANGER on connector!
Design HCS02.1E- Type Number of poles Type of design

Fig. 7-38: Design

1 phase 1
2 phase 2
Connection Cross Section HCS02.1E- Cross section Cross section Cross section
[mm²] [mm²]
W0054 0,5-10 0,5-10 20-8
W0070 0,5-10 0,5-10 20-8
Fig. 7-40: Connection cross sections
Tightening Torque HCS02.1E- Tightening torque [Nm]

W0054 1,2 – 1,5
W0070 1,2 – 1,5
Fig. 7-41: Tightening torque

⇒ You have to provide strain relief for the connection
cable in the control cabinet or use the optionally
available connection accessory (shielding plate;
CAUTION
HAS02.1).
Load Capacity
Maximum allowed current load Imax = 30 A
Ieff = 15 A
short circuit protection via fusing of devices
Fig. 7-42: Load capacity
X13, Control Voltage (+24 V, 0 V)

With regard to control voltage supply, the HCS02.1 drive controllers are
available in two different designs.
• Standard design HCS02.1E-W****-***N:
The control voltage is supplied by an external 24V power supply unit.
• Optional design HCS02.1E-W****-***V:
The control voltage is supplied by an integrated 24V power supply unit.
A power supply unit that makes available the control voltage supply for the
power section and the control section from the DC bus is integrated in the
drive controller.
Note: • Technical data: see page 7-14

• Falling short of the permissible control voltage leads to a
corresponding error message (=> refer also to firmware
function description).
• Interruption to the control voltage when the motor is
running leads to torque-free (brakeless) runout in the motor.
• If a power supply unit is used with a DC bus dynamic
braking function, an interruption to the control voltage supply
causes braking to the axes through the DC bus dynamic
braking.
Note on design -***V: see also page 7-15;

• The brake supply has to be realized via an external power supply unit.
• Applying the external supply voltage for the purpose of buffering at no-
power operation is allowed.
• Load at the terminal X13 is not allowed.
Dangerous movement caused by brakeless

motor coasting to stop in the event of an
interruption to the control voltage supply!
DANGER ⇒ Do not stay within the motional range of the machine.
Possible measures to prevent personnel accidentally
accessing the machine:
– protective fencing
– protective grid
– protective cover
– light barrier.
⇒ Fencing and covers must be adequately secured
against the maximum possible force of movement.
Design Type Number of poles Type of design

Spring power 4 Pins on connector
Fig. 7-43: Design

4 +24 V
3 +24 V
2 0V
1 0V
Connection Cross Section Cross section Cross section Cross section

[mm²] [mm²]
0.14-1.5 0.14-1.5 28-16
Fig. 7-45: Connection Cross Section
Load Capacity looping through the power supply up to max. 6 Aeff allowed
polarity reversal protection over the allowed voltage range by
internal protective diode of +24V
circuit
Fig. 7-46: Load capacity
Note: The input 0 V connected in conductive form with the housing

potential. It is therefore impossible to use an insulation monitor
at +24 V and 0 V against housing.
Lines +24 V and 0 V line cross section min. 1 mm²

line routing preferably in parallel
max. allowed inductance between 24V 100 µH
supply source and X13
(corresponds to approx. 2*75 m)
Fig. 7-47: Supply line 24 V
The control voltage can be looped through from drive controller to drive
controller:
X13 X13 X13
steuerspg_durchschleif.fh7
Fig. 7-48: Looping through the control voltage
Note: When looping through the control voltage, observe the load
capacity of the connection (see above).
The control voltage supply is routed to the connection X13 from above
(see following figure).
1: lines to control voltage supply

Fig. 7-49: Control voltage supply at X13
DC Bus (L+, L-)

The DC bus connection connects
• several drive controllers to one another, and
• drive controllers to additional components in order to
• increase the stored power by means of DC bus capacitor unit
• increase the permissible braking resistor continuous output by
means of DC bus resistor unit
Design The DC bus is connected by contact rails and screws (M6) to the front of
the drive controller. There are various lengths of contact rail depending on
the width of the drive controllers.
Tightening Torque 6 Nm
DC Bus Wiring If in special cases it is not possible to use the DC bus rails provided to
make the connection, the connection must be made using the shortest
possible twisted cables.
Length of the twisted cables max. 2 m

Wire cross-section min. 10 mm²,
however, no less than the cross-
section of the power input line
Wire protection by means of fuses in the mains
supply
Voltage stability of a single strand against > 750 V
ground (e.g., strand type - H07)
Risk of voltage arcing!

⇒ If drive controllers are stacked in the control cabinet,
the connections for the DC buses between the drive
controllers have to be correctly made. There is
CAUTION
otherwise a risk of voltage arcing (see page 13-19
onward).
Ground Connection
The ground connection (grounding) must be provided in duplicate
through:
• connection via X3
- and -
• the rear panel of the devices. To ensure ground connection the
mounting surfaces in the control cabinet must be bare and connected
to ground
XS1, Shield Connection (Control Wires)
XS1
hcs_xs1.fh7
Fig. 7-50: Shield connection XS1
Connection for shields of wires connected to the control section.
Note: Always connect shield of cables with a large metal-to-metal

contact surface to the shield connection.
Risk of damage caused by too high outlet

temperatures!
⇒ Observe outlet temperatures at the top of the drive
CAUTION controllers.
XS2, Shield Connection (Motor Cable)
XS2 XS2
hcs0028_XS2.fh7 hcs0054_XS2.fh7
Fig. 7-51: XS2
XS2 is used for mounting the accessory HAS02.1 for shield connection of
the motor cable (see page 13-6).
7.6 Touch Guard

more than 50 V!
⇒ The appropriate touch guard must be mounted for
WARNING each drive controller following connection work.
⇒ Never mount a damaged touch guard.
⇒ Immediately replace a damaged touch guard by an
undamaged touch guard.
Cutouts
A B
hcs_beruehrschutz_seite.fh7
Fig. 7-52: Cutouts at the touch guard

more than 50 V!
⇒ You have to provide the best possible protection
WARNING against contact. Therefore keep the cutouts at the
touch guard as small as possible.
⇒ Only break off the cutouts if necessary.
• If the DC bus and the control voltage are connected by means of

contact rails, only the cutout B (see picture) may be broken off the
touch guard.
• If the DC bus and the control voltage are connected by means of
cables (e.g. in the case of multiple-line arrangement of the drive
controllers), the cutouts A, and B (see picture) may be broken off the
touch guard.
• At the first and last drive controller in a line of drive controllers
connected to each other there mustn’t any cutout be broken off at the
outer side of the touch guard.
Mounting
hcs_beruehrschutz.fh7
Fig. 7-53: Touch guard
The touch guard must always be mounted following connection work.
Note: Risk of damage to the touch guard!

The maximum tightening torque for the fixing screw for the
touch guard is 2.8 Nm.
Tightening Torque 2,8 Nm
Rexroth IndraDrive C Mains Connections 8-1
8 Mains Connections
8.1 General
Note: An IndraDrive C drive controller must be permanently

connected to the supply mains.
Connection See chapter "X3, Mains Connection" on page 7-24.
Line Filter
Note: Mains filters are available to comply with EMC limits. For a
selection of information see Project Planning Manual
"Electromagnetic Compatibility (EMC) in Drive and Control
Systems", document typecode
DOK-GENERL-EMV********-PRxx.
8.2 The Ground Conditions of the Supply Mains

Grounded Three-Phase Current Drive controllers can be operated on three-phase current mains with
Mains grounded star point or external conductors without potential isolation.
Ungrounded Three-Phase Mains Ungrounded mains (IT mains) present the increased danger of
unallowable phase to ground overvoltages occurring. Drive controllers can
be protected against overvoltages
• By connecting them via an isolating transformer (the star point of the

output side and the PE connection of the power supply unit are linked
on a shared ground rail)
- or -
• If the facility is protected via an overvoltage suppressor.
Connecting drive controllers via an isolating transformer offers the best

protection against overvoltage as well as the greatest operating safety.
Overvoltage The periodic and transient overvoltages between phases and ground at
the drive controllers may not exceed the values indicated in
"Electrical Data".
Note: If higher overvoltages occur, then they must be limited with the
use of overvoltage suppressors in the cabinet or building.
Note: Mains voltages exceeding the specified range require the use
of a step-down transformer.
8-2 Mains Connections Rexroth IndraDrive C
8.3 Mains Supply Options
Single Source Supply

"Single source supply" is the standard mains supply if only one HCS02.1
drive controller or a HCS02.1 drive controller with additional components
is to be supplied with mains voltage.
Characteristic for the single source supply is that the mains voltage is
applied to the HCS02.1 drive controller via individual mains
connections.
Arranging the Single Source Supply
Note: DC bus connection of drive controllers that are connected to

the mains via separate contactors is not allowed!
1 2 n
K1
3 3
K2
3 3
Kn
3 3
einzeleinspeisung.fh7
Fig. 8-1: Single source supply
Note: In addition to the mains connections the following connections

must be wired as well:
• Bb contact of control section (see Project Planning Manual
for Control Section)
• control voltage supply
• ground wires
Note: The device-specific power data are available at each drive

controller, particularly the allowed DC bus continuous power
and the continuous regenerative power.
Group Supply
"Group supply" is the standard supply if several HCS02.1 drive controllers
are to supplied from one supply voltage.
Characteristic for the "group supply" is that the mains voltage is applied to
groups of HCS02.1 drive controllers via a common mains contactor.
The group supply is divided into:
• "group supply with DC bus connection" and
• "group supply without DC bus connection"
Both supply options have their advantages for various demands.
Arranging the Group Supply without DC Bus Connection
3 3
K1
3 3 3 3
gruppeneinspeisung.fh7
Fig. 8-2: Group supply without DC bus connection
Note: In addition to the mains connections the following connections

must be wired as well:
of the Control Section)
• ground wires
Note: The device-specific power data are available at each drive

controller, particularly the allowed DC bus continuous power
and the continuous regenerative power.
Arranging the Group Supply with DC Bus Connection
Note: Increase the available regenerative power and continuous

braking resistor power in the common DC bus for the devices
HCS02.1E.
K1 3 3
3 3
gruppeneinspeisung_m_zk.fh7
Fig. 8-3: Group supply with DC bus connection
Note: In addition to the illustrated connections of the drive controller

at the DC bus, the following connections must be wired as
well:
• module bus
• ground wires
Note: The connection lines to the drive controllers should preferably

have the same impedances in order to achieve balanced load
distribution at the power input of the drive controllers. From the
common node of the lines, you therefore have to make sure
that
• the lengths of the supply lines and
• the cross sections of the supply lines
are the same.
Note: At the common DC bus there is less than the sum of the
device-specific power data available. This particularly applies
to the continuous DC bus power PDC cont and the continuous
regenerative power PBD. Both power data are included in the
sum in reduced form. The reduction takes place with the
corresponding balancing factors for parallel operation (see
Electrical Data).
Central Supply
A "central supply" is one where several drive controllers are provided with
power via a common DC bus from only one drive controller.
Characteristic for the "central supply" is the central power supply through
the drive controller that is connected via a single mains contactor to the
mains voltage.
Note on Central Supply The "central supply" option is connected at the single phase/three phase
input with the drive controller that has the highest current type.
Arranging the Central Supply
K1
3 3
zentraleinspeisung.fh7
Fig. 8-4: Central supply
Note: In addition to the illustrated connections of the drive controller

at the DC bus, the following connections must be wired as
well:
• module bus
• ground wires (connection to the protective system)
Note: At the common DC bus the continuous DC bus power PDC cont
of the HCS02.1 drive controller connected to the mains supply
is available. The available continuous regenerative power PBD
is less than the sum of the device-specific continuous
regenerative power. The reduction takes place with the
corresponding balancing factors for parallel operation (see
Electrical Data).
Energy Circuit HCS02.1E-W0070 Using "Central Supply" as an Example

HCS02.1E-W0070 HCS02.1E-W0070
L+
3 3 3
M M
CZW CZW
L-
SN1 1/F PDC 1/K Pm
SN1 PDC
Pmn
PVn
Pm1
PV1
leistungsfluss.fh7
SN1: input power

PDC: DC bus power
PV1: power dissipation
Pm: power at output shaft of motor
Fig. 8-5: Energy circuit HCS02.1 using "Central supply" as an example
8.4 Number of Drive Controllers and Auxiliary Components

on one DC bus
Number of IndraDrive C Components

In the IndraDrive product range, drive controllers of the C type can be
operated at the common DC bus in combination with additional
components.
Note: The total number of units with braking resistor set up on one
DC bus should not exceed max. 12. Up to this number
combinations as shown below are possible.
Common means that the DC bus connections of the
concerned devices are connected.
Maximum number components on one DC bus (including central supplying unit)
HCS02.1 HAB02.1 HAB02.1
W0070 W0054 W0028
Central supply via W0070 1 1 5 1 tbd*

Central supply via W0070
1 2 8 1 tbd
with mains choke
Central supply via W0054 not allowed 1 4 1 tbd
Central supply via W0054
not allowed 1 6 1 tbd
with mains choke
Central supply via W0028 not allowed not allowed not allowed 1 tbd
Group supply with
4 6 8 1 tbd
DC bus connection
Fig. 8-6: Maximum number of components on one DC bus
Example Central supply via HCS02.1E-W0070 with mains choke:

• 8 * HCS02.1E-W0028
• 2 * HCS02.1E-W0054
• 1 * HCS02.1E-W0070
• 1 * HLB01.1C
Sum of components with braking resistor: 12

Sum of all components: 12
Note: Drive controllers with higher rated current can be replaced by

drive controllers with lower rated current.
Note: Only carry out group supply with DC bus connection with
HCS02.1 drive controllers of the same type.

⇒ Do not exceed allowed peak and continuous powers
in the DC bus.
CAUTION
Number of IndraDrive M Components

In the IndraDrive product range, drive controllers of the C type can be
operated at the common DC bus in combination with drive controllers of
the M type.
The table below shows the maximum allowed number of IndraDrive M

components at the common DC bus in the case of central supply via
HCS02.1 devices.
Maximum allowed number of IndraDrive M components at common DC bus in the

case of central supply via HCS02.1 devices
HMS01.1N HMD01.1N
W0036 W0020 W0012 W0036 W0020 W0012
central supply via W0070

1 1 1 not allowed 1 1
without mains choke
central supply via W0070 with
1 1 2 1 1 2
mains choke
central supply via W0054 1 1 1 not allowed 1 1
central supply via W0054 with
1 1 2 not allowed 1 2
mains choke
central supply via W0028 not allowed not allowed not allowed not allowed not allowed not allowed
group supply with DC bus
not allowed not allowed not allowed not allowed not allowed not allowed
connection
Fig. 8-7: Maximum number of IndraDrive M components at common DC bus
Note: Operating HMS and HMD drive controllers at the common DC

bus with HCS02 drive controllers requires additional capacities
at the DC bus. Additional capacity modules and additional
capacities are available for this purpose on request.
When arranging devices in combination, pay particular
attention to the selection of the mains filter components.
Note: HMS01.1 and HMD01.1 drive controllers with higher type

current can be replaced by drive controllers with lower type
current.
The listed IndraDrive M devices may be added to already

existing HCS02.1 drive controllers up to the maximum allowed
number according to the following rules.
• HMS01.1N-W0036 replaces HCS02.1E-W0054 or higher
• HMD01.1N-W0036 replaces 2*HCS02.1E-W0054 or higher
Drive controllers in the table "Maximum number of
IndraDrive C components at common DC bus"

⇒ Do not exceed allowed peak and continuous powers
in the DC bus.
CAUTION
Allowed DC Bus Continuous Power without Mains Choke for Three-

Phase Mains Connection
HCS02.1E-W0012
3,0
2,5
2,0
PDC cont [kW]
1,5
1,0
0,5
0,0
200 250 300 350 400 450 500
ULN [V]
Fig. 8-8: HCS02.1E-W0012
HCS02.1E-W0028
7,0
6,0
5,0
PDC cont [kW]
4,0
3,0
2,0
1,0
0,0
200 250 300 350 400 450 500
ULN [V]
Fig. 8-9: HCS02.1E-W0028
HCS02.1E-W0054
7,0
6,0
5,0
PDC cont [kW]
4,0
3,0
2,0
1,0
0,0
200 250 300 350 400 450 500
U LN [V]
Fig. 8-10: HCS02.1E-W0054
HCS02.1E-W0070
12,0
10,0
8,0
PDC cont [kW]
6,0
4,0
2,0
0,0
200 250 300 350 400 450 500
ULN [V]
Fig. 8-11: HCS02.1E-W0070
Allowed DC Bus Continuous Power with Single-Phase Mains

Connection
For operation with single-phase mains supply, DC bus continuous powers
according to the diagrams below are allowed.
Note: Single-phase mains connection via the connections L1 and L2

is only allowed for single-source supply!
Apart from the specified continuous power, there is no peak
power available in the DC bus in the case of single-phase
operation.
Allowed DC Bus Continuous Power with Single-Phase

Operation on Supply Mains with a Mains frequency of
50...60 Hz
HCS02.1E-W0012
0,4
0,3
0,3
PDC cont [kW]
0,2
0,2
0,1
0,1
0,0
200 250 300 350 400 450 500
U LN [V]
Fig. 8-12: Allowed DC bus continuous power
HCS02.1E-W0028
0,7
0,6
0,5
PDC cont [kW]
0,4
0,3
0,2
0,1
0,0
200 250 300 350 400 450 500
ULN [V]
HCS02.1E-W0054
1,2
1,0
0,8
PDC cont [kW]
0,6
0,4
0,2
0,0
200 250 300 350 400 450 500
ULN [V]
HCS02.1E-W0070
1,8
1,6
1,4
1,2
PDC cont [kW]
1,0
0,8
0,6
0,4
0,2
0,0
200 250 300 350 400 450 500
ULN [V]
8.5 Fusing via Earth-Leakage Circuit Breakers

It possible to use an earth-leakage circuit-breaker for IndraDrive C
controllers (EN 50178/1994, section: 5.3.2.3).
Due to existing capacitances against ground, the hardware components
of the drive system are generating leakage currents that are evaluated as
earth-leakage current by earth-leakage circuit breakers connected in
series. The intensity of these leakage currents is decisively determined by
the following variables:
• mains filter used
• switching frequency of the drive controllers
• existing capacitance by motors and lengths of the motor cables
• asymmetrical mains voltages at the installation location
Operating HCS02 drive controllers at earth-leakage circuit breakers is

allowed under the following conditions:
• earth-leakage circuit breakers of type B (IEC60755)
• cutoff limit of the earth-leakage circuit breaker is ≥ 300 mA
• supplying TN-S mains
• length of motor cable 20 m max. in shielded design
• use of a mains filter
• each earth-leakage circuit breaker only supplies one HCS02 drive
controller
• only Rexroth components and accessories including cables and filters
are used.
Note: For details please see Project Planning Manual

"Electromagnetic Compatibility (EMC) in Drive and Control
Systems", document typecode
DOK-GENERL-EMV********-PRxx-xx-P.
8.6 Control Circuits for the Mains Connection

The control circuits recommended by Rexroth specify the functional
principle.
Note: The choice of control and its effects depends on the extent of
the functions and the operating sequence of facility or
machine. It is therefore the responsibility of the manufacturer
of the installation and machine.
Signal Contact Bb Ready for The mains contactor has to be controlled subject to the error status of the
Operation drive controller. At the control section there is an isolated contact
available for this purpose (relay contact Rel1) that has been configured as
Bb contact in the condition as supplied (see Project Planning Manual for
Control Section). If the Bb contact closes, then the drive is ready to
receive power. The contact is thus a precondition for connecting the
mains contactor.
Risk of damage!
⇒ The effectiveness of the separation of, the mains
connection via signal contact "Ready to operate Bb" or
the multi-circuits of all Bb contacts must be ensured!
CAUTION
Switching States See Project Planning Manual for Control Section

⇒ See also Functional Description of Firmware: "Power Supply".
Note: When the mains contactor is shut off the mains coil causes
overvoltages. These can cause the Bb contact to drop
prematurely. To attenuate overvoltage use overvoltage limiters
with diode combinations.
DC 24V
Bb
K1
Bb_relais_schutz.FH7
Fig. 8-16: Recommended protective circuits
The use of varistors and RC modules as protective circuits is not allowed.

Varistors age and increase their locking currents. RC modules make
excessive demands of the switching capabilities of the Bb contact. This
leads to early failures of connected components and units.
Note: Load limits of the Bb contacts must be maintained. Contactors

with AC excitation or those that exceed the load limits of the
effected contact elements (Bb contacts, etc.) can be controlled
with the use of auxiliary contactors.
Risk of damage!
⇒ Before switching the drive controller on again, wait at
least for 300 ms plus the switch-off delay of the
mains contactor.
CAUTION
Note: In the case of devices with integrated 24V power supply

(-NNNV), the drive controller has to be supplied with external
control voltage before the mains voltage is switched on.
ext. control voltage
Emergency stop
Safety limit switch
Power off
Control error
message
Bb 2)
1)
Power on K1
Power protection K1
steuersch_netzanschluss.FH7
1): integrating the Bb contacts of other devices (see also Functional

Description of firmware for "Power Supply" and Parameter
Description of firmware for P-0-0300 and P-0-0861)
2): take switching capacity of Bb contact into account
Fig. 8-17: Control circuit
Special case for drive controllers with integrated 24V power supply,
HCS02.1E-...-NNNV drive controllers:
ext. control voltage
Emergency stop
Safety limit switch
Power off
Control error
message
Bb 2)
Power on
1)
Power protection K1
steuersch_netzanschluss_NNNV.fh7
1): integrating the Bb contacts of other devices (see also Functional

Description of firmware for "Power Supply" and Parameter
Description of firmware for P-0-0300 and P-0-0861)
2): take switching capacity of Bb contact into account
Fig. 8-18: Control circuit for HCS02.1E-...-NNNV drive controllers
Note: Take the standby time of the drive controller into account (see
Project Planning Manual for Control Section).
During the standby time the power cannot be cut off from the
drive controller via the Bb contact.
While the "Power on" button is being pressed, the message
will disappear at the control panel (display).
8.7 Mains Contactor / Fuses

To select suitable mains contactor and fuses for the power connection, a
selection table is available. Note the inrush current of the selected
contactor.
Calculating Phase Current on the Mains

To select a suitable mains contactor and fuses for the power connections
it is necessary to first calculate the phase current IN at the mains.
The mains-side phase current IN is determined out of the mains
connecting power SLN .
Select the mains connecting power in the list or calculate it according to
the following formula. With multiple controllers, add the individual powers.
MEFF ⋅ nMITTEL ⋅ 2 ⋅
PDC = ⋅k
60
PDC: required DC bus continuous power in W
MEFF: rms torque in Nm
nMITTEL: mean speed in min-1
k: factor for motor and controller efficiency = 1.25 (MKD, MHD)
Fig. 8-19: Calculating DC bus power
PDC
S LN =
cos ϕ
SLN: connected load in VA
PDC: DC bus continuous power in W
Fig. 8-20: Calculating mains connected load
SN1
Single-phase load: IN1 =
UN1
SN1
Three-phase load: IN1 =
UN1 ⋅ 3
IN1: mains-side phase current in A
SN1: connected load in VA
UN1: voltage between phases of the mains in V
Fig. 8-21: Calculating mains-side phase current
Calculating Charging Current Inrush

UN1 * 2
IEIN =
R Softstart
∑I Ein = IEinGesamt
IEin: charging current inrush of unit in A
IEinGesamt: total charging current inrush in A (value relevant for fusing)
UN1: mains input voltage
RSoftstart: softstart resistance of unit (see relevant technical data)
Fig. 8-22: Calculating charging current inrush
Note: To calculate the charging current inrush take all the units
connected to the mains voltage into account.
Q1 Fuse and K1 Contactor

When selecting a mains contactor and fuses, the continuous current in
the supply leads as well as the starting inrush current must be taken into
account. Several controllers can be operated on a single fuse and mains
contactor. The phase currents and inrush currents of the individual drives
must then simply be added up. If a transformer is used, then the fuses
and contactors must be installed on the primary side.
The Siemens type fuses and contactors in the selection table below are
only examples. Products of equal rating from other manufacturers can be
used.
Phase Lead cross Fuses Power fuses Fusible Mains Inrush Dropout delay Pull-up delay
current sections (triggering links contactor current tAbmax tAnmax
charact. C) (operating
class gl)
(1) (2) (3) (2) (3)
2
[A] [mm ] Current Siemens type Current Siemens [A] [ms] [ms]
[A] [A] type
9 1,0 10 3VU1300- .ML00 10 3TF40 54

or or
3RV1011-1JA10 3RT1016 80 120
12 1,5 16 3VU1300- .MM00 16 3TF41 72
or or
3RV1021-4AA10 3RT1017 80 120
16 2,5 20 3VU1300- .MM00 20 3TF42 96
or or
3RV1021-4AA10 3RT1025 110 190
22 4,0 25 3VU1300- .MP00 25 3TF43 132
or or
3RV1021-4DA10 3RT1026 110 190
32 6,0 32 3VU1600- .MP00 35 3TF44 186
or or
3RV1031-4EA10 3RT1034 200 120
1. Lead cross sections per EN 60204 – Installation B1 – correction factors not taken into account.
2. With recommended fuses short-term operating loads can be used by the drive for two minutes. If this is needed for
extended periods, then use a bigger fuse.
3. Allocation "2" per DIN IEC 60947-4: easily separable contact welding at contactors are permitted as a result of
short circuits.
Fig. 8-23: Selecting table for Q1 fuses and K1 contactors
Note: Observe the maximum allowed fusing according to C-UL (see

"Electrical Data" → "Power Section – Mains Supply").
Note: In order to prevent the mains contactor from being overloaded

by the load current in the case of frequent cut-off, it is first
necessary to switch off the drive via the drive enable in the
master communication and then to switch off the mains
contactor.
Mains Connection Power and DC Bus Continuous Power

The diagrams below illustrate the interrelation between mains connection
power (SLN) and DC bus continuous power (PDCcont) with and without the
use of mains chokes.
HCS02.1-E-W0012 @3AC400V
4,5
4
3,5
3
SLN [kVA]
2,5
2
1,5
1
0,5
0
0 0,5 1 1,5 2 2,5
PDC cont [kW]
Fig. 8-24: HCS02.1E-W0012
HCS02.1-E-W0028 @3AC400V
9
S LN 5
[kVA]
4
2
without choke
1
with choke
0
0 1 2 3 4 5
P DC cont [kW]
Fig. 8-25: HCS02.1E-W0028
HCS02.1-E-W0054 @3AC400V
16
14
12
10
S LN
8
[kVA]
6
4
without choke
2 with choke
0
0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,
PDC cont [kW]
Fig. 8-26: HCS02.1E-W0054
HCS02.1-E-W0070 @3AC400V
20
18
16
14
12
10
S LN 8
[kVA] 6 without choke
4 with choke
2
0
0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10, 11, 12, 13, 14,
PDC cont [kW]
Fig. 8-27: HCS02.1E-W0070
Notes
Rexroth IndraDrive C Additional Components 9-1
9 Additional Components
9.1 Mains Choke
Identification
Type Code
Abbrev. 1 2 3 4
Column 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
Example: H N L 0 1 . 1 E - 0 9 8 0 - N 0 0 2 6 - A - 4 8 0 - N N N N
1. Product
1.1 HNL . . . . . . . = HNL
2. Line
2.1 1. . . . . . . . . . . . . . . . . = 01
3. Design
3.1 1......................=1
4. Supply system
4.1 only for feeding units . . . . . . . . = E
4.2 only for regenerative units . . . . = R
5. Nominal inductance
5.1 e.g., 980 µH . . . . . . . . . . . . . . . . . . = 0980
6. Additionl option
6.1 with capacitors . . . . . . . . . . . . . . . . . . . . . . . . . = C
6.2 current-compensated . . . . . . . . . . . . . . . . . . . . = S
6.3 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = N
7. Nominal current
7.1 e.g., 26 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 0026
8. Degree of protection
8.1 IP20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = A
9. Mains connecting voltage

9.1 3 AC 400 to 480V -15+10%, 50/60 Hz. . . . . . . . . . . . . . . . . . . . . .= 480
9.2 3 AC 400 to 500V -15+10%, 50/60 Hz. . . . . . . . . . . . . . . . . . . . . .= 500
10. Other design

10.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN
11. Standard reference

Standard Title Edition
DIN EN 60529 Degrees of protection provided by enclosures (IP-Code) 2000-09
Fig. 9-1: Type code
9-2 Additional Components Rexroth IndraDrive C
Type Plate
1 2
3
4 MNR: 5
10 6 FD: 7 8
9 UN: IN: 11 15
12 LN: TA: C: Made in 15

16
13 14 17
SN: 18 19
Feld Text Benennung Einheit Beispiel
1 Word mark
2 Business Facility Number 7260
3 CE label
4 Type designation (two lines, 20 charact. each) HNL01.1E-0400-N0051-A-500-NNNN
5 MNR: Material number MNR: R911306580
6 Change release 0A01
7 FD: Manufacturing date (YYWww) FD: 04W11
8 Certification label
9 UN: Nominal voltage / Frequency V / Hz UN: AC 500 V 50...60 Hz
10 BV: Number of design specification BV: 12345 12345678
11 IN: Nominal current A IN: 032 A
12 LN: Nominal inductance µH LN: 0400 µH
13 TA: Temperature °C TA: 40°C
14 C: Numbers and data of additional capacitors µF C: 3x20 µF
15 Made in Designation of origin Made in Germany
16 Approval number 12345678901234
17 Barcode (code 39 or 93)
18 SN: Serial number SN: 123456-D1234
19 Company address Rexroth Indramat GmbH

D-97816 Lohr am Main
Fig. 9-2: Type plate
Rexroth IndraDrive C Additional Components 9-3
Technical Data
circuit diagram:
U1 U2
V1 V2
C
W1 W2
PE
a b
F
E long hole in
D B "B" direction
A
netzdrossel_hcs.fh7
Mains choke Dimensions [mm] Weight [kg]

A B C D E F
HNL01.1E-1000-N0012-A-NNNN 120 72 157 81,5 55 4,8 x 9 2,7
HNL01.1E-1000-N0020-A-NNNN 150 66 182 113 50 5,8 x 11 3,8
HNL01.1E-600-N0032-A-NNNN 150 66 182 113 50 5,8 x 11 4,5
Fig. 9-3: Mechanical Data
Mains choke UN [V] IN [A] PV [W] LN [µH] Imax [A] Lmin bei Imax Cross section
[mm²]
HNL01.1E-1000-N0012-A-NNNN 500 12 45 3 x 1000 25 50% of LN 4
(a, b: 4)
(a, b: 4)
Fig. 9-4: Electrical Data
Switching Capacity 1A/250V AC; 24V DC
Switching Temperature 125 °C
9-4 Additional Components Rexroth IndraDrive C
Notes
Rexroth IndraDrive C Replacing Devices 10-1
10 Replacing Devices

The diagnostic display enables an aimed and effective problem search in
order to:
• avoid production downtimes due to extensive searches in individual
devices and repairs of devices on the machine
• assume operations without extensive assembly and adjustments
• quickly eliminate the problem and replace the defective component
When returning a defective device to our Customer Service, please

complete the Fault Report in its entirety. The Fault Report is included in
this section (see below) and may be copied for your convenience.
Note: The new drive components must have the same type
designations as the faulty devices. To ensure this, indicate the
entire type designation when requesting replacement parts.
10.2 How to Proceed When Replacing Devices

Note: Note the safety instructions in chapter 3 when replacing
devices!
Replacing the Drive Controller

• Save parameter set.
• Switch main switch off.
• Make sure main switch cannot be switched on again.
• Make sure drive controller is completely de-energized.
Lethal electric shock caused by charged

capacitor!
⇒ Prior to touching uninsulated connecting cables and
DANGER terminals, wait for the capacitor to discharge! Only
then work on the cables!
• Remove touch guard and separate connecting line from drive

controller.
• Release screws on top and bottom of housing.
• Hand new drive controller into place and tighten screws.
• Connect drive controller as specified in the machine terminal
diagrams.
• Mount touch guard.
• Copy firmware and parameter file to drive controller (see firmware
documentation).
10-2 Replacing Devices Rexroth IndraDrive C
Replacing the Motor

• Disconnect plug-in connectors.
Note: When replacing the motor, cap open connector ends

particularly if there might be the chance that they get in contact
with coolant/lubricant or dirt (allowed level of contamination is
2 according to EN50178).
• Replace motor.
Note: To mechanically replace the AC servo motor, note the

instructions of the machine manufacturer.
• Connect plug-in connectors.
Danger caused by unwanted axis motion!

⇒ Servo axes with indirect path measuring system via
the motor encoder will loose the reference dimension
when the motor is replaced!
ATTENTION
This reference to the machine coordinate system
must therefore be reestablished after replacement.
• Servo axes with absolute motor encoder: reestablish the reference

dimension.
Replacing Cables

more than 50 V!
⇒ Power connectors of the cables may only be
ATTENTION separated or connected if the installation has been
de-energized!
Note: When replacing cables, note the instructions of the machine

manufacturer.
If you do not use standard cables from Rexroth, then check to
ensure that the cables agree with the terminal diagram of the
machine manufacturer!

• Disconnect plug-in connectors.
Note: When replacing cables, cap open connector ends particularly

if there might be the chance that they get in contact with
coolant/lubricant or dirt (allowed level of contamination is 2
according to EN50178).
• Replace cables.
Material damage caused by bad power

connectors!
⇒ Connect power connectors only when they are dry
ATTENTION and clean.
• Connect plug-in connectors.
10.3 Fault Report
Fault Report Date:

for Drive Systems Report No.:
This fault report is intended to help eliminate problems that might possibly be related to drive systems.
Please fill it out carefully and send it, together with the parameter file with which the fault occurred, to
Bosch Rexroth.
Contact person: Telephone:
Customer (machine manufacturer): Fax:
End customer: E-mail: @
Branch of industry:
System description:
Firmware Drive system
Firmware version: Power section:
FWA- - - V -MS Type code: - - - -
Software: Serial number: SN
DriveTop version: SWA-DTOP**-INB- V -MS Hardware index:
Operating system:
Service pack: Control section:
Language:
Type code: - - - - - - -
PC designation:
Serial number: SN
Hardware configuration (system RAM, hard
disk memory,...): Hardware index:
Supply module:
Type code: - - - -
Serial number:
Motor Additional components (e.g. control system involved,

Type designation: external encoder, filter, cooling system in control
cabinet,...):
Serial number: S.No.
Motor encoder:
Mounting position:
Fault description (detailed description of situation before, during and after fault occurred):
To quickly resolve your problem we ask you to send us also the parameter set with which the fault occurred.
Name of parameter set file:
General conditions:
Mode at time fault occurred: Parameterization mode
Operating mode Switch phase
Operating mode active at time fault occurred: ,
Encoder ,
7-segment display... ...before fault occurred:
...after fault occurred:
Fault status Causes Other defects
occurs permanently unknown problems in the mechanical system
occurs during commissioning incorrect connection power section failure
occurs sporadically external cause control system failure
occurs after approx. hours mechanical damage motor failure
occurs with shocks loose cable connection cable break
depends on temperature moisture in unit defective blower
foreign body in unit defective feedback
Wiring / mechanical setup (e. g. length of cables, grounding, assembly,...):
Information on the machine (e. g. operating hours, type, serial number,...):
Mains conditions (e. g. frequency, voltage,...):
Ambient conditions (e. g. ambient temperature, humidity,...):
In case of problems with DriveTop

Name of dialog in which fault occurred:
Drive connection:
Note: In order to resolve your DriveTop problem quickly, we would like to ask you to send us the file
"debug.log". You can find it in the DriveTop directory.
Notes
Rexroth IndraDrive C Disposal and Environmental Protection 11-1
11 Disposal and Environmental Protection
11.1 Disposal
Products
Our products can be returned to us free of charge for disposal. It is a
precondition, however, that the products are free of oil, grease or other
dirt.
In addition, when returned the products mustn’t contain any undue foreign
matter or foreign component.
Please send the products free domicile to the following address:

Bosch Rexroth AG
Electric Drives and Controls
Bürgermeister-Dr.-Nebel-Straße 2
D-97816 Lohr am Main
Packaging Materials
The packaging materials consist of cardboard, wood and polystyrene.
They can be easily recycled. For ecological reasons you should not return
the empty packages to us.
11.2 Environmental Protection
No Release of Hazardous Substances

Our products do not contain any hazardous substances that they can
release in the case of appropriate use. Normally there aren't any negative
effects on the environment to be expected.
Materials Contained in the Products

Electronic Devices
Electronic devices mainly contain:
• steel
• aluminum
• copper
• synthetic materials
• electronic components and modules
Motors
Motors mainly contain:
• steel
• aluminum
• copper
• brass
• magnetic materials
• electronic components and modules
11-2 Disposal and Environmental Protection Rexroth IndraDrive C
Recycling
Due to their high content of metal most of the product components can be
recycled. In order to recycle the metal in the best possible way it is
necessary to disassemble the products into individual modules.
The metals contained in the electric and electronic modules can also be
recycled by means of specific separation processes.
The synthetic materials remaining after these processes can be thermally
recycled.
Rexroth IndraDrive C Service & Support 12-1
12 Service & Support
12.1 Helpdesk
Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am
am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries.
Sie erreichen uns Contact us
- telefonisch - by phone: 49 (0) 9352 40 50 60

über Service Call Entry Center Mo-Fr 07:00-18:00
- via Service Call Entry Center Mo-Fr 7:00 am - 6:00 pm
- per Fax - by fax: +49 (0) 9352 40 49 41
- per e-Mail - by e-mail: service.svc@boschrexroth.de
12.2 Service-Hotline
Außerhalb der Helpdesk-Zeiten ist der Service After helpdesk hours, contact our service
direkt ansprechbar unter department directly at
+49 (0) 171 333 88 26

oder - or +49 (0) 172 660 04 06
12.3 Internet
Unter www.boschrexroth.com finden Sie At www.boschrexroth.com you may find

ergänzende Hinweise zu Service, Reparatur und additional notes about service, repairs and training
Training sowie die aktuellen Adressen *) unserer in the Internet, as well as the actual addresses *) of
auf den folgenden Seiten aufgeführten Vertriebs- our sales- and service facilities figuring on the
und Servicebüros. following pages.
Verkaufsniederlassungen sales agencies
Niederlassungen mit Kundendienst offices providing service
Außerhalb Deutschlands nehmen Sie bitte zuerst Kontakt mit Please contact our sales / service office in your area first.
unserem für Sie nächstgelegenen Ansprechpartner auf.
*) Data in the present documentation may have become
*) Die Angaben in der vorliegenden Dokumentation können obsolete since printing.
seit Drucklegung überholt sein.
12.4 Vor der Kontaktaufnahme... - Before contacting us...

Wir können Ihnen schnell und effizient helfen wenn For quick and efficient help, please have the
Sie folgende Informationen bereithalten: following information ready:
1. detaillierte Beschreibung der Störung und der 1. Detailed description of the failure and
Umstände. circumstances.
2. Angaben auf dem Typenschild der 2. Information on the type plate of the affected
betreffenden Produkte, insbesondere products, especially type codes and serial
Typenschlüssel und Seriennummern. numbers.
3. Tel.-/Faxnummern und e-Mail-Adresse, unter 3. Your phone/fax numbers and e-mail address,
denen Sie für Rückfragen zu erreichen sind. so we can contact you in case of questions.
12-2 Service & Support Rexroth IndraDrive C
12.5 Kundenbetreuungsstellen - Sales & Service Facilities
Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!

from abroad: don’t dial (0) after country code!
Vertriebsgebiet Mitte
Germany Centre SERVICE SERVICE SERVICE
Rexroth Indramat GmbH CALL ENTRY CENTER HOTLINE ERSATZTEILE / SPARES
Bgm.-Dr.-Nebel-Str. 2 / Postf. 1357 MO – FR MO – FR verlängerte Ansprechzeit
97816 Lohr am Main / 97803 Lohr von 07:00 - 18:00 Uhr von 17:00 - 07:00 Uhr - extended office time -
from 5 pm - 7 am ♦ nur an Werktagen
Kompetenz-Zentrum Europa from 7 am – 6 pm + SA / SO - only on working days -
Tel.: +49 (0)9352 40-0 Tel.: +49 (0)172 660 04 06 ♦ von 07:00 - 18:00 Uhr
Tel. +49 (0) 9352 40 50 60 - from 7 am - 6 pm -
Fax: +49 (0)9352 40-4885 oder / or
service.svc@boschrexroth.de Tel.: +49 (0)171 333 88 26 Tel. +49 (0) 9352 40 42 22
Vertriebsgebiet Süd Vertriebsgebiet West Gebiet Südwest

Germany South Germany West Germany South-West
Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG
Landshuter Allee 8-10 Regionalzentrum West Service-Regionalzentrum Süd-West
80637 München Borsigstrasse 15 Siemensstr.1
40880 Ratingen 70736 Fellbach
Tel.: +49 (0)89 127 14-0 Tel.: +49 (0)2102 409-0 Tel.: +49 (0)711 51046–0
Fax: +49 (0)89 127 14-490 Fax: +49 (0)2102 409-406 Fax: +49 (0)711 51046–248
+49 (0)2102 409-430
Vertriebsgebiet Nord Vertriebsgebiet Mitte Vertriebsgebiet Ost Vertriebsgebiet Ost

Germany North Germany Centre Germany East Germany East
Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG
Walsroder Str. 93 Regionalzentrum Mitte Beckerstraße 31 Regionalzentrum Ost
30853 Langenhagen Waldecker Straße 13 09120 Chemnitz Walter-Köhn-Str. 4d
Tel.: +49 (0) 511 72 66 57-0 64546 Mörfelden-Walldorf 04356 Leipzig
Service: +49 (0) 511 72 66 57-256
Fax: +49 (0) 511 72 66 57-93 Tel.: +49 (0) 61 05 702-3 Tel.: +49 (0)371 35 55-0 Tel.: +49 (0)341 25 61-0
Service: +49 (0) 511 72 66 57-783 Fax: +49 (0) 61 05 702-444 Fax: +49 (0)371 35 55-333 Fax: +49 (0)341 25 61-111
Europa (West) - Europe (West)

vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen
from abroad: don’t dial (0) after country code, Italy: dial 0 after country code
Austria - Österreich Austria – Österreich Belgium - Belgien Denmark - Dänemark

Bosch Rexroth GmbH Bosch Rexroth GmbH Bosch Rexroth NV/SA BEC A/S
Electric Drives & Controls Electric Drives & Controls Henri Genessestraat 1 Zinkvej 6
Stachegasse 13 Industriepark 18 1070 Bruxelles 8900 Randers
1120 Wien 4061 Pasching
Tel.: +43 (0)1 985 25 40 Tel.: +43 (0)7221 605-0 Tel: +32 (0) 2 582 31 80 Tel.: +45 (0)87 11 90 60
Fax: +43 (0)1 985 25 40-93 Fax: +43 (0)7221 605-21 Fax: +32 (0) 2 582 43 10 Fax: +45 (0)87 11 90 61
info@boschrexroth.be
service@boschrexroth.be
Great Britain – Großbritannien Finland - Finnland France - Frankreich France - Frankreich

Bosch Rexroth Ltd. Bosch Rexroth Oy Bosch Rexroth SAS Bosch Rexroth SAS
Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls
Broadway Lane, South Cerney Ansatie 6 Avenue de la Trentaine ZI de Thibaud, 20 bd. Thibaud
Cirencester, Glos GL7 5UH 017 40 Vantaa (BP. 74) (BP. 1751)
77503 Chelles Cedex 31084 Toulouse
Tel.: +44 (0)1285 863000 Tel.: +358 (0)9 84 91-11 Tel.: +33 (0)164 72-70 00 Tel.: +33 (0)5 61 43 61 87
Fax: +44 (0)1285 863030 Fax: +358 (0)9 84 91-13 60 Fax: +33 (0)164 72-63 00 Fax: +33 (0)5 61 43 94 12
sales@boschrexroth.co.uk Hotline: +33 (0)608 33 43 28
service@boschrexroth.co.uk
France – Frankreich Italy - Italien Italy - Italien Italy - Italien

Bosch Rexroth SAS Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth S.p.A.
Electric Drives & Controls Via G. Di Vittorio, 1 Via Paolo Veronesi, 250 Via Mascia, 1
91, Bd. Irène Joliot-Curie 20063 Cernusco S/N.MI 10148 Torino 80053 Castellamare di Stabia NA
69634 Vénissieux – Cedex Hotline: +39 02 92 365 563
Tel.: +33 (0)4 78 78 53 65 Tel.: +39 02 92 365 1 Tel.: +39 011 224 88 11 Tel.: +39 081 8 71 57 00
Fax: +33 (0)4 78 78 53 62 Service: +39 02 92 365 326 Fax: +39 011 224 88 30 Fax: +39 081 8 71 68 85
Fax: +39 02 92 365 500
Service: +39 02 92 365 503
Italy - Italien Italy - Italien Netherlands - Niederlande/Holland Netherlands – Niederlande/Holland

Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth Services B.V. Bosch Rexroth B.V.
Via del Progresso, 16 (Zona Ind.) Via Isonzo, 61 Technical Services Kruisbroeksestraat 1
35020 Padova 40033 Casalecchio di Reno (Bo) Kruisbroeksestraat 1 (P.O. Box 32)
(P.O. Box 32) 5281 RV Boxtel
5281 RV Boxtel
Tel.: +39 049 8 70 13 70 Tel.: +39 051 29 86 430 Tel.: +31 (0) 411 65 16 40 Tel.: +31 (0) 411 65 19 51
Fax: +39 049 8 70 13 77 Fax: +39 051 29 86 490 +31 (0) 411 65 17 27 Fax: +31 (0) 411 65 14 83
Fax: +31 (0) 411 67 78 14 www.boschrexroth.nl
+31 (0) 411 68 28 60
services@boschrexroth.nl
Norway - Norwegen Spain - Spanien Spain – Spanien Sweden - Schweden

Bosch Rexroth AS Bosch Rexroth S.A. Goimendi S.A. Bosch Rexroth AB
Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls
Berghagan 1 or: Box 3007 Centro Industrial Santiga Parque Empresarial Zuatzu - Varuvägen 7
1405 Ski-Langhus 1402 Ski Obradors s/n C/ Francisco Grandmontagne no.2 (Service: Konsumentvägen 4, Älfsjö)
08130 Santa Perpetua de Mogoda 20018 San Sebastian 125 81 Stockholm
Tel.: +47 (0) 64 86 41 00 Barcelona
Tel.: +34 9 37 47 94 00 Tel.: +34 9 43 31 84 21 Tel.: +46 (0)8 727 92 00
Fax: +47 (0) 64 86 90 62 Fax: +34 9 37 47 94 01 - service: +34 9 43 31 84 56 Fax: +46 (0)8 647 32 77
Fax: +34 9 43 31 84 27
Hotline: +47 (0)64 86 94 82 - service: +34 9 43 31 84 60
jul.ruud@rexroth.no sat.indramat@goimendi.es
Sweden - Schweden Switzerland East - Schweiz Ost Switzerland West - Schweiz West
Bosch Rexroth AB Bosch Rexroth Schweiz AG Bosch Rexroth Suisse SA
Electric Drives & Controls Electric Drives & Controls Av. Général Guisan 26
Ekvändan 7 Hemrietstrasse 2 1800 Vevey 1
254 67 Helsingborg 8863 Buttikon
Tel.: +46 (0) 42 38 88 -50 Tel. +41 (0) 55 46 46 111 Tel.: +41 (0)21 632 84 20
Fax: +46 (0) 42 38 88 -74 Fax +41 (0) 55 46 46 222 Fax: +41 (0)21 632 84 21
Europa (Ost) - Europe (East)

vom Ausland: (0) nach Landeskennziffer weglassen
from abroad: don’t dial (0) after country code
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Rexroth IndraDrive C Appendix 13-1
13 Appendix
13.1 Accessories
Overview
• HAS01.1-...:
accessories for mounting and installation of drive controllers in
combination, i.e. next to each other
• HAS02.1-...:
accessories for shield connection of motor cable
The table below shows the assignment of the accessories to the drive
controllers:
Devices Device width HAS01.1- HAS02.1-
[mm]
065-048- 105-048- 065-NNN- 105-NNN- 001-NNN- 002-NNN- 003-NNN-
CN CN CN CN NN NN NN
HCS02.1E-
65 X X
W0012
X
HCS02.1E-
65 (combina- X X
W0028
tion)
X
HCS02.1E-
105 (combina- X X
W0054
tion)
X
HCS02.1E-
105 (combina- X X
W0070
tion)
Fig. 13-1: Accessories - overview
13-2 Appendix Rexroth IndraDrive C
HAS01.1 (Accessories for Installation of Drive Controllers in

Combination)
HAS01.1-065-NNN-CN
Fig. 13-2: HAS01.1-065-NNN-CN
HAS01.1-065-048-CN
Fig. 13-3: HAS01.1-065-048-CN
HAS01.1-105-048-CN
Fig. 13-4: HAS01.1-105-048-CN
HAS01.1-105-NNN-CN
Fig. 13-5: HAS01.1-105-NNN-CN
HAS02.1 (Accessories for Shield Connection of Motor Cable)

For the shield connection of the motor cable at the drive controller a
special shielding plate is available HAS02.1-002-NNN-NN.
Note: Using the shielding plate guarantees optimum shield contact

of the motor cable. You should therefore always use the
shielding plate, where possible.
The shielding plate is only available as an option.
Fig. 13-6: HAS02.1-002-NNN-NN
Mounting
The shielding plate is screwed to the bottom of the drive controller (see
also figure below):
• Unscrew bottom or bottom left fixing screw of drive controller.
• Put shielding plate to bottom of drive controller and screw down fixing
screw of drive controller again.
Risk of damage to the drive controller caused

by too long screws!
⇒ Exclusively use screws of a maximum length of
CAUTION 12 mm for the thread of the shield connection XS2.
• Screw second screw (M6 x 12) in thread XS2 at bottom of drive

controller.
• Screw fixing device to shielding plate according to desired cable
routing of motor cable (45° or horizontal). (The figure below illustrates
cable routing with 45°.)
• According to diameter of motor cable, fix motor cable to corresponding
support of fixing device (12-18 mm or 19-30 mm) with a clip. Make
sure that shield of motor cable has good contact with fixing device.
1: screw in thread XS2

2: shielding plate
3: fixing device
4: shield of motor cable
5: clip
Fig. 13-7: Shield connection of motor cable
Mounting Depth Adapter

If a combination of drive controllers is to include devices of the M and C
types, different mounting depths have to be bridged so that the system
interfaces (e.g. module bus and DC bus connection) are situated at the
same mounting depth. This can be done with a mounting depth adapter.
In preparation!
13.2 Determination of Appropriate Drive Controllers
Introduction
The mains supply for an AC drive system of the IndraDrive C product
family is integrated in the drive controllers HCS. Depending on the tasks
and design of the supply unit and the conditions of its use, it may be
necessary to add link reactors, auxiliary capacitors, braking resistor
modules and transformers as needed.
The drive controller must make available to the drives the DC bus
continuous power and the DC bus peak power for acceleration. During
regenerative operation it must be able to store continuous and peak
regenerated power.
Prior to selecting drive controllers and auxiliary components it is
necessary to determine the motors and drive controllers which will be
used.
It is advisable to carry out calculations in accordance with the following
chapters in order to make sure that the drive controller layout is correct.
DC Bus Continuous Power

The DC bus continuous power is calculated from the mechanical power
and based on the efficiency of motor and controller as well as coincidence
factors.
Mechanical Power
M*n * 2π
Pm [ W ] = M ∗ ω = or
60
M*n
Pm [kW ] ≈
9550
Pm: mechanical power
M: torque [Nm]
-1
ω: angular speed [min ]
-1
n: motor speed [min ]
Fig. 13-8: Mechanical power
Continuous Mechanical Power The effective motor torque and average motor speed are needed to
for Servo Drives calculate the mechanical continuous power of a servo drive.
The effective motor torque calculations can be assumed from the servo
drive calculation. The average motor speed is determined as follows:
Average Motor Speed The average motor speed equals approximately 25% of the rapid motion
speed - in the case of servo drive tasks in conventional NC machine tools.
In some cases, however, this approximate estimation is not sufficient. A
precise calculation of the average motor speed is necessary.
If the duration over which the motor is operated at constant speed is

considerably greater than the accel and decel time, then it applies:
Average Speed without Accel
and Decel Time n1 * t 1 + n 2 * t 2 + ... + n n * t n
n av =
t 1 + t 2 ... + t n
-1
nav: average motor speed [min ]
-1
n1 ... nn: motor speed [min ]
t1 ... tn: ON time [s]
Fig. 13-9: Average speed; influence of accel and decel time is not taken into
consideration
n1
n2
n3
t1 t2 t3 t4
DGoE.fh7
Fig. 13-10: Speed cycle; influence of accel and decel time is not taken into
consideration
Accel and decel times with short cycle times must be taken into
consideration in such dynamic applications as is the case with rollers and
nibble machines:
Average Speed with Accel and
Decel Times n n
* t H + n * t1 + * tB
n av = 2 2
tH + t1 + t B + t 2
-1
-1
n: motor speed [min ]
t: time [s]
tH: accel time [s]
tB: decel time [s]
Fig. 13-11: Average speed; influence of accel and decel time is taken into
consideration
t
tH t1 tB t2
DGmE.fh7
Fig. 13-12: Average speed; influence of accel and decel time is taken into
consideration
M eff * n av
PmSe =
9550
PmSe: continuous mech. power for servo drives [kW]
Meff: effective motor torque [Nm]
-1
Fig. 13-13: Mechanical power for servo drives
Mechanical Power for Main Main drives are primarily used with constant power over a specific speed
Drives range. This means that when planning power supply, nominal power is
important. The mechanical nominal power of the main drives is illustrated
in the operating characteristics or it can be calculated using nominal
speed and torque.
Mn * n n
PmHa =
9550
PmHa: mechanical nominal power for main drives (shaft output) [kW]
Mn: motor nominal torque [Nm]
-1
n n: motor nominal speed [min ]
Fig. 13-14: Mechanical power for main drives
DC Bus Continuous Power for The drive controller resp. the combination of drive controllers must make
Servo Drives the DC bus continuous power available to all servo drives. All drives are
operated simultaneously in only a few applications which means that only
the simultaneously occurring output needs to be considered. For the
calculation of the required DC bus continuous power for typical NC feed
axes on tool machines, it has proven in practice that a so-called
coincidence factor is included:
Number of Axes 1 2 3 4 5 6
Coincidence factor (FG) 1 1,15 1,32 1,75 2,0 2,25
Fig. 13-15: Coincidence factors
(PmSe1 + PmSe 2 + ... + PmSen ) * 1,25

P =
FG
PZWSe: DC bus continuous power for servo drives [kW]
PmSe1 ... PmSen: cont. mech. power for servo drives [kW]
F G: coincidence factor
1,25: constant for motor and controller efficiency
Fig. 13-16: DC bus continuous power for servo drives
DC Bus Continuous Power for If several main drives are operated on one DC bus, then add the
Main Drives simultaneously required power:
PZWHa = (PmHa1 + PmHa 2 + ... + PmHan ) * 1,25

PZWHa: DC bus continuous power for main drives [kW]
PmHa1 ... PmHan: mech. cont. power for main drives [kW]
Fig. 13-17: DC bus continuous power for main drives
Chokes and auxiliary capacitors are selected in terms of the actually

required DC bus continuous power. It is fixed by the nominal power of the
spindle drives.
Note: When selecting the drive controller make sure that the DC bus
continuous power does not limit the short-term power of the
main drives.
DC Bus Continuous Power for If main and servo drives are operated on a drive controller, the required
Main and Servo Drives DC bus continuous power needs to be added.
It is the spindle drive in a NC machine tool that primarily determines the
DC bus power needed. Therefore, the following equation should be
applied in such applications:
PZW = [PmHa + 0,3 * (PmSe1 + PmSe 2 + ... PmSen )] * 1,25

0,3: experimental value for standard machine tools
PZW : DC bus continuous power [kW]
PmSe1 ... PmSen: continuous mech. servo drive output [kW]
PZWHa: nominal power for spindle drives (shaft output) [kW]
Fig. 13-18: DC bus continuous power for spindle and servo drives in machine
tools
∑P ZWD, Anlage ≤ ∑P ZWD, Geräte
PZWD,Anlage: DC bus continuous power of installation

PZWD,Geräte: DC bus continuous power of the drive controllers
Fig. 13-19: Supply condition: DC bus peak power
DC Bus Peak Power

The DC bus peak power is demanded of the drive controller resp.
combination of drive controllers when, e.g., several axes of a machine
tool simultaneously accelerate to rapid traverse and then go to a
workpiece after a tool change.
Damages due to overloaded power supply unit!

⇒ Damages to the drive controller can be avoided, if the
sum of the peak power of all drives does not exceed
the DC bus peak power of the drive controller.
CAUTION
(MNC ± MG ) * n eil * 1,25

PZWS =
9550
MNC: acceleration torque in NC mode [Nm]
MG: weight torque in vertical axes [Nm]
-1
neil: speed in rapid traverse [min ]
PZWS: DC bus peak power [kW]
Fig. 13-20: DC bus peak power per drive
∑P ZWS, Anlage ≤ ∑P ZWS, Geräte
PZWS,Anlag: DC bus peak power of installation

PZWS,Geräte: DC bus peak power of drive controllers
Fig. 13-21: Sum of DC bus peak powers
Regenerated Energy
The energy content of all main and servo drives that brake simultaneously
under unfavorable conditions may not be greater than the maximum
regenerated energy of the drive controller resp. of the combination of
drive controllers. If this is not taken into consideration during the layout
stage, then there could be thermal damage to the braking resistors in the
drive controllers!
Property damages due to overloaded braking

resistor!
⇒ Use a drive controller resp. a combination of drive
CAUTION controllers that is appropriate for the consumption of
the regenerated power which arises when all the
main and servo drives connected to the drive
controller resp. to the combination of drive controllers
brake simultaneously.
2
JG  2π 
Wrot = *  n eil * 
2  60 
W rot: rotary energy [Ws]
-1
neil: rapid traverse speed [min ]
J G: inertia of motor and load inertia reduced to shaft [kgm²]
Fig. 13-22: Regenerated energy per drive
∑W R, Anlage ≤ ∑W R, Geräte
W R,Anlage: rotary energy of installation

W R,Geräte: max. permissible regenerated energy of the drive controllers
Fig. 13-23: Sum of regenerated energies
Calculation with Regard to Reduction of Resulting Power Dissipation

When braking the drive, the rotary energy present in the mechanics is fed
back to the DC bus of the drive controller resp. combination of drive
controllers in the form of regenerated energy.
• It can be reduced to dissipated heat via the braking resistor integrated
into the drive controller or an auxiliary braking resistor can additionally
be built in.
- or -
• It can be stored as energy in the drive controller with connected
auxiliary capacitance module and then re-used for acceleration
procedures. This reduces the heat in the control cabinet and lowers
energy consumption.
For a successful implementation and an avoidance of unnecessary heat

loss in the control cabinet, it applies:
W R, Anlage ≤ W ZW , DKC + W ZW , CZM

W R,Anlage: required regenerative power of the system
W ZW : storable energy of the DC bus capacitors
Fig. 13-24: Condition to avoid power dissipation from the regenerative power
Auxiliary Capacitance as Energy In servo drive applications with numerous accel and decel procedures, as
Storage is the case, for example, with nibble machines and rollers, it is advisable
to connect additional capacitors to the DC bus. The following advantages
result from this:
• This prevents the braking resistor in the drive controller from being
actuated while braking: The heat dissipated within the control cabinet
is considerably reduced.
• The stored energy can be used to accelerate thus reducing energy
requirements of the installation.
WZW =
C ZW
2
(
* UB2 − U 2ZW )
W ZW : energy stored in the DC bus
CZW : DC bus capacitor [F]
UB: braking resistor actuation threshold
UZW : DC bus nominal voltage
Fig. 13-25: Energy that can be stored in the DC bus
The auxiliary capacitor must be designed so that it is capable of storing

rotary drive energy:
2Wrot
CZu ≥ * 1000 − Cintern
 U2 − U2 
 B 
ZW 

UB: braking resistor actuation threshold (approx. 820 V)
UZW : DC bus nominal voltage
W rot: rotatory energy [Ws]
CZu: auxiliary capacitor [mF]
Cintern: internal capacitance of supply unit [mF]
Fig. 13-26: Required auxiliary capacitance
Note: We recommend to dimension the auxiliary capacitance for

10% overvoltage.
Continuous Regenerated Power

The average sum of the continuous regenerated power of all drives may
not exceed the continuous power in the braking resistors.
The processing time in servo drive applications given a typical NC
machine tool, is relatively long in terms of the entire cycle time. There is
little regenerated continuous power. An exact calculation is not required
for such applications. It is sufficient if the peak regenerated power is not
exceeded.
An exact calculation is needed in specific cases such as, for example:
• servo drive applications with numerous accel / decel procedures such
as is the case in nibble machines and rollers
• machine tools with modular main drives
• applications in which excessive masses must be lowered as is the
case with those overhead gantries used with storage and transport
technologies
To calculate continuous regenerated power, the rotary energy of the
drives and the potential energy of non-compensated masses must be
known.
2
Jg  2π 
Wrot = *  n eil *  *z
2  60 
W rot: rotary energy [Ws]
-1
neil: speed in rapid traverse [min ]
J g: moment of inertia (motor + load) [kgm²]
z: number of decels per cycle
Fig. 13-27: Rotary energy
Wpot = m * g * h * z
W pot: potential energy [Ws]
m: load mass [kg]
g: gravity constant = 9,81 m/s²
h: drop height [m]
z: number of drops per cycle
Fig. 13-28: Potential energy of non-compensated masses
Wpotg + Wrotg
PRD,Anlage =
tz ∑P RD, Anlage ≤ ∑P
BD,Geräte
PRD,Anlage: continuous regenerated power [kW]

PBD,Geräte: continuous braking resistor power [kW]
tz: cycle time [s]
W potg: sum of potential energy [kWs]
W rotg: sum of rotary energies [kWs]
Fig. 13-29: Continuous regenerated energy
Peak Regenerated Power

The peak regenerated power usually arises, when an Emergency Stop
signal has been released and all the axes brake simultaneously.
Property damages due to longer braking

periods/paths!
⇒ Choose the power supply unit such that the sum of
CAUTION the peak regenerated power of the all drives does not
exceed the braking resistor peak power of the power
supply unit.
The peak regenerated power of the servo drives is listed in the motor
selection documentation.
Roughly estimated, the peak regenerated power can be calculated as
follows:
Mmax * n max
PRS =
9550 * 1,25 ∑P RS,Anlage ≤ ∑P
BS,Geräte
PRS,Anlage: peak regenerated power [kW]

PBS,Geräte: peak braking resistor power [kW]
Mmax: max. drive torque [Nm]
-1
nmax: max. NC usable speed [min ]
Fig. 13-30: Peak regenerated power
Calculating Allowed Continuous Braking Resistor and DC Bus Power

By connecting the DC bus connections of several HCS02 and HLB01
drive controllers the regenerative power and regenerative continuous
power resulting in the common DC bus is evenly distributed to all
IndraDrice C components with a braking resistor.
The distribution to the components involved is realized takes place with a
high balancing factor.
For Central Supply and Group

Supply with DC Bus Connection PBD, Geräte ¤ (P
BD, DKC PBD, BZM)*0,8
PBD, Geräte : continuous braking resistor power that can be consumed in
continuous operation by all devices on the common DC bus,
in kW
PBD, HCS02 : continuous braking resistor power that the drive controller
can consume in continuous operation, in kW
PBD, HLB01 : continuous braking resistor power that the auxiliary braking
resistor module can consume in continuous operation, in kW
f: balancing factor for parallel operation (see "Electrical
Data")
Fig. 13-31: Continuous braking resistor power of all devices on the common DC
bus
PZW, Geräte ¤P ZW * 0,8

PZW, Geräte : available continuous DC bus power on the common DC bus,
in kW
PZW : continuous DC bus power of the single devices in kW
f: balancing factor for parallel operation (see "Electrical Data")
Fig. 13-32: Continuous DC bus power of all devices on the common DC bus
For Single Source Supply and See chapter "Electrical Data" and "Mains Connection"
Group Supply without DC Bus
Connection
13.3 Use of the Connections for Looping Through the Control

Voltage
X13 X13 X13
steuerspg_durchschleif.fh7
Fig. 13-33: Looping through the control voltage
Calculation for 3 HCS02.1E-W0028 drive controllers:
PN 3
ID = 3 x
UN 3
Fig. 13-34: Continuous current ID
IE = 3 x IEIN3
Fig. 13-35: Charging current IE
Duration of the charging current peak is tEIN3lade.(see data of control

voltage).
13.4 Stacked Drive Controllers

⇒ If drive controllers are stacked in the control cabinet,
the connections for the DC buses between the drive
controllers have to be correctly made.
CAUTION
The connection depends on the cable routing (clockwise or

anticlockwise).
The following figures show the correct DC bus connection for stacked
drive controllers. The illustrated way of connection keeps bare wire
sections from being situated directly vis-à-vis. This avoids voltage arcing.
Anticlockwise Cable Routing

⇒ Insulate ring terminals and connecting lines with a
heat-shrinkable sleeve. Afterwards only strip the
insulation of the contact surface of the ring terminal.
CAUTION
device 1
(DC bus connection)
device 2
(DC bus connection)
device 1
(DC bus connection)
device 2
(DC bus connection)
correct incorrect
DC bus nach links_1f4
Fig. 13-36: DC bus connection for anticlockwise cable routing
Clockwise Cable Routing

⇒ Insulate ring terminals and connecting lines with a
heat-shrinkable sleeve. Afterwards only strip the
insulation of the contact surface of the ring terminal.
CAUTION
device 1
(DC bus connection)
device 2
(DC bus connection)
device 1
(DC bus connection)
device 2
(DC bus connection)
correct incorrect
DC bus nach rechts_1f4.fh7
Fig. 13-37: DC bus connection for clockwise cable routing
Rexroth IndraDrive C Index 14-1
14 Index
A
Accessories 13-1
for shield connection of motor cable 13-6
HAS01.1 13-2
HAS02.1 13-6
Accompanying documents 4-1
Additional components
mains choke 9-1
Ambient conditions 6-1
Appropriate use 2-1
Auxiliary capacitance
calculation 13-14
B
Battery safety 3-11
Bb contact 1-3, 8-15
Block diagrams 1-4
Braking resistor
connection 7-33
C
Cable
replacing 10-2
Calculating
charging current inrush 8-20
phase current on the mains 8-19
CE mark 1-7
Central supply 8-5
Certifications 1-7
Choke 9-1
Commutation choke 9-1
Component designation 4-2
Condensation 6-20
Condition as supplied 4-1
Conditions
ambient 6-1
mounting 6-1
operating 6-1
storing 5-1
transporting 5-1
Connection
braking resistor 7-33
control voltage 7-34
DC bus 7-37
diagram 7-17
ground 7-38
HCS02.1E-W0012 7-18
HCS02.1E-W0028 7-20
HCS02.1E-W0054 7-20
HCS02.1E-W0070 7-20
mains 8-1
mains (X3) 7-24
motor 7-26
motor holding brake 7-30
motor temperature monitoring 7-30
PE 7-38
Continuous braking resistor and DC bus power
calculation 13-17
Control cabinet
arrangement of components 6-13
multiple line structure 6-13, 13-19
Control circuits
for the mains connection 8-15
14-2 Index Rexroth IndraDrive C
Control section 1-3

documentation 1-1
type plate 4-2
Control voltage
connection 7-34
data 7-14
looping through 13-18
Control wires
shield connection 7-39
Cooling 6-14
Cooling units
mounting 6-19
C-UL-US listing 1-7
D
Data
electrical 7-5
mechanical 6-4
DC bus 7-37
numbers of drive controllers and auxiliary components on one DC bus 8-7
DC bus continuous power
allowed power with single-phase mains connection 8-12
allowed power without mains choke for three-phase mains connection 8-10
calculation 13-9
DC bus continuous power and mains connection power 8-22
DC bus peak power
calculation 13-12
Degree of protection 6-1
Derating 6-2
Device types 4-4
Dissipation
power 6-14
Documentation
IndraDrive 1-1
overview 1-1
purpose 1-1
Dripping or sprayed water 6-19
Drive controller
basic structure 1-2
block diagrams 1-4
control section 1-3
determination of appropriate drive controllers 13-9
HCS02.1 4-4
power dissipation 6-14
power section 1-2
replacing: 10-1
stacked drive controllers 13-19
type codes 4-4
Drive system
overview 1-3
Duty capacity 6-2
E
Earth-leakage circuit breakers 8-15
Electrical data 7-5
Electrical installation 7-1
EMC
correct installation of drives 7-2
F
Fault Report 10-4
Fuses 8-19
Fusing
via earth-leakage circuit breakers 8-15
G
Ground
connection 7-38
Group supply 8-3
with DC bus connection 8-4
without DC bus connection 8-3
H
HAS01.1 13-2
HAS02.1 13-6
XS2 7-40
Hazards by Improper Use 3-2
HCS02.1 4-4
HNL
choke 9-1
type code 9-1
I
Identification
of components 4-2
Improper use
hazards 3-2
Inappropriate use 2-2
Consequences, Discharge of liability 2-1
IndraDrive
documentation 1-1
Installation
connection diagram 7-17
electrical 7-1
orientation 6-7
K
K1 Contactor 8-21
L
L+, L- 7-37
Line filter 8-1
M
Mains
connection (X3) 7-24
connections 8-1
Mains choke 9-1
Mains connection
control circuits 8-15
Mains connection power and DC bus continuous power 8-22
Mains Contactor 8-19
Mains supply
central supply 8-5
group supply 8-3
options 8-2
single source supply 8-2
Mechanical data 6-4
Module bus 7-23
Motor
connection 7-26
holding brake 7-30
power cable 7-27
replacing 10-2
temperature monitoring 7-30
Motor cable
length 7-29
shield connection 7-40
shielding 7-27
shielding plate 13-6

third party cables 7-29
Motor holding brake 7-30
Motor temperature monitoring 7-30
N
Numbers of drive controllers and auxiliary components on one DC bus 8-7
O
Operating conditions 6-1
P
Packaging
labels 4-1
material 4-1
units 4-1
PE
connection 7-38
Power dissipation 6-14
Power section 1-2
type plate 4-2
Power-dependent arrangement 6-12
Protection
against contact with electrical parts 3-5
against contact with hot parts 3-10
against dangerous movements 3-7
against electric shock by protective low voltage (PELV) 3-6
against magnetic and electromagnetic fields during operation and mounting 3-9
against pressurized systems 3-11
Degree of protection 6-1
during handling and mounting 3-10
Q
Q1 Fuse 8-21
R
Ready to operate (Bb) 8-16
Regenerated energy 13-13
Regenerated power
continuous 13-15
peak 13-16
Rel1 8-15
Replacing
cable 10-2
drive controller 10-1
motor 10-2
S
Safety Instructions for Electric Drives and Controls 3-1
Service & Support 12-1
Shield connection
control wires 7-39
motor cable 7-40
Shielding
motor cables 7-27
Shielding plate
option 13-6
Single source supply 8-2
Stacked drive controllers 13-19
Storing 5-1
Supply mains
ground conditions 8-1
overvoltage 8-1
Support 12-1
T
Technical data
electrical 7-5
mechanical 6-4
Temperatures
above top of device 6-8
Tests 1-7
Three-phase current mains
grounded 8-1
ungrounded 8-1
Touch guard 7-41
Transporting 5-1
Type code
HCS02.1 4-4
HNL 9-1
mains choke 9-1
Type plates 4-2
U
UL 1-7
Use
directions for use 2-1
hazards by improper use 3-2
inappropriate 2-2
V
vibration
distortion 6-1
sinus 6-1
W
Warning symbols 3-1
Weight 6-7
X
X1 7-23
X13 7-34
X3 7-24
X5 7-26
X6 7-30
X9 7-33
XS1 7-39
XS2 7-40
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 (0)93 52-40-50 60
Fax +49 (0)93 52-40-49 41
service.svc@boschrexroth.de
www.boschrexroth.com
Printed in Germany
R911306138 DOK-INDRV*-HCS02.1****-PR01-EN-P

Hcs02.1e WW012

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Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

Rexroth IndraControl VCP 20

Title Rexroth IndraDrive C

Document Typecode DOK-INDRV*-HCS02.1****-PR01-EN

Internal File Reference Document number 120-2400-B314-01/EN

Record of Revisions Description Release Notes

Copyright  Bosch Rexroth AG 2004

Published by Bosch Rexroth AG

Note This document has been printed on chlorine-free bleached paper.

2 Important Directions for Use 2-1

3 Safety Instructions for Electric Drives and Controls 3-1

4 Identifying and Checking the Delivered Components 4-1

Type Plates on the Drive Controller ......................................................................................... 4-2

5 Transport and Storage 5-1

6 Mechanical Mounting 6-1

7 Electrical Installation 7-1

X13, Control Voltage (+24 V, 0 V) ......................................................................................... 7-34

8 Mains Connections 8-1

9 Additional Components 9-1

10 Replacing Devices 10-1

11 Disposal and Environmental Protection 11-1

Products ................................................................................................................................. 11-1

12 Service & Support 12-1

Purpose of this Documentation

1.2 Introducing the Devices

The drive controller consists of two essential parts:

• module bus (for cross communication in the case of DC bus

Note: The control sections are described in a separate

DC bus resistor unit

DC bus capacitor unit

mains contactor motor antriebssystem_c_v1.fh7

Components shown in gray are absolutely necessary

Drive Controllers - Block Diagram

line input with braking resistor DC bus converter

Fig. 1-4: HCS02.1E-W0012-NNNN - Block diagram

line input with optional braking resistor DC bus converter

Fig. 1-5: HCS02.1E-W0012-NNNV - Block diagram

Fig. 1-6: HCS02.1E-W0028-NNNN - Block diagram

Fig. 1-7: HCS02.1E-W0028-NNNV - Block diagram

Fig. 1-8: HCS02.1E-W0054/70-NNNN - Block diagram

Fig. 1-9: HCS02.1E-W0054/70-NNNV - Block diagram

Tests and Certifications

Fig. 1-10: CE mark

C-UL-US Listing In accordance with UL508 C.

Note: Observe the C-UL limit values according to C-UL when

Fig. 1-11: C-UL-US label

Tests High voltage test in Routine testing with DC 2230 V, 1 s

2 Important Directions for Use

2.1 Appropriate Use

Note: Rexroth, as manufacturer, is not liable for any damages

Areas of Use and Application

Every drive controller has to be programmed before starting it up, making

2.2 Inappropriate Use

3 Safety Instructions for Electric Drives and Controls

Improper use of this equipment, failure to follow

Death or severe bodily harm will occur.

Death or severe bodily harm may occur.

Bodily harm or material damage may occur.

3.3 Hazards by Improper Use

High voltage and high discharge current!

Dangerous movements! Danger to life, severe

High electrical voltage due to wrong