Bosch Rexroth IndraDrive CsDrive System with HCS01 Project Planning Manual Download Page 153 | Manualshive

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X77, L+ L-, DC Bus Connection

Lethal electric shock by live parts with more

than 50 V!

WARNING

Before working on live parts: De-energize installation and secure power

switch against unintentional or unauthorized re-energization.
Before accessing the device, wait at least 30 minutes after switching off the

supply voltages to allow discharging.
Check whether voltage has fallen below 50 V before touching live parts!
Never operate the drive controller without touch guard or without DC bus con‐

nector. Only remove the touch guard, if you want to use the DC bus connec‐

tor at the drive controller. If you do not use the DC bus connector any longer,

you have to cover the DC bus connection with the supplied touch guard.

Observe the information on DC bus coupling (see

"DC bus coupling" on page 105

Function, Pin Assignment

The DC bus connection connects
●

several HCS01.1E-W00xx-x-03 to each other

●

one drive controller to a DC bus capacitor unit (to backup the DC bus

voltage)

Touch Guard

The DC bus connection has been provided with a touch guard at the factory.

To plug the DC bus connector, you have to remove the touch guard.

DOK-INDRV*-HCS01******-PR05-EN-P

Bosch Rexroth AG

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Rexroth IndraDrive CsDrive Systems with HCS01

Mounting and installation

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Summary of Contents for Rexroth IndraDrive CsDrive System with HCS01

Page 1: ...Rexroth IndraDrive Cs Drive Systems with HCS01 Project Planning Manual R911322210 Edition 05 ...

Page 2: ...s document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be re produced or given to third parties without its consent Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract All rights are r...

Page 3: ... Firmware 26 Your feedback 27 2 Important directions for use 29 2 1 Appropriate use 29 2 1 1 Introduction 29 2 1 2 Areas of use and application 29 2 2 Inappropriate use 30 3 Safety instructions for electric drives and controls 31 3 1 Definitions of terms 31 3 2 General information 32 3 2 1 Using the Safety instructions and passing them on to others 32 3 2 2 Requirements for safe use 32 3 2 3 Hazar...

Page 4: ...d Party Motors 48 General Information on Third Party Motors 48 Requirements on Third Party Motors 49 Requirements on the Encoder of the Third Party Motor 52 Notes on Selection and Commissioning 52 4 3 5 Cables 53 Motor power cables 53 Selection 53 Allowed cable lengths 53 Encoder cables 54 MSM motors 54 MSK Motors 54 4 4 Installation conditions 54 4 4 1 Ambient and operating conditions 54 4 4 2 Co...

Page 5: ...rrent 85 Dimensioning the line cross sections and fuses 87 Dimensioning and selecting the mains transformer 95 Dimensioning the mains filter 95 Selecting the mains filter 98 Determining the Mains Choke 102 Dimensioning the mains contactor 102 Combining transformer mains filter and mains choke 103 Control Circuit for the Mains Connection 104 4 6 4 DC bus coupling 105 Requirements for DC bus couplin...

Page 6: ...r Connection HCS01 1E W0003 W0013 x 02 W0005 x 03 W0008 x 03 135 X5 Motor Connection HCS01 1E W0018 x 02 W0018 x 03 W0028 x 03 136 X5 Motor Connection HCS01 1E W0054 x 03 137 X6 Motor Temperature Monitoring and Motor Holding Brake 138 X9 integrated external braking resistor 141 X13 24V Supply Control Voltage 143 X24 P2 X25 P1 communication 144 X26 Engineering interface 146 X31 Digital Inputs Digit...

Page 7: ...ntactors switches chokes and in ductive loads 180 7 Technical data of the components 181 7 1 Control section 181 7 1 1 EC standard encoder evaluation 181 Supported encoder systems 181 Encoder type 181 IndraDyn S MSM motors 5V supply voltage 181 IndraDyn S MSK QSK motors S1 M1 S2 M2 S3 M3 S5 M5 12 V supply voltage 183 HIPERFACE 12 V supply voltage 184 EnDat 2 1 according to Heidenhain standard 5 V ...

Page 8: ...s 218 Digital Inputs Type A Standard 218 Digital inputs type B probe 219 Digital inputs safety technology L options 220 Digital inputs safety technology S options 221 Digital outputs 222 Digital Outputs Standard 222 Digital Outputs Safety Technology L Options 223 Digital outputs safety technology S options 224 7 1 8 Analog Voltage Input 226 7 1 9 Analog current input 227 7 1 10 Analog Output 228 7...

Page 9: ...70 Installation 271 Replacement of devices 273 8 2 7 D Sub Connector for Encoder Cable and Battery Connection RGS0001 K01 274 8 2 8 Encoder cable for MSM motors with absolute value encoder M5 RKG0065 278 8 2 9 RKB0011 Multi Ethernet Cable 279 8 2 10 RKB0013 Multi Ethernet Cable 280 8 2 11 Hall Sensor Adapter Box SHL03 1 NNN S NNN 281 8 2 12 Snap on ferrite HAS05 1 015 287 8 3 Additional components...

Page 10: ... Technical data 309 Connection 310 Operation 311 9 Environmental protection and disposal 313 9 1 Environmental protection 313 9 2 Disposal 313 10 Service and support 315 11 Appendix 317 11 1 Dimensioning the line cross sections and fuses 317 11 2 Determining the Leakage Capacitance 325 11 3 Leakage Capacitances 326 11 3 1 Leakage Capacitance of Motors 326 11 3 2 Leakage Capacitance of Power Cables...

Page 11: ...Rexroth IndraDrive Cs Rexroth IndraDrive Cs HCS01 converter MSM MS2N MSK MCL motors third party motors Tab 1 1 Components of the Rexroth IndraDrive Cs range DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 9 341 Rexroth IndraDrive CsDrive Systems with HCS01 System presentation ...

Page 12: ...Food and packaging industry Filling and closing palletizing erecting cartons closing cartons labeling Printing machines Label printing labeling digital printing positioning servo drives Semiconductor industry Semiconductor wafer production and handling metalizing cleaning solar cell production Tab 1 2 Target applications Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 10 341 Rexroth IndraDrive CsDrive ...

Page 13: ... Performance dependent fan control Integrated brake current measurement and monitoring Winding short circuit at motor output for shutdown as reaction to fatal er rors Compact MSM motors 2 options for buffering the data of MSM encoders Battery box SUP E0x MSM BATTERYBOX can be mounted near the motor one battery box is required for each drive controller Encoder cables RKG0041 RKG0065 with D Sub conn...

Page 14: ... Control S4 Safe Motion S5 Safe Motion SB Safe Motion Bus L3 Safe Torque Off L4 Safe Torque Off Safe Brake Control S4 Safe Motion S5 Safe Motion SB Safe Motion Bus IndraMotion MLD S3 MLD S3 MLD M3 Freely configurable digital in puts outputs incl probe Analog input Control panel With programming module function With slot for microSD memory card Optional I O extension digital analog Engineering Port...

Page 15: ... 110 230 V 3 AC 200 500 V 3 AC 110 230 V 3 AC 200 500 V Maximum cur rent Arm s 3 3 6 0 9 0 13 0 5 0 8 0 18 0 18 0 28 0 54 0 Single phase operation allowed for HCS01 1E W0013 and HCS01 1E W0018 A 02 with derating Single phase operation not allowed Tab 1 4 Converter HCS01 Performance Features DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 13 341 Rexroth IndraDrive CsDrive Systems with HCS01 System prese...

Page 16: ...exroth IndraSize is a software for optimum sizing of a drive sys tem consisting of the components Rexroth IndraDrive and Indra Dyn Rexroth IndraSize is available as a download Interfaces Overview Compatible with IndraDrive platform Ethernet based communication with the following supported protocols sercos III PROFINET IO EtherNet IP EtherNet POWERLINK EtherCAT Alternative communication PROFIBUS DP...

Page 17: ...er with reference track 5V TTL square wave encoder with reference track SSI Combined encoder for SSI combination of SSI and 1Vpp sin cos encod er Resolver resolvers are not supported if optional Safe Motion safety technology is also in use Hall sensor box SHL02 1 Digital Hall sensor in conjunction with Hall sensor adapter box SHL03 1 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 15 341 Rexroth IndraD...

Page 18: ...or unit for devices with DC bus connection HLR External braking resistor HNL Mains choke NF Mains filter K1 External mains contactor M Motor RB Integrated braking resistor at the back of the drive controller Fig 1 1 Drive System Rexroth IndraDrive Cs Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 16 341 Rexroth IndraDrive CsDrive Systems with HCS01 System presentation ...

Page 19: ... Feeding Cooling type W Air internal Maximum current 1 0003 3 A 0005 5 A 0006 6 A 0008 8 A 0009 9 A 0013 13 A 0018 18 A 0028 28 A 0054 54 A Degree of protection A IP20 Mains connection voltage 1 02 3 AC 110 230 V 03 3 AC 200 500 V Control section design 2 A ADVANCED B BASIC E ECONOMY Communication 2 S3 sercos 3 EtherCAT CC sercos 3 master cross communication ET Multi Ethernet DOK INDRV HCS01 PR05 ...

Page 20: ...Other design NN None Firmware FW With control panel firmware has to be ordered separately NW Without control panel without firmware 1 See table Possible combinations of maximum current and mains connection voltage 2 See table Possible combinations of options 3 The L3 S4 S5 and SB interfaces guarantee both the function and the certification Tab 1 6 Type code HCS01 Possible combinations of maximum c...

Page 21: ...3 L4 NN S4 S5 SB A CC ET B ET E S3 Tab 1 8 Possible combinations of options The figure illustrates the basic structure of the type code Our sales representative will assist you with the versions available DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 19 341 Rexroth IndraDrive CsDrive Systems with HCS01 System presentation ...

Page 22: ...A ADVANCED control panel with memory card slot N Standard control panel without memory card slot Memory size 018 18 MB example Other design NN None Firmware FW Firmware must be ordered as a separate subposition Tab 1 9 HAP01 type code The figure illustrates the basic structure of the type code Our sales representative will assist you with the versions available Bosch Rexroth AG DOK INDRV HCS01 PR0...

Page 23: ...FWA INDRV MPE 17VRS D5 x NNN NN FWA INDRV MPE 18VRS D5 x NNN NN FWA INDRV MPE 20VRS D5 x NNN NN BASIC FWA INDRV MPE 18VRS D5 x NNN NN FWA INDRV MPB 16VRS D5 x xxx xx FWA INDRV MPB 17VRS D5 x xxx xx FWA INDRV MPB 18VRS D5 x xxx xx FWA INDRV MPB 20VRS D5 x xxx xx ADVANCED FWA INDRV MPC 17VRS D5 x xxx xx FWA INDRV MPC 18VRS D5 x xxx xx FWA INDRV MPC 20VRS D5 x xxx xx See also chapter Firmware types o...

Page 24: ...n Notes 05 Changes in comparison to previous edition Revised contents Added technical data inverter power section for HCS01 1E W0013 Analog current input DA option Updated electrical data 04 Changes in comparison to previous edition New contents External braking resistors HLR01 2N 0K06 N100R E 003 NNNN HLR01 2N 0K06 N180R E 007 NNNN SB option Safe Motion Bus EP option Engineering interface SUP E02...

Page 25: ...errite accessory Revised contents Type code HCS01 HLR01 Revised information on fuses for individual and group supply Dimensioning of line cross sections and fuses Revised recommendations for fuses On board connection point X24 X25 Revised data tables of inputs outputs digital analog DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 23 341 Rexroth IndraDrive CsDrive Systems with HCS01 System presentation ...

Page 26: ...ED control panel Third party motors Tightening torques of the connection points EtherCAT display elements Revised contents Type code Technical data Project planning for control voltage supply DC bus coupling Mains filter Dimensioning and selection Standard encoder evaluation Connection diagram for HIPERFACE encoder HAS09 mounting and connection accessories SUP E03 DKC CS BATTRY accessory Control c...

Page 27: ...P 330592 S Synchronous Motors MKE Project Planning Manual MKE GEN2 PRxx EN P 297663 S Synchronous Motors MSK Project Planning Manual MSK PRxx EN P 296289 S Synchronous Motors MSM Data Sheet MSM DAxx EN P 329338 S Synchronous Motors MS2N Project Planning Manual MS2N PRxx EN P 347583 T Synchronous Torque Motors Project Planning Manual MBT PRxx EN P 298798 1 In the document typecodes xx is a placehol...

Page 28: ...iagnostic Messages Reference Book GEN1 DIAG RExx EN P 326738 Integrated Safety Technology as of MPx 1x Application Manual SI3 VRS APxx EN P 332634 Integrated Safety Technology as of MPx 1x Safe Motion Application Manual SI3 SMO VRS APxx EN P 338920 Rexroth IndraMotion MLD Libraries as of MPx 17 Reference Book MLD SYSLIB2 RExx EN P 332627 Rexroth IndraMotion MLD Libraries as of MPx 18 Reference Boo...

Page 29: ...entation and changes you suggest we would be grateful for your feedback Please send your remarks to Address for your feedback Bosch Rexroth AG Dept DC IA EDY1 Buergermeister Dr Nebel Str 2 97816 Lohr Germany E mail dokusupport boschrexroth de DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 27 341 Rexroth IndraDrive CsDrive Systems with HCS01 System presentation ...

Page 30: ...Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 28 341 Rexroth IndraDrive CsDrive Systems with HCS01 ...

Page 31: ...heir original state in other words no structural changes are permitted It is not permitted to decompile software products or alter source codes Do not install damaged or faulty products or put them into operation Make sure that the products have been installed in the manner descri bed in the relevant documentation 2 1 2 Areas of use and application Drive controllers made by Rexroth are designed to...

Page 32: ...des for example operation under water under extreme temperature fluctuations or extremely high maximum temperatures Furthermore Drive controllers may not be used in applications which have not been expressly authorized by Rexroth Please carefully follow the specifications outlined in the general Safety Instructions Components of the Rexroth IndraDrive Cs system are products of Category C3 with res...

Page 33: ...ines and ca bles Installation An installation consists of several devices or systems interconnected for a defined purpose and on a defined site which however are not intended to be placed on the market as a single functional unit Machine A machine is the entirety of interconnected parts or units at least one of which is movable Thus a machine consists of the appropriate machine drive elements as w...

Page 34: ...disabling of safety de vices could result in property damage injury electric shock or even death 3 2 2 Requirements for safe use Read the following instructions before initial commissioning of the compo nents of the electric drive and control system in order to eliminate the risk of injury and or property damage You must follow these safety instructions Rexroth is not liable for damages resulting ...

Page 35: ... the applica tion are met The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective application docu mentation The machine or installation manufacturer is responsible for compliance with the limit values as prescribed in the national regulations The technical data connection and installation conditions of the compo nents are specifie...

Page 36: ...conductor must have been permanently connected to all electric components in accordance with the connection diagram Even for brief measurements or tests operation is only allowed if the equipment grounding conductor has been permanently connected to the points of the components provided for this purpose Before accessing electrical parts with voltage potentials higher than 50 V you must disconnect ...

Page 37: ...tion outer con ductor Minimum cross section equipment grounding conductor Leakage current 3 5 mA 1 equipment grounding conductor 2 equipment grounding conductors 1 5 mm2 16 AWG 10 mm2 8 AWG 2 1 5 mm2 16 AWG 2 5 mm2 14 AWG 2 2 5 mm2 14 AWG 4 mm2 12 AWG 2 4 mm2 12 AWG 6 mm2 10 AWG 2 6 mm2 10 AWG 10 mm2 8 AWG 16 mm2 6 AWG 16 mm2 6 AWG 25 mm2 4 AWG 35 mm2 2 AWG 50 mm2 1 0 AWG 25 mm2 4 AWG 70 mm2 2 0 A...

Page 38: ...ovements will occur The extent of faulty drive movements depends upon the type of control and the state of opera tion Dangerous movements Danger to life risk of injury serious injury or property damage A risk assessment must be prepared for the installation or machine with its specific conditions in which the components of the electric drive and control system are installed As a result of the risk...

Page 39: ...es cannot be avoided check the machine or installation at initial commissioning of the electric drive and control system for possible malfunctions when operating such high fre quency remote control and radio equipment in its possible positions of normal use It might possibly be necessary to perform a special electro magnetic compatibility EMC test 3 3 4 Protection against electromagnetic and magne...

Page 40: ...and mounting Risk of injury by improper handling Injury by crushing shearing cutting hit ting Observe the relevant statutory regulations of accident prevention Use suitable equipment for mounting and transport Avoid jamming and crushing by appropriate measures Always use suitable tools Use special tools if specified Use lifting equipment and tools in the correct manner Use suitable protective equi...

Page 41: ...nes or connections can cause injuries or property damage Risk of injury by improper handling of pressurized lines Do not attempt to disconnect open or cut pressurized lines risk of ex plosion Observe the respective manufacturer s operating instructions Before dismounting lines relieve pressure and empty medium Use suitable protective equipment safety goggles safety shoes safety gloves for example ...

Page 42: ...hich pre cedes the signal words DANGER WARNING and CAUTION is used to alert the reader to personal injury hazards DANGER In case of non compliance with this safety instruction death or serious injury will occur WARNING In case of non compliance with this safety instruction death or serious injury could occur CAUTION In case of non compliance with this safety instruction minor or moderate in jury c...

Page 43: ...nection voltage 3 AC 110 230 V 03 Mains connection voltage 3 AC 200 500 V Design block diagram 1 Mains input with rectifier 2 Braking resistor circuit charging current limitation 3 DC bus capacitances 4 Inverter stage with output to motor 5 DC bus connection Fig 4 1 HCS01 block diagram 4 3 Configuring the drive system 4 3 1 Converter The selection of the appropriate converter depends on Mains type...

Page 44: ...E W0018 A 03 HCS01 1E W0028 A 03 HCS01 1E W0054 A 03 Tab 4 1 Mains Type and Mains Voltage Mains Supply 1 phase1 3 phase 1 AC 110 230 V 3 AC 200 500 V Autotransformer 3 AC 110 230 V HCS01 1E W0003 A 02 HCS01 1E W0006 A 02 HCS01 1E W0009 A 02 HCS01 1E W0013 A 02 HCS01 1E W0018 A 02 HCS01 1E W0005 A 03 HCS01 1E W0008 A 03 HCS01 1E W0018 A 03 HCS01 1E W0028 A 03 HCS01 1E W0054 A 03 Mains supply Indivi...

Page 45: ... Brake Control S4 Safe Motion S5 Safe Motion SB Safe Motion Bus L3 Safe Torque Off L4 Safe Torque Off Safe Brake Control S4 Safe Motion S5 Safe Motion SB Safe Motion Bus IndraMotion MLD S3 MLD S3 MLD M3 Freely configurable digital in puts outputs incl probe Analog input Control panel With programming module function With slot for microSD memory card Optional I O extension digital analog Engineerin...

Page 46: ...d firmware Firmware types Structure of the firmware type des ignation The type designation of the firmware consists of the following type code ele ments Firmware Base package of variant Version Release Lan guage Characteris tic Open loop Closed loop Alternative expansion packages Additive ex pansion packages FWA INDRV MPE 16 VRS D5 x NNN NN 17 18 20 FWA INDRV MPB 16 VRS D5 x xxx xx 17 18 20 FWA IN...

Page 47: ... expansion packages Additive expansion packages NN No additive expansion package MA IndraMotion MLD Advanced for MPB MPC firmware only ML IndraMotion MLD for free programming incl use of technology functions for MPB MPC firmware The Rexroth sales representative in charge will help you with the currently available firmware types For detailed information see the Functional Description of the firmwar...

Page 48: ...onomy performance MPB Single axis firmware with Basic performance MPC Single axis firmware with Advanced performance OL Open loop characteristic CL Closed loop characteristic 1 For Economy firmware MPE there is only one expanded base package available 2 The expanded base package contains the parameter set switching function Tab 4 6 Dependance of functional packages on hardware and firmware var ian...

Page 49: ...SM031B T T MSM031C T T MSM041B T T Optimum combination Allowed combination converter overdimensioned Allowed combination motor overdimensioned T Allowed combination transformer required as operation of MSM motors only allowed with a maximum of 3 AC 230 V Combination not allowed Tab 4 7 Combination of HCS01 converters and MSM motors DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 47 341 Rexroth IndraDri...

Page 50: ...and built in accordance with the present state of the art of standardization In order to comply with the machine directives regarding electromagnetic compatibility EMC a conformity test of the drive system motor with con troller and connection design must be carried out The machine manufactur er must guarantee the test of the drive system and compliance with the direc tives Third Party Motors to b...

Page 51: ...al ap plication is mainly influenced by the following characteristics The output variables of the drive controller which is used feed the trans mission distance Cable parameters depending on cable design and length determine the properties of the transmission distance such as the attenuation The motor design regarding capacitive and inductive properties form the end of the transmission distance As...

Page 52: ...ing measures by measur ing the voltage at the motor terminals Use an isolated measuring device Minimum Inductance of Third Party Motor Depending on the drive controller used the motor has to have a minimum value for inductance The actually available inductance of a motor can be measured directly between two motor terminals by means of an inductance measuring bridge The measurement has to be made f...

Page 53: ...rive controller The insulation class has to correspond at least to that of the motor or has to be sized for higher temperatures The voltage load of the choke depends on the drive controller used Tab 4 9 Data for Possibly Required Choke Temperature Evaluation of Third Party Motor Only operate such motors with incorporated temperature sensor at Rexroth IndraDrive Cs controllers so that the motor can...

Page 54: ...ystem The drive controller can evaluate measuring systems as motor encoder when they are contained in P 0 0074 Encoder type 1 motor encoder For information on absolute and relative measuring systems see section Measuring Systems of firmware documentation Motor Encoder Resolver Notes on Selection Resolvers must first be checked as to whether they are suited as motor en coders To check whether they ...

Page 55: ... forms for entering the required data see firm ware documentation 4 3 5 Cables Motor power cables Selection How to select a suitable motor power cable See documentation Rexroth Connection Cables IndraDrive and IndraDyn R911322949 Allowed cable lengths Allowed cable lengths at ambient temperature Ta_work 40 C according to EN 60 204 HCS01 1E A 02 PWM frequency kHz 4 8 12 16 W0003 40 m 20 m 15 m 5 m ...

Page 56: ...n for Encoder Cables 4 4 Installation conditions 4 4 1 Ambient and operating conditions Lethal electric shock by live parts with more than 50 V WARNING Exclusively operate the device with plugged on connectors even if there haven t been any lines con nected to the connectors and with connected equipment grounding conductor Control cabinet The devices in the Rexroth IndraDrive Cs product range as w...

Page 57: ...the components on page 120 Allowed mounting position Definition of mounting positions see chapter Mounting Positions of Components on page 67 G1 Installation altitude hnom m 1000 Ambient temperature range Ta_work C 0 40 Derating vs Ambient temperature The performance data is reduced by the factor FTa in the ambient temperature range Ta_work_red FTA 1 Ta 40 x fTa Example With an ambient temperature...

Page 58: ...c category IEC 721 3K3 Allowed pollution degree EN 50178 2 Allowed dust steam EN 50178 Tab A 2 Vibration sine Amplitude peak peak at 10 57 Hz 1 mm 0 15 Vibration sine Acceleration at 57 150 Hz 1 g 1 Overvoltage category III according to IEC 60664 1 1 According to EN 60068 2 6 2 Reduced performance data for drive controllers permitted DC bus continuous power permitted mains voltage braking resis to...

Page 59: ... cabinet NOTICE Operating a control cabinet with a fan but without the corresponding filters can damage the devices or cause malfunction Install filters at the air intake opening of the control cabinet so that un clean air cannot get into the control cabinet Service the filters at regular intervals according to the dust loading in the environment Only replace the filters when the fan has been swit...

Page 60: ...control cabinet through possibly existing leaky points leaky cable ducts damaged seals etc 4 4 3 UL ratings This chapter contains Limit values for use within the scope of CSA UL Applied standards CE conformity UL listing Ambient and operating conditions UL ratings Description Symbol Unit HCS01 1E W0003 _ 02 HCS01 1E W0006 _ 02 HCS01 1E W0009 _ 02 HCS01 1E W0013 _ 02 HCS01 1E W0018 _ 02 Short circu...

Page 61: ...only Tab 4 16 HCS Ambient and operating conditions UL ratings 4 4 4 Compatibility with foreign matters All Rexroth controls and drives are developed and tested according to the state of the art technology As it is impossible to follow the continuing development of all materials e g lubricants in machine tools which may interact with the controls and drives it cannot be completely ruled out that an...

Page 62: ...003 5 6 8 9 13 Standard Mounting Left hand or right hand mounting A Minimum mounting clearance B Boring dimensions C Mounting surface Fig 4 5 Dimensional Drawing HCS01 1E W0003 5 6 8 9 13 Left Hand or Right Hand Mounting Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 60 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combining the individual components ...

Page 63: ...E W0018 28 Standard Mounting Left hand or right hand mounting A Minimum mounting clearance B Boring dimensions C Mounting surface Fig 4 7 Dimensional Drawing HCS01 1E W0018 28 Left Hand or Right Hand Mounting DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 61 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combining the individual components ...

Page 64: ... 1E W0054 Standard Mounting Left hand or right hand mounting A Minimum mounting clearance B Boring dimensions C Mounting surface Fig 4 9 Dimensional Drawing HCS01 1E W0054 Left Hand or Right Hand Mounting Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 62 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combining the individual components ...

Page 65: ...ta for mass dimensions sound pressure level insulation Data for mass dimensions sound pressure level insulation Description Symbol Unit HCS01 1E W0005 _ 03 HCS01 1E W0008 _ 03 HCS01 1E W0018 _ 03 HCS01 1E W0028 _ 03 HCS01 1E W0054 _ 03 Mass m kg 0 72 1 70 4 22 Device height1 H mm 215 268 Device depth2 T mm 196 Device width3 B mm 50 70 130 Insulation resistance at 500 V DC Ris Mohm 10 00 Capacitanc...

Page 66: ... continuous current and continuous DC bus power respectively4 PDiss_cont W 8 00 10 00 12 00 20 00 70 00 Minimum distance on the top of the device5 dtop mm 90 Minimum distance on the bottom of the device6 dbot mm 90 Horizontal spacing on the device7 dhor mm 10 0 Temperature increase with mini mum distances dbot dtop PBD ΔT K tbd Last modification 2015 06 12 1 Also depending on firmware and control ...

Page 67: ...continuous DC bus power respectively4 PDiss_cont W 37 00 46 00 80 00 120 00 400 00 Minimum distance on the top of the device5 dtop mm 90 Minimum distance on the bottom of the device6 dbot mm 90 Horizontal spacing on the device7 dhor mm 10 0 Temperature increase with mini mum distances dbot dtop PBD ΔT K tbd tbd Last modification 2014 09 23 1 Also depending on firmware and control section see param...

Page 68: ...ombustible are insensitive to the occurring high temperatures A Air intake B Air outlet C Mounting surface in control cabinet dtop Distance top dbot Distance bottom dhor Distance horizontal Fig 4 10 Air intake and air outlet at device Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 66 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combining the individual components ...

Page 69: ...irectly mounted to mounting surface g Direction of gravitational force G1 Normal mounting position The natural convection supports the forced cooling air current This avoids the generation of pock ets of heat in the component G2 180 to normal mounting position G3 90 to normal mounting position G4 Bottom mounting mounting surface on bottom of control cabi net G5 Top mounting mounting surface at top...

Page 70: ...or overload protection level is set automatical ly while connecting the motor to the drive There is no adjust ment necessary Otherwise refer to the Rexroth firmware docu mentation X31 No standard assignment preset make the assignment by means of firmware documentation see Functional Description index entry Digital inputs outputs X47 1 X47 2 For the ready for operation message of the device the Bb ...

Page 71: ... Rexroth IndraDrive Cs range use a power supply unit or a control power transformer with protection by PELV according to IEC 60204 1 section 6 4 In the scope of CSA UL the data of the control power transformer are limited to Max output voltage 42 4 Vpeak or 30 Vac Max output power 10000 VA Sizing the control voltage supply Determining the power requirements Drive controller power require ments The...

Page 72: ...1E Control section design E S3 ECONOMY B ET BASIC A CC ADVANCED W0003 A 02 x xx EC 8 1 W 12 7 W 13 4 W W0006 A 02 x xx EC W0009 A 02 x xx EC W0013 A 02 x xx EC 9 4 W 14 3 W 15 W W0018 A 02 x xx EC 12 7 W 17 3 W 18 W W0005 A 03 x xx EC 9 4 W 14 3 W 15 W W0008 A 03 x xx EC W0018 A 03 x xx EC 12 7 W 17 3 W 18 W W0028 A 03 x xx EC W0054 A 03 x xx EC 25 7 W 30 3 W 31 W 1 The wild card x xx in this colu...

Page 73: ...neering Port 1 The power requirement of the on board connection point EC HCS01 1E W00xx A 0x x xx EC is already taken into ac count with the power requirement of the basic device see ta ble 1 column Maximum current series 2 The power requirement of the on board connection point ET HCS01 1E W00xx A 0x x ET is already taken into account with the power requirement of the basic device see table 1 colu...

Page 74: ...3 from the 24 V control voltage of a drive controller is calculated with PN3 Pbasic device ΣPoptional connection points ΣPexternal loads Example of calculation Component HCS01 1E W0028 A 03 B ET EC PB L4 NN FW Power requirement Basic device HCS01 1E W0028 A 03 B ET EC 17 3 W Optional connection point PROFIBUS PB 1 1 W Optional connection point STO SBC L4 1 0 W 12 V encoder system of motor 12 V 200...

Page 75: ... The power consumption is indicated as the maximum value of each compo nent and can occur in individual components In drive systems with several components the occurring power consumption under statistical assumptions will be lower than the calculated one Required peak current When the 24 V control voltage unit is switched on the 24 V power supply unit is loaded with the charging current of the ca...

Page 76: ... PLC valve etc 1 Connection to central ground point e g PE earth circuit con nector Fig 4 14 Installing the 24 V supply If you use several 24 V power supply units Output voltages of the 24 V power supply units must be with in the permitted voltage range Interconnect reference conductors 0 V of the individual 24 V power supply units with low impedance Always switch 24 V power supply units on and of...

Page 77: ...additional fusing General information The following designations are used for residual current operated circuit breakers RCCB Residual Current Operated Circuit Breaker RCD Residual Current Operated Device RCM Residual Current Monitoring Device Earth leakage circuit breaker voltage independent Residual current circuit breaker voltage dependent It is only to a limited extent that residual current op...

Page 78: ...ers shielded lines the leakage current in the ground wire is inevitably increased especially when switching on or in the case of mains unbalance Given these operating conditions residual current operated circuit breakers can trigger without an error having occurred The EMC measures are mainly based on capacitive short circuiting of the in terference currents within the drive system Inductive filte...

Page 79: ...ent operated circuit breaker to be used Connect the neutral point of the secondary winding of the isolating transformer to the equipment grounding conductor of the drive system Adjust the ground fault loop impedance to the overcurrent protective device so that the unit can be switched off in the case of failure Before operating enable check the correct function of the overcurrent protec tion devic...

Page 80: ...TN S mains type is the usual mains type in Europe T Direct grounding of a point station ground N Exposed conductive parts directly connected to station ground S Separate neutral conductor and equipment grounding conduc tor in entire mains Fig 4 17 TN S mains type Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 78 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combining the individual components ...

Page 81: ... conductor the PEN conductor Fig 4 18 TN C mains type IT mains type I Insulation of all active parts from ground or connection of one point to ground via an impedance RE T Exposed conductive parts directly grounded independent of grounding of current source station ground Fig 4 19 IT mains type DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 79 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combinin...

Page 82: ...s type the drive system including mains filter and mains choke should be electrically separated from the mains by an isolating transformer In this way the ground fault detection or monitoring can remain effective in the system TT system T Direct grounding of a point station ground T Exposed conductive parts directly grounded independent of grounding of current source station ground Fig 4 20 TT mai...

Page 83: ...grounded with outer conductor HNF01 HNS02 or NFD03 1 mains filters are not suited for opera tion on mains grounded with outer conductor Use isolating trans formers Allowed mains connection voltage see technical data for each device Mains connection type Mains Supply 1 phase1 3 phase 1 AC 110 230 V 3 AC 200 500 V Autotransformer 3 AC 110 230 V HCS01 1E W0003 A 02 HCS01 1E W0006 A 02 HCS01 1E W0009 ...

Page 84: ...ire see also IEC 61800 5 1 and UL 508C For distribution in North America single fuses are required for this type of mains connection see UL 508A In the scope of international and European standards IEC EN not North America it is allowed to use a group fuse instead of the single fuses When selecting the nominal current of the group fuse observe the loop impedance the line length and the line cross ...

Page 85: ...omponents Components marked with gray background color Option al depending on the application the choke is used to re duce current harmonics A Component HCS01 more powerful than component B all components A identical connected to supply mains via balancing chokes connected to other components via DC bus B Component HCS01 less powerful than component A connected to other components via DC bus Bb Bb...

Page 86: ...pe of international and European standards IEC EN not North America it is allowed to use a group fuse instead of the single fuses When selecting the nominal current of the group fuse observe the loop impedance the line length and the line cross section of the mains supply feeder see IEC 60204 1 chapter Appendix A Observe the data for dimensioning line cross sections and fuses see al so IEC 60204 1...

Page 87: ...he mains side phase current The mains side phase current is required for the following cases Selecting mains contactor Determining fuses in the mains connection Determining line cross section Selecting other components in the mains connection mains filter mains choke Operation under rated conditions For data on mains contactor fuses and cross section in operation under rat ed conditions see techni...

Page 88: ...l load TPF Total Power Factor For the value TPF at rated power and TPF10 at 10 of rated power see technical data mains voltage of the component 5 Calculate mains connected load SLN Mains connected load VA PDC DC bus continuous power W TPF Total Power Factor λ 6 Calculate mains side phase current 3 phase 1 phase ILN Mains side phase current in A SLN Mains connected load VA ULN Voltage between phase...

Page 89: ...carrying capacity table row select the value that is immedi ately above the value determined in the first step 5 In Fuse table row read corresponding fuse 6 In Cross section A table row read corresponding required cross section International except for USA Canada installation type B1 Country of use international except for USA Canada Fuse IN A Current carrying ca pacity 0 87 IZ 40 A Cross section ...

Page 90: ...800 315 719 84 3 300 Tab 4 26 Line cross sections and fuses B1 according to EN 60204 1 2006 Table 6 for 150mm and more DIN IEC 60364 5 52 2004 Table B 52 4 International except for USA Canada installation type B2 Country of use international except for USA Canada Fuse IN A Current carrying ca pacity 0 87 IZ 40 A Cross section A mm2 Installation type B2 1 2 3 2 1 6 0 75 4 3 3 0 75 6 5 0 0 75 10 8 5...

Page 91: ... 70 125 327 03 3 95 160 376 36 3 120 160 411 08 3 150 200 465 89 3 185 200 542 62 3 240 250 619 35 3 300 Tab 4 27 Line cross sections and fuses B2 according to EN 60204 1 2006 Table 6 for 150mm and more DIN IEC 60364 5 52 2004 Table B 52 4 International except for USA Canada installation type E Country of use international except for USA Canada Fuse IN A Current carrying ca pacity 0 87 IZ 40 A Cro...

Page 92: ...25 374 10 240 500 432 39 300 160 272 83 2 x 70 200 331 30 2 x 95 250 384 19 2 x 120 250 444 05 2 x 150 315 506 69 2 x 185 400 598 56 2 x 240 400 691 82 2 x 300 160 358 09 3 x 70 200 434 83 3 x 95 200 504 25 3 x 120 250 582 81 3 x 150 250 665 03 3 x 185 315 785 61 3 x 240 400 908 02 3 x 300 Tab 4 28 Line cross sections and fuses E according to EN 60204 1 2006 Ta ble 6 for 150mm and more DIN IEC 603...

Page 93: ...00 3 AWG 125 115 2 AWG 150 130 1 AWG 175 150 1 0 AWG 200 175 2 0 AWG 225 200 3 0 AWG 250 230 4 0 AWG 300 255 250 kcmil 300 285 300 kcmil 350 310 350 kcmil 350 335 400 kcmil 400 380 500 kcmil 450 420 600 kcmil 600 460 700 kcmil 600 475 750 kcmil 600 490 800 kcmil 600 520 900 kcmil 800 545 1000 kcmil 800 590 1250 kcmil 800 625 1500 kcmil 800 650 1750 kcmil DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG ...

Page 94: ...700 kcmil 600 950 2 750 kcmil 600 980 2 800 kcmil 800 1040 2 900 kcmil 800 1090 2 1000 kcmil 200 450 3 1 0 AWG 225 525 3 2 0 AWG 250 600 3 3 0 AWG 300 690 3 4 0 AWG 300 765 3 250 kcmil 350 855 3 300 kcmil 350 930 3 350 kcmil 400 1005 3 400 kcmil 450 1140 3 500 kcmil 200 600 4 1 0 AWG 225 700 4 2 0 AWG 250 800 4 3 0 AWG 300 920 4 4 0 AWG 300 1020 4 250 kcmil 350 1140 4 300 kcmil 350 1240 4 350 kcmi...

Page 95: ... core line routed in cable duct E in accordance with EN 60204 1 e g multi core line routed on open cable tray In accordance with NFPA 79 external wiring UL508A internal wiring NEC NFPA 70 1 cable with 3 conductors 1 neutral conductor and 1 equip ment grounding conductor Routed in pipe on the wall Internal wiring Routing inside of control cabinet or inside of devi ces External wiring Routing outsid...

Page 96: ...8 0 94 1 00 1 1 1 18 1 32 1 52 Tab 4 30 Ambient temperature correction factor in accordance with EN 60204 1 2006 and NFPA 79 2007 Correction factor for bundling lines installation methods B2 and E and cir cuits installation method B11 Number of lines 1 2 3 4 5 Correction factor according to EN 60204 1 2006 table D 2 1 1 25 1 43 1 54 1 67 Correction factor according to NFPA 79 2007 table 12 5 5 b 1...

Page 97: ...ormer 4 Applications for autotransformers With HCS01 components there are two applications that require autotrans formers 1 HCS01 1E W00xx A 02 components are used With a mains voltage of 3 AC 400 V the voltage must be adjusted via an autotransformer to use HCS01 1E W00xx A 02 components with an input voltage range of 3 AC 110 230 V 2 An MSM motor is used in conjunction with an HCS01 1E W00xx A 03...

Page 98: ...rrent in a separate chapter see chapter Calculating the mains side phase current on page 85 For selecting the components calculate the effective rms val ue Check or determine the maximum occurring ambient temperature Se lect a mains filter with a higher nominal current if the ambient tempera ture is above 45 C 5 The nominal current of the selected mains fuse should not exceed the nominal current o...

Page 99: ...capacitance Motor cable per device nF Motor cable length m 4 40 40 8 24 20 12 20 15 16 12 5 Tab 4 34 Clock frequency leakage capacitance motor cable length HCS01 1E W0054 Clock frequency kHz Maximum leakage capacitance Motor cable per device nF Motor cable length m 4 85 75 8 43 38 12 30 25 Tab 4 35 Clock frequency leakage capacitance motor cable length Select the appropriate mains connection suppl...

Page 100: ...kage capacitance motor ca ble nF Mains filters EMC limit value class to be ach ieved IEC EN 61800 3 4 8 100 NFD03 1 1 C2 12 16 30 1 Leakage capacitances 100 nF overload the mains filter over temperature saturation phenomenon Tab 4 36 Mains filter 3 400 V HCS01 1E W0005 W0008 W0018 A 03 W00028 W00054 Nominal voltage of mains filter 3 400 500 V Clock frequency kHz Leakage capacitance motor ca ble nF...

Page 101: ... 20 FN3280H Schaffner C2 1 This combination allows 3 phase and 1 phase HCS01 devices to be interconnected at one common 4 phase mains filter Thereby the nominal current of the mains filter and the maxi mum allowed leakage capacitance are taken into account Tab 4 39 Mains filter 3 400 V N Limit Value Classes IEC EN 61800 3 CISPR 11 EN55011 Explanation Curves of limit value character istic Category ...

Page 102: ...up 1 Limit value in residential area or at facilities at low voltage mains supply ing buildings in residential areas To be complied with for applications with restricted distribution 3 1 3 2 Category C1 1st environ ment Unrestricted distribution Class B Group 1 Limit value in residential areas to be complied with for applications with unrestricted distribution 4 1 4 2 Tab 4 40 Limit Value Classes ...

Page 103: ...ironment class A group 1 3 2 Category C2 First environment restricted distribution AV first environment even if source of interference in second environ ment class A group 1 4 1 Category C1 First environment unrestricted distribution QSP first environment even if source of interference in second en vironment class B group 1 4 2 Category C1 First environment unrestricted distribution AV first envir...

Page 104: ...ave the induc tance of the mains choke available Some mains chokes are assigned to certain drive controllers see technical data of the drive controller Data for mains voltage supply Assigned type of mains choke Dimensioning the mains contactor Required data Nominal current ILN of the drive controller see chapter 7 3 2 Mains voltage on page 233 Number of drive controllers connected to the mains con...

Page 105: ... Not allowed 1 We are currently checking whether it is possible to combine HNF mains filters and several HCS01 components 2 Only possible with W0028 and W0054 components 3 DST Autotransformer 4 DLT Isolating transformer Tab 4 41 Additional Components in the Mains Connection of HCS01 Compo nents DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 103 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combini...

Page 106: ... of control unit F1 Fuse of power supply F3 Fuse of 24V power supply unit K1 External mains contactor S1 Emergency stop S2 Axis end position S4 Power Off S5 Power On Fig 4 29 Control Circuit for the Mains Connection Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 104 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combining the individual components ...

Page 107: ...The devices in the group can be of different types For the project planning of the application observe that the supplying devices can only make available the DC bus power for other devices which they do not consume themselves With central supply one HCS01 device charges the DC bus and the other devices are supplied using DC bus coupling Features The supplying device has to be of the HCS01 1E W0028...

Page 108: ...ing devices have to be connected in series This guarantees that the mains contactor is switched off in the case of error in a device The DC bus coupling lines should not be run outside of the con trol cabinet The maximum line length of a DC bus coupling is 2 m See also description of the connection point X77 for more in formation chapter X77 L L DC Bus Connection on page 151 Balancing To distribut...

Page 109: ...pplying devices HCS01 1E W0028 HCS01 1E W0054 DC bus continuous power of the supplying devices reduced by parallel operation Energy compensation between the devices is possible the DC bus ca pacitors of the devices are connected in parallel Balancing of the integrated braking resistors exists equal load of all braking resistors integrated in the devices Balancing chokes or balancing resistors requ...

Page 110: ...ces Balancing chokes or balancing resistors required in supply feeder It is possible to connect DC bus capacitor units Wiring effort for the mains connection of all devices relatively big DC bus short circuit functionality has to be realized externally if required Implementing the DC bus coupling Maximum number of devices A maximum of 8 devices can be coupled at a common DC bus The maximum number ...

Page 111: ... voltage Number of supplied devices If the sum of power reserves Preserve of the supplying devices is greater then the continuous power of X77 PX77_cont the maximum number of supplied de vices results from PX77_cont minus the respective DC bus continuous power of the individual devices at average speed If the sum of power reserves Preserve of the supplying devices is smaller than the continuous po...

Page 112: ...wer consumption of a de vice the nearer to the supplying devices it has to be arranged Example 1 2 HCS01 1E W0028 supplying devices 3 4 5 HCS01 1E W0018 supplied devices Fig 4 35 Looping through On the left the two supplying HCS01 1E W0028 devices have been ar ranged to their right the three supplied HCS01 1E W0018 devices The DC bus connector of the second device from the left 2 limits the possi ...

Page 113: ...n assigned to this drive controller Use the mains choke HNL01 1E 1000 N0012 A 500 NNNN Connection The maximum allowed capacitance of a DC bus capacitor unit depends on the device which assumes the DC bus supply Even if several devices supply the DC bus the specific external DC bus capacitance of the biggest supplying device may only be connected once for the entire DC bus group For the maximum all...

Page 114: ...ng through the module bus Parameterization For all devices only supplied via the DC bus DC bus inverter mode has to be set as the source of power supply in the parameter P 0 0860 Convert er configuration For detailed information see the documentation of the firmware used Parameter description P 0 0860 Converter configuration P 0 0118 Power supply configuration Functional description Power supply B...

Page 115: ... NOTICE Include the Bb relay contact in the switch off chain of the mains contactor so that the power supply is interrupted in the case of error DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 113 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combining the individual components ...

Page 116: ...l com database Under UL File Number enter the file number or under Company Name en ter the company name Bosch Rexroth AG UL standard UL 508C CSA standard Canadian National Standard C22 2 No 14 10 Company Name BOSCH REXROTH ELECTRIC DRIVES CON TROLS GMBH Category Name Power Conversion Equipment File numbers Rexroth IndraDrive Cs components E134201 E227957 Tab 4 45 C UL listing UL ratings When using...

Page 117: ...k is a compulsory certification of safety and quality for certain products mentioned in the product catalog First Catalogue of Products Sub ject to Compulsory Certification and in the CNCA document Application Scope for Compulsory Certification of Products acc first Catalogue and put in circulation in China This compulsory certification has existed since 2003 CNCA is the Chinese authority responsi...

Page 118: ...umentation certifi cation is currently not required so they are not CCC certified Negative certifi cations will not be issued Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 116 341 Rexroth IndraDrive CsDrive Systems with HCS01 Combining the individual components ...

Page 119: ... standards 5 1 2 Customer testing Risk of damage to the installed Rexroth com ponents by customer side testing of the ma chine or installation NOTICE Before conducting voltage testing or insulation resistance testing for an instal lation or machine in which these components are used Disconnect all connections to the Rexroth components or disconnect the plug in connections to protect the electronic...

Page 120: ...1 Device type 2 Part number 3 Production week 11W36 for example means year 2011 week 36 4 Factory identifier 5 Bar code 6 Serial number 7 Hardware index 8 Country of manufacture 9 Identification Fig 5 2 Type plate device Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 118 341 Rexroth IndraDrive CsDrive Systems with HCS01 Condition as supplied identification transport and storage ...

Page 121: ... separately Drive controller HCS01 DC bus connector X77 DC bus connection for HCS01 1E W00xx x 03 devices Order code RLS0778 K06 Mounting and connection accessories HAS09 microSD memory card PFM04 1 512 FW with firmware PFM04 1 512 NW without firmware Connectors X3 X5 X6 X13 X31 X32 X47 Other accessories such as SUP E0x MSM BATTERYBOX Touch guard X77 DC bus connection for HCS01 1E W00xx x 03 devic...

Page 122: ...storage When storing the following components for a longer period of time run them once a year for at least 1 hour Converters and supply units Operated with mains voltage ULN Inverters and DC bus capacitor units Operated with DC bus voltage UDC Ambient and operating conditions for storage Description Symbol Unit Value Temperature range Ta_store C 20 55 Relative humidity 5 95 Absolute humidity g m3...

Page 123: ...clearance between control cabinet wall and control cabinet front is not sufficient for back side mounting NOTICE Risk of damage by high temperatures At the back of the HCS01 devices there are braking resistors which can become very hot during operation When arranging the devices in the control cabinet make sure there aren t any heat sensitive materials close to the braking resistors In the case of...

Page 124: ...M6 20 contained in the supplied accesso ry HAS09 Mounting the drive controller 1 Fix screws to the back panel of the control cabinet 2 Attach the drive controller to the screws 3 Fix the screws with 6 Nm Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 122 341 Rexroth IndraDrive CsDrive Systems with HCS01 Mounting and installation ...

Page 125: ...otor overload protection level is set automatical ly while connecting the motor to the drive There is no adjust ment necessary Otherwise refer to the Rexroth firmware docu mentation X31 No standard assignment preset make the assignment by means of firmware documentation see Functional Description index entry Digital inputs outputs X47 1 X47 2 For the ready for operation message of the device the B...

Page 126: ...r C Control line shield connection D Motor cable shield connection E Control panel X3 Mains connection X4 Motor encoder X5 Motor connection X6 Motor temperature monitoring motor holding brake X8 Encoder evaluation EC option encoder emulation EM op tion X9 Integrated external braking resistor X13 24V supply control voltage Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 124 341 Rexroth IndraDrive CsDriv...

Page 127: ...odule bus module bus at HCS01 1E W00xx x 03 devices only X49 Safety technology L3 option Safe Torque Off L4 option Safe Torque Off Safe Brake Control X61 CANopen communication CN option X77 DC bus connection at HCS01 1E W00xx x 03 devices only DC bus connector optionally available if the DC bus connec tor is not used the DC bus connection must be covered with the supplied touch guard Fig 6 3 HCS01...

Page 128: ...4 Motor encoder X5 Motor connection X6 Motor temperature monitoring motor holding brake X8 Encoder evaluation EC option encoder emulation EM op tion X9 Integrated external braking resistor X13 24V supply control voltage X22 X23 Multi Ethernet communication ET option X24 X25 sercos III master X26 Engineering interface X30 PROFIBUS communication PB option Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 1...

Page 129: ... shock WARNING Before switching on and before commissioning ground or connect the components of the electric drive and control system to the equipment grounding conductor at the grounding points Connect the equipment grounding conductor of the components of the electric drive and control system permanently to the main power supply at all times The leakage current is greater than 3 5 mA Establish a...

Page 130: ...ctors of the mains supply feeder Additionally mount the housing to a bare metal mounting plate Connect the mounting plate too with at least the same cross section to the equipment grounding conductor system in the con trol cabinet Installation Connect the equipment grounding conductor of the mains or motor cable via thread M5 to the housing of the device identification mark tightening tor que 5 Nm...

Page 131: ...the connection point X3 see chapter Connection of Equip ment Grounding Conductor on page 127 Measure the necessary cross section of the connection cables accord ing to the determined phase current ILN and the mains fuse Single phase mains connection outer conductor and neutral conductor Connection to X3 can be made via L1 L2 or L3 Risk of damage to the device NOTICE Provide strain relief for the t...

Page 132: ...ULN_nom Tab 6 1 Function pin assignment properties X3 mains connection HCS01 1E W0018 x 02 W0018 x 03 W0028 x 03 View Identifica tion Function L1 Connection to supply mains L1 L2 Connection to supply mains L2 L3 Connection to supply mains L3 Terminal block Unit Min Max Connection cable Stranded wire mm2 0 25 6 0 AWG 24 10 Stripped length mm 10 Tightening torque Nm 0 5 0 8 Occurring current load an...

Page 133: ...anded wire mm2 0 75 10 0 AWG 18 8 Stripped length mm 14 Tightening torque Nm 1 5 1 7 Occurring current load and minimum required connection cross section See technical data of device used ILN and ALN Occurring voltage load See technical data of device used ULN or ULN_nom Tab 6 3 Function pin assignment properties DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 131 341 Rexroth IndraDrive CsDrive Systems...

Page 134: ...er MS2N motor encoder MSK motor encoder 1Vpp sin cos encoder HIPERFACE 1Vpp sin cos encoder EnDat 2 1 EnDat 2 2 1Vpp sin cos encoder with reference track 5V TTL square wave encoder with reference track SSI Combined encoder for SSI combination of SSI and 1Vpp sin cos encod er Resolver resolvers are not supported if optional Safe Motion safety technology is also in use Hall sensor box SHL02 1 Digita...

Page 135: ...ata Data transmission negative A TTL Track A TTL negative 9 R Reference track positive 10 R Reference track negative 11 12V Encoder supply 12V 12 5V Encoder supply 5V 13 EncCLK Clock positive B TTL Track B TTL positive 14 EncCLK Clock negative B TTL Track B TTL negative 15 Sense Return of reference potential Sense line VCC_Resolver Resolver supply Connector housing Overall shield Tab 6 5 Pin Assig...

Page 136: ...ted directly to the device and not via the connection point X5 The indicated connection cross sections are the cross sections which can be connected Dimension the required cross section of the connection lines ac cording to the occurring current load For optimum shield contact of the motor power cable use the supplied accessory HAS09 For the connection between drive controller and motor use our re...

Page 137: ...load and minimum required connection cross section A See technical data of device used Iout Occurring voltage load V See technical data of device used Uout Short circuit protection A1 A2 A3 against each other and each of them against ground Connection of equipment grounding conductor Via connection point of equipment grounding conductor at device see index entry Connection Equipment ground ing con...

Page 138: ... 0 5 0 8 Occurring current load and minimum required connection cross section A See technical data of device used Iout Occurring voltage load V See technical data of device used Uout Short circuit protection A1 A2 A3 against each other and each of them against ground Connection of equipment grounding conductor Via connection point of equipment grounding conductor at device Tab 6 7 Function Pin Ass...

Page 139: ...curring current load and minimum required connection cross section A See technical data of device used Iout Occurring voltage load V See technical data of device used Uout Short circuit protection A1 A2 A3 against each other and each of them against ground Connection of equipment grounding conductor Via connection point of equipment grounding conductor at device Tab 6 8 Function Pin Assignment Pro...

Page 140: ...ssibly high e g because of a flashover of the motor winding voltage this voltage may come into contact with the housing Ensure that the temperature sensor of the con nected motor has a double isolation against the motor winding Excessive voltage at the input of the motor temperature evaluation may cause damage to the device NOTICE The voltage allowed at the input of the motor temperature evaluatio...

Page 141: ...pply voltage of the motor holding brake If Ubr max 24 V 5 25 2 V this results in Rbr min 20 16 Ω applicable to all operating and ambient conditions Motor holding brake installation instructions Make sure the power supply for the motor holding brake at the motor is suffi cient You have to take into account that voltage drops on the supply line Use connection lines with the highest possible cross se...

Page 142: ...ion diagram Fig 6 6 Connection of motor temperature monitoring and motor holding brake Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 140 341 Rexroth IndraDrive CsDrive Systems with HCS01 Mounting and installation ...

Page 143: ... DC bus Parameterize the external braking resistor by means of the firm ware to protect the drive controller and the braking resistor against overload P 0 0860 Converter configuration P 0 0858 Data of external braking resistor Connection HCS01 1E W0003 W0028 Fig 6 7 Connecting the braking resistor HCS01 1E W0003 W0028 Connection HCS01 1E W0054 Fig 6 8 Connecting the braking resistor HCS01 1E W0054...

Page 144: ... Outside of the control cabinet run the con nection lines of an HLR braking resistor in a metal pipe with a wall thickness of at least 1 mm Do not touch hot housing surfaces Mount the HLR braking resistor on a tem perature resistant mounting surface Provide a sufficient distance between the HLR braking resistor and heat sensitive materials Make sure the cooling air supply is unrestricted Take care...

Page 145: ... 0V 24V to 24V A 10 Polarity reversal protection Within the allowed voltage range by internal protective diode Insulation monitoring Possible Tab 6 10 Function Pin Assignment Properties Notes on Installation Requirements on the connection to the 24V supply Minimum cross section 1 mm2 Maximum allowed inductance 100 µH 2 twisted single strands 75 m long Parallel line routing where possible Depending...

Page 146: ...et ET With the Multi Ethernet communication module ET drive controllers can be integrated in different Ethernet field bus systems e g sercos III EtherCAT EtherNet IP or PROFINET IO Tab 6 11 X24 P2 X25 P1 communication Description The connection point complies with IEEE 802 3 standard Tab 6 12 Connection point P1 P2 P1 means Port 1 and P2 means Port 2 Thereby the error counter of the firmware can b...

Page 147: ...s 100 m at maximum to connect the drive system to the high er level control unit or remote communication nodes Minimum bending radius 48 75 mm if laid flexibly 32 50 mm if laid permanently Order code for a 30 m long cable RKB0011 030 0 RKB0013 Short cables to connect devices arranged side by side in the control cabi net 4 lengths available 0 19 m 0 25 m 0 35 m 0 55 m Order code for a 0 55 m long c...

Page 148: ...de cables which can be ordered RKB0011 Long cables 100 m at maximum to connect the drive system to the high er level control unit or remote communication nodes Minimum bending radius 48 75 mm if laid flexibly 32 50 mm if laid permanently Order code for a 30 m long cable RKB0011 030 0 RKB0013 Short cables to connect devices arranged side by side in the control cabi net 4 lengths available 0 19 m 0 ...

Page 149: ... 2 1 5 AWG 24 16 Stripped length mm 10 Input current A 0 01 Input voltage V 24 Output current I O_8 A 0 5 1 Digital Inputs Type B Probe 2 Digital Inputs Type A Standard Tab 6 15 Function Pin Assignment Properties The reference potential for the digital inputs and the digital input output is applied to X13 1 and X13 2 Technical Data chapter Digital Inputs Type A Standard on page 218 chapter Digital...

Page 150: ...0 2 1 5 AWG 24 16 Stripped length mm 10 Shielding Only use shielded cables for cable lengths 30 m Tab 6 16 Function pin assignment properties Shield connection chapter Analog inputs outputs Shield connection on page 157 Technical data chapter 7 1 8 Analog Voltage Input on page 226 Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 148 341 Rexroth IndraDrive CsDrive Systems with HCS01 Mounting and installa...

Page 151: ...tact rating V 30 A 0 01 1 1 Wire the Bb relay contact in the control circuit for mains con nection see chapter Control Circuit for the Mains Connection on page 104 When the contact opens the mains contactor must interrupt the power supply Tab 6 17 Function pin assignment properties Technical data chapter Relay Contact Type 2 on page 229 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 149 341 Rexroth In...

Page 152: ...cts X47 of all supplying devices in series 2 The pins 3 4 and 5 6 are jumpered This allows the module bus to be looped through from one device to the next Tab 6 18 Function pin assignment properties Module bus connections Maximum allowed length of an individual module bus connection 10 m In the following cases use shielded cables for the module bus connection The length of an individual module bus...

Page 153: ...if you want to use the DC bus connec tor at the drive controller If you do not use the DC bus connector any longer you have to cover the DC bus connection with the supplied touch guard Observe the information on DC bus coupling see chapter 4 6 4 DC bus coupling on page 105 Function Pin Assignment The DC bus connection connects several HCS01 1E W00xx x 03 to each other one drive controller to a DC ...

Page 154: ...d simultaneously lever out the touch guard 2 Pull off touch guard 3 Store the touch guard in a place where you can find it later on If you want to operate the device without DC bus connector you have to plug the touch guard on connection point X77 again Fig 6 9 How to Remove the Touch Guard Fig 6 10 DC bus connector at device Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 152 341 Rexroth IndraDrive Cs...

Page 155: ... to L L to L A 31 Tab 6 19 Function Pin Assignment Properties Notes on Installation To wire the DC bus use the shortest possible flexible twisted wires When the DC buses of several devices have been coupled the lines mustn t be run outside of the control cabinet Risk of damage by reversing the polarity of the DC bus connections L and L NOTICE Make sure the polarity is correct Length of twisted wir...

Page 156: ...C buses of several devices Direct connection Indirect connection via connecting bars Tab 6 21 DC Bus Connection Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 154 341 Rexroth IndraDrive CsDrive Systems with HCS01 Mounting and installation ...

Page 157: ...tion Fig 6 11 Shield connection The shield connection should not be used for strain relief of the cables Mount a separate strain relief near the drive controller Motor cable shield connection 1 Plates 2 Shield of motor cable A Screw M5 12 or M5 16 tightening torque 5 Nm B Screw M5 30 tightening torque 1 Nm Fig 6 12 Motor cable shield connection DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 155 341 Re...

Page 158: ...e shield connection Fig 6 13 Shield Connection of Shielded Lines at the Top of the Device Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 156 341 Rexroth IndraDrive CsDrive Systems with HCS01 Mounting and installation ...

Page 159: ...onnection cable Fig 6 14 Shield connection for analog inputs Analog output A Analog output of drive controller B External device only connect the inner shield of the connection cable to the external device if GND has not been connected to ground in the external device IS Inner shield of the connection cable OS Overall shield of the connection cable Fig 6 15 Shield connection for analog outputs DOK...

Page 160: ... bare metal back panel of the drive controller in conductive form to the mounting surface in the control cabinet To do this use the supplied mounting screws 2 Connect the mounting surface of the control cabinet in conductive form to the equipment grounding system 3 For the ground connection observe the maximum allowed ground re sistance Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 158 341 Rexroth In...

Page 161: ...anded wire mm2 0 25 0 5 Tab 6 22 Function Pin Assignment Properties Emulated Encoder Systems Incremental encoder SSI encoder Incremental encoder with signal level converter Pin Assignment Connec tion Signal Level Input Output Function Incremen tal encod er SSI en coder Incremen tal encod er with signal lev el convert er 1 n c Not assigned 2 UL 5 30 V In Power supply for output driver 3 SSI_CLK RS4...

Page 162: ...ive 10 0 V 0 V Reference potential inner shield 11 ULA0 RS422 Out Reference track negative SSI_Data RS422 Out SSI data negative 12 UA1 RS422 Out Track A1 positive 13 UA1 RS422 Out Track A1 negative 14 UA2 RS422 Out Track A2 positive 15 UA2 RS422 Out Track A2 negative Connector housing Overall shield Tab 6 23 Pin Assignment Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 160 341 Rexroth IndraDrive CsDri...

Page 163: ...nt Technical data chapter X24 P2 X25 P1 communication on page 144 X26 Engineering interface See chapter X26 Engineering interface on page 146 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 161 341 Rexroth IndraDrive CsDrive Systems with HCS01 Mounting and installation ...

Page 164: ...ive transmit data negative 9 0V 0 V Tab 6 26 Signal Assignment Shield Connection Via D sub mounting screws and metallized connector housing Compatibility of the Interface According to DIN EN 50 170 Recommended Cable Type According to DIN EN 50 170 2 cable type A Bus Connectors The PROFIBUS connectors each have a connectable terminating resistor The terminating resistor must always be active at bot...

Page 165: ...above Insert both cores into screw terminal block Do not interchange the cores for A and B Press cable sheath between both clamps Screw on both cores in screw terminals 1 Switch position for first slave and last slave in PROFIBUS DP 2 Cable shield must have direct contact to metal Fig 6 18 Bus Connection for First and Last Slave Bus Connector With 9 pin D Sub Female Connector INS0541 DOK INDRV HCS...

Page 166: ...t and Last Slave Without 9 pin D Sub Fe male Connector INS0540 1 Terminating resistor is off 2 Cable shield must have direct contact to metal Fig 6 21 Bus Connection for all Other Slaves Without 9 pin D Sub Female Connector INS0540 Connect the drive controller to a control unit using a shielded two wire line in accordance with DIN 19245 Part 1 Signal Specification chapter 7 1 4 PB PROFIBUS on page...

Page 167: ...O_6 1 7 24V_Ext Power supply Uext 2 7 O_7 1 8 0V_Ext 2 8 O_8 Spring terminal con nector Unit Min Max Connection cable Stranded wire mm2 0 2 1 5 AWG 24 16 Stripped length mm 10 Tab 6 27 Function Pin Assignment Properties Technical Data chapter Digital Inputs Type A Standard on page 218 chapter Digital Outputs Standard on page 222 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 165 341 Rexroth IndraDrive...

Page 168: ...ND_AnaEA GND reference 2 5 IA_1 Spring terminal con nector Unit min max Connection cable Stranded wire mm2 0 2 1 5 AWG 24 16 Stripped length mm 10 Tab 6 28 Function pin assignment properties Shield connection chapter Analog inputs outputs Shield connection on page 157 Technical data chapter 7 1 8 Analog Voltage Input on page 226 chapter 7 1 9 Analog current input on page 227 chapter 7 1 10 Analog ...

Page 169: ... connector Unit Min Max Connection cable Stranded wire mm2 1 1 5 AWG 16 16 Stripped length mm 10 Polarity reversal protection for power supply Available Overvoltage protection Available Tab 6 29 X41 Safe Motion safety technology Technical data chapter Digital inputs safety technology S options on page 221 chapter Digital outputs safety technology S options on page 224 DOK INDRV HCS01 PR05 EN P Bos...

Page 170: ...t devices arranged side by side in the control cabinet Available lengths 0 19 m 0 25 m 0 35 m 0 55 m Minimum bending radius 4xD 4x6 mm 24 mm Order code for a 0 55 m long cable RKB0051 00 55 RKB0052 Long cables to connect remote communication nodes also outside of the con trol cabinet Available lengths 1 m 2 m 5 m Minimum bending radius 8xD 8x6 mm 48 mm Order code for a 5 m long cable RKB0052 005 0...

Page 171: ... connector Unit min max Connection cable Stranded wire mm2 1 1 5 AWG 16 16 Stripped length mm 8 Tab 6 31 X49 optional safety technology Safe Torque Off Technical data chapter Digital inputs safety technology L options on page 220 chapter Digital Outputs Safety Technology L Options on page 223 When the dynamization outputs do not work check the power supply connection The polarity might possibly ha...

Page 172: ...nal Function 1 n c 2 CAN L Negated CAN signal Dominant Low 3 CAN GND Reference potential of CAN signals 4 n c 5 Drain Shield Shield connection 6 GND Reference potential of device 7 CAN H Positive CAN signal Dominant High 8 n c 9 n c Tab 6 33 Signal Assignment Technical Data chapter 7 1 5 CN CANopen on page 215 Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 170 341 Rexroth IndraDrive CsDrive Systems wi...

Page 173: ... plates Separate the incoming and outgoing cables for the radio interference suppression filter Interference suppression elements Equip the following components in the control cabinet with interference sup pression combinations Contactors Relays Solenoid valves Electromechanical operating hours counters Connect these combinations directly at each coil Twisted wires Twist unshielded wires belonging...

Page 174: ...ts in the control cabinet See section Control cabinet de sign according to interference areas exemplary arrangements page 173 There are three areas 1 Control cabinet area free from interference area A This includes Supply feeder input terminals fuse main switch mains side of mains filter for drives and corresponding connecting lines Control voltage or auxiliary voltage connection with power supply...

Page 175: ... sec tion Make sure connection points have good contact Control cabinet design according to interference areas exemplary ar rangements Do not operate any additional loads at the mains filter Do not run any other loads at the connection from the mains filter output to the mains connection of the supply unit Use separate mains filters for e g motor fans and power supply units DOK INDRV HCS01 PR05 EN...

Page 176: ...DR1 Mains choke E1 E5 Equipment grounding conductor of the components Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 174 341 Rexroth IndraDrive CsDrive Systems with HCS01 Mounting and installation ...

Page 177: ...tion Maintain the recommended distance of at least 200 mm distances d1 and d3 in the figure Between supply feeder or lines between filter and control cabinet exit point in area A and the lines in area B and C If this is not possible there are two alternatives 1 Install shielded lines and connect the shield at several points at least at the beginning and end of the line to the mounting plate or the...

Page 178: ... as follows Only use shielded lines in area A Connect shields to the mounting plate at the beginning and end of the line with clips The same procedure may be required for cables longer than 2 m between the point of power supply connection for the control cabinet and the filter in the control cabinet Mains filters for AC drives Ideally mount the mains filter on the parting line between areas A and ...

Page 179: ... A transmitting antenna effect Design and installation in area C control cabinet area highly prone to interference Area C mainly concerns the motor power cables especially at the connection point at the drive controller Influence of the motor power cable The longer the motor power cable the greater its leakage capacitance To comply with a certain EMC limit value the allowed leakage capacitance of ...

Page 180: ...ct Tab 6 34 Routing converter cables Ground connections Housing and mounting plate It is possible to avoid the emission of interference with proper ground connec tions because interference is discharged to ground through the most direct route Ground connections of the metal housings for EMC critical components such as filters devices of the drive system connection points of the cable shields devic...

Page 181: ...nected spare cables at both ends at least in or der to avoid an antenna effect Do not use more line than is necessary Run cables as close to grounded metal surfaces as possible reference potential Closed grounded cable ducts or metal pipes are ideal but are only needed to meet strict requirements sensitive instrument leads Avoid suspended lines or lines routed along synthetic carriers because they...

Page 182: ... By arranging free wheeling diodes for DC operation By arranging commercial RC interference suppression elements based on contactor type directly on the inductance for AC operation Only the interference suppression element arranged immediately on the in ductance serves this purpose Otherwise the emitted noise level is too high and can affect the function of the electronic system and the drive Bosc...

Page 183: ... 1 Digital Hall sensor in conjunction with Hall sensor adapter box SHL03 1 Encoder type IndraDyn S MSM motors 5V supply voltage Properties Encoder systems of the MSM motors are digital encoder systems that can be evaluated in absolute form The optionally available battery box SUP E0x MSM BATTERYBOX facili tates the multi turn functionality Connection diagram 1 Line cross section 0 5 mm observe all...

Page 184: ...tion of the power supply See chapter 5 V power supply on page 195 Cable length 40 m at most Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 182 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 185: ...ction 0 5 mm observe allowed encoder cable length 2 Line cross section 0 14 mm Fig 7 2 MSK QSK encoder interface connection diagram for S1 M1 S2 M2 S5 M5 encoder systems For direct connection to the encoder system use our RKG4200 cable Power supply 12 V the voltage is made available via the EC interface Technical specification of the power supply See chapter 12 V power supply on page 195 Cable len...

Page 186: ...This supply voltage is made available via the EC interface Technical specification of the power supply See chapter 12 V power supply on page 195 Please observe that the third party encoder used has to be suited for the voltage available at the EC interface as the encoder supply voltage Cable length The maximum possible cable length depends on several factors See chapter Encoder cable length on pag...

Page 187: ... is made available via the EC interface Technical specification of the power supply See chapter 5 V power supply on page 195 Cable Length 75 m at most when using the Sense function When you do not use the Sense function the maximum cable length is re duced see chapter Encoder cable length on page 197 Technical properties Use the Sense function to ensure stable power supply at the encoder De script...

Page 188: ...ade available via the EC interface Technical specification of the power supply See chapter 5 V power supply on page 195 Cable Length 75 m at most when using the Sense function When you do not use the Sense function the maximum cable length is re duced see chapter Encoder cable length on page 197 Technical properties Use the Sense function to ensure stable power supply at the encoder De scription o...

Page 189: ...ystem connection diagram Power supply 12 V the voltage is made available via the EC interface Technical specification of the power supply See chapter 12 V power supply on page 195 Cable length The maximum allowed cable length depends on several factors See chapter Encoder cable length on page 197 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 187 341 Rexroth IndraDrive CsDrive Systems with HCS01 Techn...

Page 190: ...ication of the power supply See chapter 5 V power supply on page 195 Cable Length 75 m at most when using the Sense function When you do not use the Sense function the maximum cable length is re duced see chapter Encoder cable length on page 197 Technical properties Use the Sense function to ensure stable power supply at the encoder De scription of the Sense function See chapter 5 V power supply o...

Page 191: ...stem connection diagram Power supply 12 V the voltage is made available via the EC interface Technical specification of the power supply See chapter 12 V power supply on page 195 Cable length The maximum allowed cable length depends on several factors See chapter Encoder cable length on page 197 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 189 341 Rexroth IndraDrive CsDrive Systems with HCS01 Techni...

Page 192: ...ication of the power supply See chapter 5 V power supply on page 195 Cable Length 75 m at most when using the Sense function When you do not use the Sense function the maximum cable length is re duced see chapter Encoder cable length on page 197 Technical properties Use the Sense function to ensure stable power supply at the encoder De scription of the Sense function See chapter 5 V power supply o...

Page 193: ...stem connection diagram Power supply 12 V the voltage is made available via the EC interface Technical specification of the power supply See chapter 12 V power supply on page 195 Cable length The maximum allowed cable length depends on several factors See chapter Encoder cable length on page 197 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 191 341 Rexroth IndraDrive CsDrive Systems with HCS01 Techni...

Page 194: ...de available via the EC interface Technical specification of the power supply See chapter 5 V power supply on page 195 Cable Length 75 m at most when using the Sense function When you do not use the Sense function the maximum cable length is re duced see chapter Encoder cable length on page 197 Technical properties Use the Sense function to ensure stable power supply at the encoder De scription of...

Page 195: ...ical specification of the power supply See chapter Resolver power supply on page 195 Please observe that the resolver encoder used has to be suited for the voltage available at the EC interface as the encoder supply voltage Cable length 75 m at most Specific technical features The encoder evaluation has been sized for resolvers with a transfer ratio of 0 5 Resolvers are not supported if an optiona...

Page 196: ...l specification of the power supply See chapter 12 V power supply on page 195 Cable length The maximum allowed cable length depends on several factors See chapter Encoder cable length on page 197 Specific technical features For detailed information on the Hall sensor box SHL02 1 see the Func tional Description Rexroth Hall sensor box SHL02 1 R911292537 Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 19...

Page 197: ...d back to the drive controller Thus the drive controller can influence the voltage of the encoder supply For correct Sense evaluation the encoder supply lines 5V and GND_Encoder have to have the same line cross section If the encoder has a Sense connection connect the Sense line at this connection A possibly existing Sense connection is not used If the encoder has no Sense connection apply the 0 V...

Page 198: ... 7 3 Resolver encoder supply Switching off power supply via firmware The parking axis firmware command C1600 causes the encoder power supply to be switched off Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 196 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 199: ...ction depending on line cross section Allowed encoder cable length for 5 V encoder systems with Sense function 75 m at most exception 40 m at most for IndraDyn S MSM motors Besides the maximum allowed cable lengths depend on the motor size See documentation of motor used The cross section of the supply voltage lines has to be at least 0 5 mm2 Allowed encoder cable length for 12 V encoder systems R...

Page 200: ...e cross section at supply voltage of 10 V Nominal current consumption of the MSK motor encoders 60 mA Allowed encoder cable length for resolver encoder systems 75 m at most The cross section of the supply voltage lines has to be at least 0 5 mm2 Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 198 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 201: ...Differential input sine Resolver input circuit for A A B B Fig 7 17 Input circuit for resolver evaluation block diagram Input circuit for square wave sig nals Fig 7 18 Input circuit for square wave signals block diagram Properties of differential input for square wave signals Data Unit min typ max Input voltage high V 2 4 5 0 Input voltage low V 0 0 8 Input frequency kHz 1000 Input resistance ohm ...

Page 202: ...mplitude encoder signal sine Upp V 5 6 Input resistance kOhm 12 Converter width A D converter Bit 12 Tab 7 6 Resolver operation input data Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 200 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 203: ...om the front toward the A side shaft end Linear Rexroth motor Increasing actual position val ues with motor motion in the di rection of cable outlet Square wave TTL Without absolute value Sine 1 Vpp With absolute value e g EnDat Amplitude modulated signal Resolver 1 See following note Tab 7 7 Signal assignment to the actual position value DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 201 341 Rexroth ...

Page 204: ...prerequisite negation of the encoder signals was not parameterized If available the reference track R R R provides the refer ence mark pulse at positive signals of track A and track B in the so called 0 th quadrant Standard setting See Functional Description of firmware Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 202 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components...

Page 205: ...eld m 30 Capacitance C pF m 60 Tab 7 8 Cables Incremental encoder emulation Connection Fig 7 19 Incremental encoder with signal level conversion single ended Fig 7 20 Incremental encoder RS422 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 203 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 206: ...UOut_High V 2 5 5 Output voltage low UOut_Low V 0 0 5 Output current IOut mA 20 Output frequency f MHz 4 Overload protection Present Short circuit protection Present Tab 7 10 Outputs RS422 Data Symbol Unit min typ max Input voltage high UIn_High V 2 5 5 Input voltage low UIn_Low V 0 0 5 Input resistance difference RIn_D ohm 110 130 Input resistance RIn kOhm 150 Output frequency f MHz 4 Overload pr...

Page 207: ...t voltage low UIn_Low V 0 0 5 Input resistance difference RIn_D ohm 110 130 Input resistance RIn kOhm 150 Clock frequency f kHz 100 1000 Overload protection Present Short circuit protection Present Tab 7 12 Differential inputs Differential outputs absolute en coder emulation Data Symbol Unit min typ max Output voltage high UOut_High V 2 5 5 Output voltage low UOut_Low V 0 0 5 DOK INDRV HCS01 PR05 ...

Page 208: ...I data signal If this resistor is not available connect an external line terminating resistor 150 180 ohm Pulse diagram 1 Resolution for 4096 revolutions 2 Resolution for 1 revolution G0 Least significant bit in Gray code G23 Most significant bit in Gray code m Stored parallel information T Clock time Tp Clock break 20 μs tv Max delay 200 ns PFB Power failure bit not used and always logically LOW ...

Page 209: ... field bus system Port LED chapter EtherNet IP on page 208 chapter EtherCAT on page 208 chapter sercos III on page 208 chapter PROFINET IO on page 209 Diagnostic LED chapter EtherNet IP on page 210 chapter EtherCAT on page 211 chapter sercos III on page 212 chapter PROFINET IO on page 213 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 207 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical dat...

Page 210: ...tly lit green Connection to network available but no telegram exchange EtherCAT bus inactive Flashing green Connection to network available with telegram exchange EtherCAT bus active Tab 7 15 Port LED sercos III LED Color flashing pat tern Significance Off No connection No data transmission Permanently lit yellow Data transmission running Permanently lit green Connection to network available Tab 7...

Page 211: ... No data transmission Permanently lit yellow Data transmission running Permanently lit green Connection to network available Tab 7 17 Port LED DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 209 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 212: ...connection has been established without error Flashing red The existing I O connection was unexpectedly aborted e g watchdog Permanently lit red The Duplicate IP Adress Check showed that the IP address which was set already exists in the network Flashing red green The device is running up and carries out a self test Tab 7 18 Diagnostic LED Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 210 341 Rexroth...

Page 213: ...erCAT configuration error Red one LED lighting up Synchronization error The drive controller has not been synchronized to the EtherCAT master Communication error of the drive control ler Red two LEDs lighting up Timeout watchdog Timeout while cyclic process data are monitored Watchdog of the EtherCAT master 1 Flashing pattern One square corresponds to a duration of 200 ms the arrow marks the end o...

Page 214: ... 0 1045 sercos Device Status S Dev bit15 3 Permanently lit red Communication error Sub device device error C1D 2 Flashing orange Identification S 0 1044 sercos Device Control C Dev bit15 1 Flashing red Internal watchdog 0 1 Flashing pattern One square corresponds to a duration of 250 ms the arrow marks the end of a cycle abbreviations on the squares GN LED permanently lit green OG LED per manently...

Page 215: ...on has been established without error Flashing red The existing I O connection was unexpectedly aborted e g watchdog Permanently lit red The Duplicate IP Adress Check showed that the IP address which was set already exists in the network Flashing red green The device is running up and carries out a self test Tab 7 21 Diagnostic LED DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 213 341 Rexroth IndraDr...

Page 216: ...eceive transmit data EIA RS485 standard Tab 7 22 Signal Specification Danger of destroying output 5V repeater supply by overload NOTICE Do not short circuit the output Do not exceed the maximum current Diagnostic Displays For the significance of the diagnostic displays see firmware documentation Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 214 341 Rexroth IndraDrive CsDrive Systems with HCS01 Techni...

Page 217: ...ne topology Bus terminator ISO 11898 124 ohm each 1 200 mW connect at both bus ends to X61 2 and X61 7 Transmission medium 2 twisted two wire lines 4 pin with shield Max allowed bus line lengths Depending on bit rate Recommended connection cable Our RKS number or third party type Tab 7 24 Main Features Bus Lengths Depending on Bit Rates Bit rate kBaud Max allowed network dimension m 1000 25 800 50...

Page 218: ...ty technology status H26 Bicolor LED Connection status X41 X42 X43 Not available for Safe Motion Bus option Fig 7 25 Safe Motion display elements Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 216 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 219: ...ying the axis identifier Flashing red green Indentifying the safety technology Flashing red green TUNID 2 not yet set Flashing red Abortion of connections Faulty abortion of at least one active con nection Permanently lit red Critical error Critical connection error 1 Flashing pattern One square corresponds to a duration of 250 ms the arrow marks the end of a cycle abbreviations on the squares GN ...

Page 220: ...nputs outputs Digital inputs Digital Inputs Type A Standard Fig 7 26 Symbol Data Unit Min Max Allowed input voltage V 3 30 High V 15 30 Low V 3 5 Current consumption mA 2 5 Control delay µs 1000 position control ler clock 200 position controller clock 1 1 Applies to optional I O extension DA Tab 7 27 Digital Inputs Type A Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 218 341 Rexroth IndraDrive CsDriv...

Page 221: ... a digital input Does not apply when used as a probe Tab 7 28 Digital inputs type B A Signal B Signal Detection at Probe Input tPuls Pulse width tx Measuring accuracy of the signal edges Fig 7 28 Signal Detection at Probe Input Use To acquire fast digital input signals Probe inputs are fast inputs For control use bounce free switch ing elements e g electronic switches to avoid incorrect evalua tio...

Page 222: ...tage V 3 30 High V 11 30 Low V 3 5 Current consumption 1 mA 7 15 1 For KCU02 the specified values must be multiplied with the number of zone nodes of the drive line Tab 7 29 Digital inputs safety technology L options Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 220 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 223: ...n mA 2 5 Tab 7 30 Digital inputs safety technology S options Time behavior Description Unit min max Test pulse width tPL µs 0 1000 Percentage of High time TPH TP 100 90 100 Phase shift between two test pulses on both channels φ ms Tab 7 31 Time behavior DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 221 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 224: ...g to the number of outputs the total current must be related to to 4 or 8 outputs 3 In the case of inductive loads with a greater energy content an external free wheeling arm must be installed The effective ter minal voltage must be 25 V 4 The maximum energy content depends on the switching fre quency f of the outputs 5 Applies to optional I O extension DA Tab 7 32 Digital Outputs The digital outp...

Page 225: ...tput voltage ON V 18 2 30 Output voltage OFF V 5 Output current ON mA 350 Allowed energy content of con nected inductive loads e g re lay coils only allowed as single pulse mJ 400 Short circuit protection Available Overload protection Available Tab 7 33 Digital Outputs Safety Technology L Options DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 223 341 Rexroth IndraDrive CsDrive Systems with HCS01 Techn...

Page 226: ...s are detected Wiring error with short circuit to high Wiring error with short circuit to low Wiring error with short circuit between the two channels Internal errors In the case of an error the control panel shows the corresponding error message F83xx 1 At a maximum switching frequency of 1 Hz 2 In the case of inductive loads with currents 200 mA or in the case of inductive loads with a greater e...

Page 227: ...tPL μs 100 200 Periodic time TP ms 500 1000 Phase shift between two test pulses on both channels φ ms 50 Tab 7 35 Time behavior DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 225 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 228: ...ode rejection dB 50 Relative measuring error at 90 Uon_work 1 1 Resolution Bit 14 1 13 2 Cables For cable lengths 30 m only use shielded cables 1 Applies to Cxx02 control sections X32 optional I O extension DA X38 HCS01 drive controllers X32 2 Applies to Control sections with extended scope CSx02 1B X35 CDB02 1B X36 Tab 7 36 Analog Voltage Input Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 226 341 R...

Page 229: ...nt Wiring Only use shielded cables for cable lengths 30 m 1 Measuring range 20 20 or 4 20 can be set using a pa rameter With a measuring range 4 20 the minimum value monitoring wire break is automatically active 2 Only possible with a measuring range 4 20 3 Monitoring switched off at approx 35 mA 4 In the case of input currents greater than the maximum value an error is signaled and the input is s...

Page 230: ...0 250 1 Output clock Position controller clock Precision in relation to the measur ing range 0 5 with load 10 kΩ 1 with load 2 kΩ Short circuit protection Present Overload protection Present 1 Applies to optional I O extension DA Tab 7 38 Analog Output Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 228 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 231: ...stance at minimum cur rent mΩ 1000 Switching actions at max time con stant of load 1 106 Number of mechanical switching cy cles 1 108 Time constant of load ms ohmic Pick up delay ms 10 Drop out delay ms 10 Tab 7 39 Relay Contacts Type 2 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 229 341 Rexroth IndraDrive CsDrive Systems with HCS01 Technical data of the components ...

Page 232: ...ontroller is switched on so that it can be recognized not suited for hot plug can be used as programming module The display shows operating states command and error diagnoses and pending warnings Using the four keys the commissioning engineer or service technician can have extended diagnoses displayed and trigger simple commands Memory 400 kbytes for MLD boot program 492 bytes for MLD retain varia...

Page 233: ...line display is suited for hot plug can be used as programming module The display shows operating states command and error diagnoses and pending warnings Using the four keys the commissioning engineer or service technician can have extended diagnoses displayed and trigger simple commands Memory 2 MB data flash memory 16 MB code flash memory 32 kB retain data FRAM memory DOK INDRV HCS01 PR05 EN P B...

Page 234: ...or motor holding brakes 4 See information on Rated power consumption control voltage input at UN3 Tab 7 40 HCS Control voltage supply data Rated power consumption control voltage input at UN3 Including control section plus safety option Control voltage supply data Description Symbol Unit HCS01 1E W0005 _ 03 HCS01 1E W0008 _ 03 HCS01 1E W0018 _ 03 HCS01 1E W0028 _ 03 HCS01 1E W0054 _ 03 Control vol...

Page 235: ...the allowed value Overvoltage limiters at the control cabinet input that limit ex isting overvoltage to the allowed value This too applies to long 24V lines that have been run in parallel to power cables and mains cables and can absorb overvoltage by inductive or capacitive coupling 7 3 2 Mains voltage Mains voltage supply data Description Symbol Unit HCS01 1E W0003 _ 02 HCS01 1E W0006 _ 02 HCS01 ...

Page 236: ...ILN A 1 80 2 80 5 00 8 30 12 80 Mains input continuous current at ULN_nenn and PDC_cont three phase without mains choke 6 ILN A 0 60 1 20 2 30 4 50 9 60 Mains input continuous current at ULN_nenn and PDC_cont single phase with mains choke 7 ILN A Mains input continuous current at ULN_nenn and PDC_cont three phase with mains choke 8 ILN A Nominal current AC1 for mains contactor at nom data ILN Main...

Page 237: ... 0 49 Power factor TPF λL at ULN_nenn and PDC_cont three phase without mains choke 11 TPF 0 47 0 52 0 56 0 52 Power factor TPF λL at ULN_nenn and PDC_cont single phase with mains choke 12 TPF Power factor TPF λL at ULN_nenn and PDC_cont three phase with mains choke 13 TPF Power factor TPF λL at ULN_nenn and 10 PDC_cont single phase without mains choke TPF10 tbd Power factor TPF λL at ULN_nenn and ...

Page 238: ...ure 90 C Ta 40 C in accordance with NFPA 79 chapter 12 and UL 508A chapter 28 Tab 7 42 HCS Mains voltage supply data Mains voltage supply data Description Symbol Unit HCS01 1E W0005 _ 03 HCS01 1E W0008 _ 03 HCS01 1E W0018 _ 03 HCS01 1E W0028 _ 03 HCS01 1E W0054 _ 03 Mains frequency fLN Hz 50 60 Mains frequency tolerance Hz 2 Maximum allowed mains frequen cy change ΔfLN Δt Hz s 2 Rotary field condi...

Page 239: ...LN A 1 50 2 50 5 00 8 00 25 00 Mains input continuous current at ULN_nenn and PDC_cont single phase with mains choke 7 ILN A Mains input continuous current at ULN_nenn and PDC_cont three phase with mains choke 8 ILN A tbd 10 00 28 00 Nominal current AC1 for mains contactor at nom data ILN Mains fuse according to EN 60204 1 single phase with out mains choke A Mains fuse according to EN 60204 1 thre...

Page 240: ... factor TPF λL at ULN_nenn and PDC_cont single phase with mains choke 12 TPF Power factor TPF λL at ULN_nenn and PDC_cont three phase with mains choke 13 TPF tbd 0 72 0 78 Power factor TPF λL at ULN_nenn and 10 PDC_cont single phase without mains choke TPF10 Power factor TPF λL at ULN_nenn and 10 PDC_cont three phase without mains choke TPF10 0 30 0 35 0 38 0 40 0 45 Power factor TPF λL at ULN_nen...

Page 241: ...grounded neutral point do not use autotransform ers 3 Otherwise use HNL mains choke 4 Maximum allowed number of switch on processes 250000 5 6 7 8 10 11 12 13 Find interim values by interpolation 9 Copper wire PVC insulation conductor tempera ture 90 C Ta 40 C in accordance with NFPA 79 chapter 12 and UL 508A chapter 28 Tab 7 43 HCS Mains voltage supply data IL_trans_max_on Maximum inrush current ...

Page 242: ... x 0 0025 PDC_cont and PDC_max vs mains in put voltage ULN ULN_nenn V No power increase Maximum allowed DC bus power at ULN_nenn with mains choke PDC_max kW Maximum allowed DC bus power at ULN_nenn without mains choke PDC_max kW 0 45 0 75 1 38 2 40 4 80 Balancing factor for PDC_cont for parallel operation at common DC bus with mains choke Balancing factor for PDC_cont for parallel operation at com...

Page 243: ...wer t 10 min at fs 4 kHz ULN_nenn control factor a0 0 8 without mains choke PDC_cont kW 0 46 0 86 1 70 2 60 9 00 Factor to reduce PDC_cont at single phase mains voltage f1_3ph 1 phase operation not allowed PDC_cont and PDC_max vs mains in put voltage ULN ULN_nenn V PDC_cont ULN PDC_cont x 1 400 ULN x 0 0025 PDC_cont and PDC_max vs mains in put voltage ULN ULN_nenn V No power increase Maximum allow...

Page 244: ...g resistor data Description Symbol Unit HCS01 1E W0003 _ 02 HCS01 1E W0006 _ 02 HCS01 1E W0009 _ 02 HCS01 1E W0013 _ 02 HCS01 1E W0018 _ 02 Braking resistor continuous power PBD kW 0 02 0 03 0 15 Braking resistor peak power PBS kW 1 68 2 24 Nominal braking resistor RDC_Bleeder ohm 100 68 Braking resistor switch on thresh old independent of mains volt age1 UR_DC_On_f V 390 Braking resistor switch o...

Page 245: ...or PBD for paral lel operation at common DC bus f 0 80 Cooling of integrated braking re sistor Forced ventilation Last modification 2012 05 16 1 2 Factory setting Tab 7 47 HCS Integrated braking resistor data 7 3 5 Inverter Power section data inverter Description Symbol Unit HCS01 1E W0003 _ 02 HCS01 1E W0006 _ 02 HCS01 1E W0009 _ 02 HCS01 1E W0013 _ 02 HCS01 1E W0018 _ 02 Allowed switching freque...

Page 246: ... current when fs 16 kHz Iout_max16 A 3 3 6 0 9 0 13 0 18 0 Continuous output current when fs 4 kHz Iout_cont4 A 1 4 2 4 3 0 4 4 7 6 Continuous output current when fs 8 kHz Iout_cont8 A 1 0 1 8 2 6 4 2 7 6 Continuous output current when fs 12 kHz5 Iout_cont12 A 0 6 1 2 1 7 2 7 7 6 Continuous output current when fs 16 kHz6 Iout_cont16 A 0 5 0 8 1 1 1 9 7 6 Continuous output current when fs 4 kHz out...

Page 247: ...3 HCS01 1E W0008 _ 03 HCS01 1E W0018 _ 03 HCS01 1E W0028 _ 03 HCS01 1E W0054 _ 03 Allowed switching frequencies1 fs kHz 4 8 12 16 4 8 12 Output voltage fundamental wave for V Hz U f control Vout_eff V UDC x 0 71 Output voltage fundamental wave for closed loop operation Vout_eff V UDC x 0 71 Rise of voltage at output with ULN_nenn and 15 m motor cable length phase phase 10 90 2 dv dt kV µs 5 00 Ris...

Page 248: ... kHz6 Iout_cont16 A 0 7 1 0 2 5 3 1 Continuous output current when fs 2 kHz output frequency fout fout_still Iout_cont0Hz_2 A Continuous output current when fs 4 kHz output frequency fout fout_still Iout_cont0Hz_4 A 1 8 2 7 7 0 11 5 21 0 Continuous output current when fs 8 kHz output frequency fout fout_still Iout_cont0Hz_8 A 1 3 1 9 2 3 4 7 12 0 Continuous output current when fs 12 kHz output fre...

Page 249: ...he power section used Especially when using standard motors make sure that they com ply with the occurring voltage load Reduced output current at motor standstill Depending on the electric output frequency the output current is reduced for thermal protection of the power section The output current is reduced when the electric output frequency has fallen below the threshold to detect motor standsti...

Page 250: ...Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 248 341 Rexroth IndraDrive CsDrive Systems with HCS01 ...

Page 251: ... level control unit RKB0013 To connect devices arranged side by side Tab 8 1 Cables overview 8 1 2 Accessories Accessories Note Mounting and connection accessories HAS09 Screws for mounting the component Screws for connecting the equipment grounding conductor Parts for shield connection and strain relief of cables plates screws clips Adhesive labels with notes on safety in the English and French l...

Page 252: ...ssory for assembling an encoder cable for MSM motors with absolute value encoder M0 To be ordered separately Hall sensor adapter box SHL03 1 NNN S NNN Accessory for connecting digital Hall sensors To be ordered separately Snap on ferrite HAS05 1 015 NNN NN Accessory for external HLR braking resistors To be ordered separately Tab 8 2 Accessories overview 8 1 3 Additional Components Additional compo...

Page 253: ... French languag es Place the adhesive labels clearly visibly at the component or in the immediate vicinity of the component if the adhesive labels existing at the component are hidden by neighboring components The accessories are part of the standard scope of supply Assignment Accessories Component HAS09 1 001 NNN NN HCS01 1E W0003 W0028 HAS09 1 003 NNN NN HCS01 1E W0054 HAS09 1 004 NNN NN HLC01 2...

Page 254: ...t insert HAS09 1 001 NNN NN Fig 8 1 HAS09 1 001 NNN NN product insert Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 252 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 255: ...HAS09 1 003 NNN NN Fig 8 2 HAS09 1 003 NNN NN product insert DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 253 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 256: ... for cable diameters 4 13 mm and 8 19 mm HAS09 1 003 Plates for cable diameters 8 19 mm and 9 28 mm Fig 8 3 HAS09 plates Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 254 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 257: ...HAS09 1 004 NNN NN Fig 8 4 HAS09 1 004 NNN NN product insert DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 255 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 258: ...les of a conductor size 2 0 5 mm2 Observe the data of connection point X47 Assembling cables 1 Strip cable A 24 mm B 180 mm C 35 mm Fig 8 5 Stripping the cable 2 Remove protective foil then wrap self adhesive copper tape around shield braid Fig 8 6 Copper tape 3 Put 2 heat shrink tubings on cable and shrink them Fig 8 7 Heat shrink tubing 4 Fold back shield braid over cable jacket and strip wire e...

Page 259: ... 8 9 Heat shrink tubing wire end ferrules 6 Connect cable shield to plate from accessories Optional Fasten cable with cable tie Fig 8 10 Shield connection DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 257 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 260: ... drive controller to a DC bus capacitor unit Fig 8 11 Connecting the DC Buses via DC Bus Connectors DC bus connector DC bus connector at device connection point X77 Order code RLS0778 K06 Tab 8 5 DC Bus Connector Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 258 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 261: ... V 1800 mA lithium lifetime up to 10 years depending on use and ambient temperature Assembly screws M6 30 screw head Torx and slot The battery box SUP E01 MSM BATTERYBOX is delivered in ready for use state with battery Components 1 Assembly screw 2 Housing 3 Housing lid 4 Housing lid screw self shaping screw 30 10 tightening torque 0 8 Nm 5 Battery Fig 8 13 Components of battery box DOK INDRV HCS0...

Page 262: ...g 8 15 Drilling diagram for battery box Assembly screws M6 30 Tightening torque MA 3 Nm Cabling RKG0033 Encoder cable RKG0034 Extension cable optional Fig 8 16 Cabling of battery box Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 260 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 263: ...TERYBOX battery box The refresh resistor is used to prepare the battery before the battery is used in the battery box SUP E01 MSM BATTERYBOX Content Fig 8 17 SUP E03 DKC CS BATTRY product insert DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 261 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 264: ...resistor 10 ohm the refresh resistor is used to prepare the battery before the battery is used in the battery box SUP E01 MSM BATTERYBOX Documentation DOZ SUPPL SUP E03 DKC MA01 D5 P Information in 5 languages on the refresh procedure of the battery and on how to connect the battery and the base load resistor Base load resistor The base load resistor 500 kOhm is only relevant to EcoDrive Cs drive ...

Page 265: ...rom mating connector Replacing the battery To maintain the absolute value encoder position when the battery is replaced the following requirements have to be fulfilled The control voltage at the drive controller has been switched on The encoder has been connected to the drive controller via the encoder cable Fig 8 20 Control voltage switched on and encoder connected DOK INDRV HCS01 PR05 EN P Bosch...

Page 266: ...ction Establishing position data reference for absolute measuring sys tems Set absolute position command 1 If not yet done carry out refresh procedure with the new battery 2 Unscrew cover of battery box Remove old battery and dispose of it according to di rectives valid in your country Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 264 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessori...

Page 267: ...n in the next step 4 Screw on cover in correct orientation tightening tor que 0 8 Nm Check whether cover fits correctly Cable in battery compartment should not get stuck between cover and battery box Cover has to be flush with battery box at all points Tab 8 7 Replacing the battery DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 265 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories a...

Page 268: ...erational condition Battery Type PRM1 03V6 2600C D2 LITH ZNR 50 3 6 V 2600 mAh lithium Lifetime up to 10 years depending on load and ambient temperature Replacement battery R911369925 SUP E02 MSM BATTERY Parts 1 Housing screw MA 0 7 Nm 2 Housing cover 3 Battery 4 Housing 5 Battery connector Fig 8 21 Battery box parts Mounting To fasten the battery box use mounting screws 2 M4 with washer and screw...

Page 269: ...s 1 Nm Cabling RKG0062 Encoder cables RKG0063 Extension cable optional Fig 8 22 Battery box cabling DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 267 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 270: ... encoder data are buffered and the position of the absolute value encoder is retained in case voltage is switched off For drive controllers arranged side by side the voltage can be looped through via the spring terminal to the neighboring drive controllers 3 6 V Direct voltage source battery or UPS A Shielded lines e g 2x0 5 C RKG0041 Encoder cables RGS0001 K01 D Sub connector with integrated 4 pi...

Page 271: ... nection Signal name Function 3 6V Voltage input 0V Reference potential Spring terminal connector Unit min max Connection cable Stranded wire mm2 0 2 1 5 AWG 24 16 Stripped length mm 10 Tab 8 10 Spring terminal DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 269 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 272: ...mes of the drive with a battery capacity of 1 8 Ah it is approx 2 to 10 years Battery current per drive encoder current base load current Drive Off approx 70 μA Drive On approx 10 μA Battery base load and battery ca pacity The D Sub connector contains a base load resistance of 499 kΩ The base load resistance causes a standby current of 7 μA which has to flow with 3 6 V 1 8 Ah for a lithium battery...

Page 273: ...ed base load current Installation Connecting the battery UPS Risk of injury by exploding batteries WARNING Pay attention to the correct polarity when connecting the battery NOTICE Incorrect polarity might damage the encoder system the correct dimensioning of the external resistor the safety instructions of the battery manufacturer 3 6 V Direct voltage source battery or UPS A Shielded lines e g 2x0...

Page 274: ...tion of Shielded Lines at the Top of the Device Fig 8 26 Example of a complete wiring Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 272 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 275: ...oping through the voltage Replacement of devices When replacing an HCS01 observe the following aspect Leave the 4 pin spring terminal with the connected battery UPS at the D Sub connector so that voltage is still applied and the encoder position is retained DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 273 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 276: ...terminal so that the encoder data are buffered and the position of the absolute value encoder is retained in case voltage is switched off RGS0001 K01 1 Top shell of housing 2 Mounting screws 3 Circuit board with terminal connector for the encoder cable female connector 6 base load resistance to avoid premature aging of a connected 3 6 V lithium battery and D Sub connector 15 pin 4 Bottom shell of ...

Page 277: ...ection in the connector INS0753 C01 Scope of Supply RGS0001 K01 Product insert with information on assembly Dimensions Fig 8 29 Dimensions Interconnection Diagram Fig 8 30 Interconnection Diagram Assembly in Conjunction with Ca ble INK0448 1 Assemble cable Required ferrules 4 0 25 mm 2 0 50 mm DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 275 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables a...

Page 278: ... into housing in accordance with desired outgoing di rection of encoder cable Put shield braid under clip A of strain relief and screw on clip A Insert mounting screws B and tuck wires away 5 Close housing Put top shell of housing onto bottom shell of housing engage it in bot tom shell and screw housing screw down 6 Unless already done By means of appropriate crimping tool add the two contacts for...

Page 279: ...DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 277 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 280: ...e encoder M5 The encoder cable is connec ted to the encoder evaluation of the drive controller via a D Sub connector with integrated 4 pin spring terminal RGS0001 K01 Encoder connection Bulk cable HCS01 connection Tab 8 12 RKG0065 Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 278 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 281: ...RKB0011 xxx x xxx x length in meters Example 13 5 m RKB0011 013 5 R911316888 5 m RKB0011 005 0 R911321548 Tab 8 13 RKB0033 RKB0011 Plug in connector bus Bulk cable Plug in connector bus RBS0016 S01 RJ 45 4 pin REB0400 RBS0016 S01 RJ 45 4 pin Tab 8 14 Interconnection Diagram RKB0011 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 279 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories a...

Page 282: ...ode Length Order code Parts number 0 55 m RKB0013 00 55 R911317801 Tab 8 15 RKB0013 RKB0013 Plug in connector bus Bulk cable Plug in connector bus RJ 45 8 pin sercos III cable 100 Base T CAT5E shielded RJ 45 8 pin Use instruction only fixed lengths Tab 8 16 Interconnection Diagram RKB0013 Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 280 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables access...

Page 283: ...is made of sheet steel and has the degree of protection IP20 For detailed information on linear MCL motors see the documentation Rexroth IndraDyn L Ironless Linear Motors MCL R911330592 Dimensions Fig 8 33 Dimensions Mounting Options for mounting Top hat rail TH 35 7 5 according to EN 60715 With 2 screws M4 to the mounting surface select the appropriate screw type and length for the mounting surfa...

Page 284: ...nnection Signal Function 1 GND_shld Connection signal shields inner shields 2 A Track A positive 3 A Track A negative 4 GND_Encoder Reference potential for power supplies 5 B Track B positive 6 B Track B negative 7 n c 8 n c 9 R Reference track positive 10 R Reference track negative 11 12V Encoder supply 12 V Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 282 341 Rexroth IndraDrive CsDrive Systems wit...

Page 285: ...nment Properties Connection Signal Function 1 12 V Power supply 2 S1 Hall sensor signal 1 3 GND Reference potential for power supply 4 S2 Hall sensor signal 2 5 GND Reference potential for power supply 6 GND Reference potential for power supply 7 GND Reference potential for power supply 8 S3 Hall sensor signal 3 9 GND Reference potential for power supply Connector housing Overall shield Tab 8 20 P...

Page 286: ... 5 B Track B analog positive 6 B Track B analog negative 7 Data_Hall Data transmission Hall sensor signal positive 8 Data_Hall Data transmission Hall sensor signal negative 9 R Reference track positive 10 R Reference track negative 11 12V Encoder supply 12 V 12 5V Encoder supply 5V 13 CLK_Hall Clock Hall sensor signal positive 14 CLK_Hall Clock Hall sensor signal negative 15 Sense Return of refere...

Page 287: ...ll sensor adapter box Hall X4 In2 length max 30 m RKG0051 Length measuring system Hall sensor adapter box Encoder X4 In1 length max 30 m Fig 8 35 Cables Interconnection Diagram RKG0049 Fig 8 36 RKG0049 Interconnection Diagram RKG0050 Fig 8 37 RKG0050 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 285 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 288: ...Interconnection Diagram RKG0051 Fig 8 38 RKG0051 Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 286 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 289: ... outside of the control cabinet The snap on ferrite is designed for the following components HCS01 1E W0018 HLR01 2N 01K0 N68R0 E 007 HCS01 1E W0028 HLR01 2N 01K0 N68R0 E 007 HCS01 1E W0054 HLR01 2N 01K0 N28R0 E 007 Product insert Fig 8 39 Product insert DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 287 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 290: ... heat sources The maximum allowed ambient temperature of the snap on fer rite is 105 C Fix the snap on ferrite within the control cabinet to the cable jacket of the connection line of the braking resistor see picture The snap on fer rite is designed for cable diameters of 6 5 7 mm Fig 8 40 Snap on ferrite at connection line of external braking resistor Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 28...

Page 291: ...e snap on ferrite use the proper tool Fig 8 41 Opening the snap on ferrite DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 289 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 292: ...s for drive controllers Types Short type designation 1 2 3 4 5 6 7 8 9 1 0 1 2 3 4 5 6 7 8 9 2 0 1 2 3 4 5 6 7 8 9 3 0 1 2 3 4 5 6 7 8 9 4 0 Example T R A F O D S T 4 0 0 S 3 8 0 4 1 5 4 4 0 2 2 0 1 0 M M Object TRAFO transformer Product DST AC autotransformer Nominal power 2 00 2 0 kVA 2 50 2 5 kVA 4 00 4 0 kVA 5 00 5 0 kVA 7 50 7 5 kVA Type of construction design S upright mounting Nominal input...

Page 293: ... 210 120 95 145 85 7 15 4 12 2 50 S 380 415 440 220 R911219217 205 210 130 95 145 95 7 15 6 13 4 00 S 380 415 220 R911216703 240 260 150 110 170 120 11 15 6 24 5 00 S 380 415 440 220 R911219831 300 325 140 140 210 110 11 15 10 31 7 50 S 380 415 440 220 R911219497 300 310 155 140 210 125 11 18 10 36 Tab 8 24 Data DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 291 341 Rexroth IndraDrive CsDrive Systems ...

Page 294: ... 1 Mains Filter Single Phase Fig 8 43 Type Code NFE02 1 NFD03 1 Mains Filter Three Phase Fig 8 44 Type Code NFD03 1 Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 292 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 295: ...minal connectors Fig 8 45 Single Phase Filter NFE02 1 for Drives Allowed Mounting Positions Every mounting position is allowed DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 293 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 296: ... M5 2 2 0 8 NFD 03 1 480 030 270 100 60 240 255 30 5 4 270 M5 2 2 2 NFD 03 1 480 055 250 105 90 220 235 60 5 4 260 M6 4 2 2 NFD 03 1 480 075 270 145 90 240 255 60 6 5 280 M6 4 4 5 NFD 03 1 480 130 270 160 100 240 255 65 6 5 330 M10 18 8 NFD 03 1 480 180 380 180 130 350 365 102 6 5 455 M10 18 20 NFE 02 1 230 008 90 210 60 60 80 40 5 3 40 0 75 15 10 0 8 0 8 MAE Maximum tightening torque of the groun...

Page 297: ...ltage of mains 50 60 Hz UN Nominal mains current Inenn 1 Number of pha ses Mains filter type Terminal connectors 3 Power dissipa tion ap prox Weig ht Type of construc tion In V In A Flexible mm2 Rigid mm2 AWG W kg AC 480V 10 7 3 NFD 03 1 480 007 4 3 6 3 AWG 12 3 9 0 7 Vertical AC 480V 10 16 3 NFD 03 1 480 016 4 3 6 3 AWG 12 6 4 1 0 Vertical AC 480V 10 30 3 NFD 03 1 480 030 10 16 AWG 6 11 9 1 4 Ver...

Page 298: ...ncy From 0 60 Hz at 45 C Power dissipation Measured 2 or 3 RI2 Nenn DC Temperature range 25 85 Overload 1 5 INenn 1 minute per hour or 4 INenn for 10 s Effective attenuation Frequency range 0 15 30 MHz Saturation behavior Reduction of filter attenuation by 6 dB at 2 5 fold to 3 fold nominal current Test voltage L N PE or L PE 2000 V 50 Hz 2 s at 25 C L N L DC 1 100 V 2 s at 25 C Current reduction ...

Page 299: ...8 3 3 Mains chokes Type code Fig 8 47 Type code DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 297 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 300: ... frequency 10 Nominal current 11 Number of design specification 12 Nominal inductance 13 Temperature 14 Number and value of additional capacitors 15 Designation of origin 16 Approval number 17 Bar code 39 or 93 18 Serial number 19 Company address Fig 8 48 Type plate Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 298 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional compon...

Page 301: ...section mm2 AWG Tightening torque Nm U1 V1 W1 U2 V2 W2 a b U1 V1 W1 U2 V2 W2 a b HNL01 1E 1000 N0012 A 500 NNNN 4 4 Observe the data imprinted on the com ponent HNL01 1E 0600 N0032 A 500 NNNN 10 4 Tab 8 30 Connection cross section tightening torque Basic data Mains choke UN V IN A LN µH PV W Imax A Lmin At Imax HNL01 1E 1000 N0012 A 500 NNNN 500 12 3 1000 40 25 50 of LN HNL01 1E 0600 N0032 A 500 N...

Page 302: ...DC 24 V 125 C HNL01 1E mains chokes of type 1 are equipped with a temperature contact a b types 2 3 and 4 are not Tab 8 32 Temperature contact Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 300 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 303: ...K0 N68R0 E 007 NNNN Preliminary HLR01 2N 0K 06 N100R E 003 NNNN HLR01 2N 0K 06 N180R E 007 NNNN Degree of protection according to IEC 60529 IP IP54 Ambient temperature range for operation with nominal data Ta_work C 0 40 Last modification 2014 05 26 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 301 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 304: ...g type natural Volumetric capacity of forced cool ing V m3 h Temperature increase with mini mum distances dbot dtop PBD ΔT K Minimum distance on the top of the device1 dtop mm 200 150 Minimum distance on the bottom of the device2 dbot mm 200 150 Horizontal spacing on the device3 dhor mm 200 50 Allowed range tightening torque M Nm Required wire size in accordance with NFPA 79 and UL 508 A in ternal...

Page 305: ...g dimensions Dimensions with suspended mounting A Minimum mounting clearance Fig 8 52 Dimensions with suspended mounting on the wall DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 303 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 306: ...nt ing A Minimum mounting clearance Fig 8 53 Dimensions with upright mounting on the floor Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 304 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 307: ...tivity Ltd Type Mini Universal MATE N LOK 2 Number 794186 1 Contacts female Number 794223 1 Connection cross section 0 5 1 4 mm2 16 20 AWG Tab 8 34 Connector DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 305 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 308: ...0 3 is complied with for braking resis tors installed outside of the control cabinet The snap on ferrite is designed for the following components HCS01 1E W0018 HLR01 2N 01K0 N68R0 E 007 HCS01 1E W0028 HLR01 2N 01K0 N68R0 E 007 HCS01 1E W0054 HLR01 2N 01K0 N28R0 E 007 Bimetal protection relay Using a bimetal protection relay you can establish overload protection for ex ternal braking resistors Int...

Page 309: ...stic of bimetal protection relay Braking resistor HLR01 2N Current measuring range A Tripping current A 01K0 N28R0 E 007 4 6 6 01K0 N68R0 E 007 4 6 4 DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 307 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 310: ...6 N100R E 003 0 6 1 0 8 0K06 N180R E 007 0 6 1 0 6 Tab 8 36 HLR and bimetal protection relay Current measuring range and trip ping current Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 308 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accessories additional components ...

Page 311: ...0 Power dissipation at continuous current and continuous DC bus power respectively UL PDiss_cont W 4 10 5 28 Maximum discharge time from UR_DC_On to DC 50 V tentl_ZK sec 238 378 Allowed input current at L L Imax rms A 15 30 Insulation resistance at DC 500 V Ris Mohm 10 10 Cooling Natural convection Tab 8 37 HLC technical data DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 309 341 Rexroth IndraDrive Cs...

Page 312: ...r switch against unintentional or unauthorized re energization Wait at least 30 minutes after switching off the supply voltages to allow dis charging Check whether voltage has fallen below 50 V before touching live parts Fig 8 60 Connection points DC Bus L L equipment grounding conductor Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 310 341 Rexroth IndraDrive CsDrive Systems with HCS01 Cables accesso...

Page 313: ...the most powerful drive controller of a drive system Operation Mains Choke Always operate the DC bus capacitor units together with the mains choke as signed to the drive controller see chapter 7 3 2 Mains voltage on page 233 Special case HCS01 1E W0018 _ 03 in the technical data no mains choke has been assigned to this drive controller Use the mains choke HNL01 1E 1000 N0012 A 500 NNNN DC bus coup...

Page 314: ...Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 312 341 Rexroth IndraDrive CsDrive Systems with HCS01 ...

Page 315: ...s free domicile to the following address Bosch Rexroth AG Electric Drives and Controls Buergermeister Dr Nebel Strasse 2 97816 Lohr am Main Germany Packaging The packaging materials consist of cardboard wood and polystyrene These materials can be recycled anywhere without any problem For ecological reasons please refrain from returning the empty packages to us Batteries and accumulators Batteries ...

Page 316: ...e of plastics can contain flame retardants These plastic parts are labeled according to EN ISO 1043 They have to be recycled separately or disposed of according to the valid legal requirements Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 314 341 Rexroth IndraDrive CsDrive Systems with HCS01 Environmental protection and disposal ...

Page 317: ...Additional information on service repair e g delivery addresses and training can be found on our internet sites Service worldwide Outside Germany please contact your local service office first For hotline numbers refer to the sales office addresses on the internet Preparing information To be able to help you more quickly and efficiently please have the following information ready Detailed descript...

Page 318: ...Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 316 341 Rexroth IndraDrive CsDrive Systems with HCS01 ...

Page 319: ...ation type e g B1 or B2 4 In Current carrying capacity table row select the value that is immedi ately above the value determined in the first step 5 In Fuse table row read corresponding fuse 6 In Cross section A table row read corresponding required cross section International except for USA Canada installation type B1 Country of use international except for USA Canada Fuse IN A Current carrying ...

Page 320: ...0 200 540 79 3 185 800 250 632 14 3 240 800 315 719 84 3 300 Tab 11 1 Line cross sections and fuses B1 according to EN 60204 1 2006 Table 6 for 150mm and more DIN IEC 60364 5 52 2004 Table B 52 4 International except for USA Canada installation type B2 Country of use international except for USA Canada Fuse IN A Current carrying ca pacity 0 87 IZ 40 A Cross section A mm2 Installation type B2 1 2 3...

Page 321: ... 240 315 471 89 2 300 100 272 22 3 70 125 327 03 3 95 160 376 36 3 120 160 411 08 3 150 200 465 89 3 185 200 542 62 3 240 250 619 35 3 300 Tab 11 2 Line cross sections and fuses B2 according to EN 60204 1 2006 Table 6 for 150mm and more DIN IEC 60364 5 52 2004 Table B 52 4 International except for USA Canada installation type E Country of use international except for USA Canada Fuse IN A Current c...

Page 322: ... 87 25 125 109 62 35 160 133 11 50 200 170 52 70 250 207 06 95 315 240 12 120 355 277 53 150 400 316 68 185 425 374 10 240 500 432 39 300 160 272 83 2 x 70 200 331 30 2 x 95 250 384 19 2 x 120 250 444 05 2 x 150 315 506 69 2 x 185 400 598 56 2 x 240 400 691 82 2 x 300 160 358 09 3 x 70 200 434 83 3 x 95 200 504 25 3 x 120 250 582 81 3 x 150 250 665 03 3 x 185 Bosch Rexroth AG DOK INDRV HCS01 PR05 ...

Page 323: ...A Canada Fuse IN Current carry ing capacity IZ A Cross section A Installation type E 1 2 3 4 2 1 6 14 AWG 4 3 3 14 AWG 6 5 14 AWG 10 8 3 14 AWG 16 13 14 AWG 20 15 14 AWG 25 20 12 AWG 40 30 10 AWG 70 50 8 AWG 80 65 6 AWG 100 85 4 AWG 110 100 3 AWG 125 115 2 AWG 150 130 1 AWG 175 150 1 0 AWG 200 175 2 0 AWG 225 200 3 0 AWG 250 230 4 0 AWG 300 255 250 kcmil 300 285 300 kcmil 350 310 350 kcmil 350 335...

Page 324: ...0 AWG 300 510 2 250 kcmil 350 570 2 300 kcmil 350 620 2 350 kcmil 400 670 2 400 kcmil 450 760 2 500 kcmil 600 840 2 600 kcmil 600 920 2 700 kcmil 600 950 2 750 kcmil 600 980 2 800 kcmil 800 1040 2 900 kcmil 800 1090 2 1000 kcmil 200 450 3 1 0 AWG 225 525 3 2 0 AWG 250 600 3 3 0 AWG 300 690 3 4 0 AWG 300 765 3 250 kcmil 350 855 3 300 kcmil 350 930 3 350 kcmil 400 1005 3 400 kcmil 450 1140 3 500 kcm...

Page 325: ...g stranded wires routed in cable duct B2 in accordance with IEC 60364 5 52 e g multi core line routed in cable duct E in accordance with EN 60204 1 e g multi core line routed on open cable tray In accordance with NFPA 79 external wiring UL508A internal wiring NEC NFPA 70 1 cable with 3 conductors 1 neutral conductor and 1 equip ment grounding conductor Routed in pipe on the wall Internal wiring Ro...

Page 326: ...79 2007 table 12 5 5 a 0 88 0 94 1 00 1 1 1 18 1 32 1 52 Tab 11 5 Ambient temperature correction factor in accordance with EN 60204 1 2006 and NFPA 79 2007 Correction factor for bundling lines installation methods B2 and E and cir cuits installation method B11 Number of lines 1 2 3 4 5 Correction factor according to EN 60204 1 2006 table D 2 1 1 25 1 43 1 54 1 67 Correction factor according to NFP...

Page 327: ...eld and ground wire Capacitances of motors winding capacitance against housing The leakage capacitance consists of the values of power cable and motor of all individual drives operated at the mains filter Calculation Cab_g Total value of leakage capacitance Cab_Mg Total value of leakage capacitance of motor Cab_Kg Total value of leakage capacitance of cable Fig 11 2 Total Leakage Capacitance The t...

Page 328: ...e total capacitance of the power connections U V W against the motor housing The tables below contain excerpts from the technical data of motors Leakage capacitance Type Leakage capacitance of the component Cab nF MSM019A 0300 NN __ ___ 0 3 MSM019B 0300 NN __ ___ 0 7 MSM031B 0300 NN __ ___ 0 7 MSM031C 0300 NN __ ___ 1 4 MSM041B 0300 NN __ ___ 1 3 Last modification 2008 11 20 Tab 11 7 MSM019A 0300 ...

Page 329: ... 0150 NN __ ___ ____ 6 3 MSK071C 0200 FN __ ___ ____ 4 6 MSK071D 0200 FN __ ___ ____ 6 9 MSK071E 0200 FN __ ___ ____ 8 9 MSK075C 0200 NN __ ___ ____ 3 8 MSK075D 0200 NN __ ___ ____ 4 6 MSK075E 0200 NN __ ___ ____ 5 8 MSK076C 0300 NN __ ___ ____ 6 5 MSK100A 0200 NN __ ___ ____ 4 8 MSK100B 0200 NN __ ___ ____ 10 3 MSK100C 0200 NN __ ___ ____ 12 8 MSK100D 0200 NN __ ___ ____ 17 6 Last modification 20...

Page 330: ...ower Cables The power cables bulk cables of the RKL line by Rexroth have the capaci tances per unit length listed below The values refer to the sum of the single capacitances of power cores 1 2 and 3 against the overall shield See also Rexroth Connection Cables Data Sheet Bulk Cables Data Sheet Excerpt Bulk Cables Type Cross section of power core Leakage capacitance mm2 CY_K_typ nF m INK0653 1 0 0...

Page 331: ...heet Excerpt Bulk Cables Type Cross section of power core Leakage capacitance CY_K_typ mm2 nF m REH0800 2 5 0 2 Tab 11 10 REH Technical Data Excerpt Approximate calculation is allowed with the following values Cross section 1 6 mm2 1 nF m Cross section 10 50 mm2 1 2 nF m DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 329 341 Rexroth IndraDrive CsDrive Systems with HCS01 Appendix ...

Page 332: ...Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 330 341 Rexroth IndraDrive CsDrive Systems with HCS01 ...

Page 333: ...ransformers 290 Axis coupling 105 B BASIC HCS01 12 43 Batteries 313 Battery Battery box 259 266 Buffer battery for absolute value encoder of an MSM motor 270 Refresh 263 Replace 263 Replacement battery 261 SUP E03 DKC CS BATTRY 261 Bb relay contact Connection point X47 149 Control circuit for the mains connection 104 DC bus coupling 112 Technical data 229 Braking resistor External connection 141 E...

Page 334: ...7 151 Digital inputs digital output X31 147 Digital inputs outputs X37 165 Electrical 123 Encoder emulation X8 159 Equipment grounding conductor 127 Ground 158 Mains 75 Mains X3 129 Module bus X47 149 Motor X5 134 Motor encoder X4 132 Motor holding brake X6 138 Motor temperature monitoring X6 138 Optional encoder X8 159 Probe 147 PROFIBUS X30 162 Shield 155 Shield connection analog input 157 Shiel...

Page 335: ...type A standard input 218 Technical data type B probe 219 Digital outputs Connection point X31 147 Connection point X37 165 Technical data safety technology L options 223 Technical data safety technology S options 224 Technical data standard output 222 Dimensional drawing HCS01 1E W0003 5 6 8 9 13 60 HCS01 1E W0018 28 61 HCS01 1E W0054 62 Dimensional drawings HCS01 59 Dimensioning Line cross secti...

Page 336: ...upply voltage 185 Engineering interface X26 146 Environmental protection 313 Equipment grounding conductor Connection 127 ET Multi Ethernet connection point 144 Multi Ethernet LEDs 207 EtherCAT Multi Ethernet interface 144 External braking resistor Data 301 External wiring 93 323 F Field wiring 93 323 File numbers UL 114 Firmware Assigned HCS01 device types 44 Documentation 26 MPB 16VRS 44 MPB 17V...

Page 337: ...N NN 287 Type code 301 HNL Type code 297 Type plate 298 HNL01 1E 299 Technical data 299 Hotline 315 Housing dimensions HCS01 63 I Identification Of the components 118 Inappropriate use 30 Consequences exclusion of liability 29 Individual components Combining 41 Individual supply 82 IndraDrive Cs Overview 9 Target applications 10 Input Analog X32 148 Digital X31 147 Probe 147 Installation 24V suppl...

Page 338: ...2 Other loads 176 Mains transformer Dimensioning 95 Selecting 95 Mains types 78 Mains voltage HCS01 233 Mains side phase current Calculating 85 Mass HCS01 63 Mechanical project planning 59 microSD memory card ADVANCED control panel 231 PFM04 1 119 Module bus Connection point X47 149 Parameterization 112 Motor Cable lengths 53 Cable shield connection 155 Capacitance 326 Connection X5 134 Connection...

Page 339: ...Phase current Calculating 85 Port LED Displays 208 Probe Technical data 219 Probe input X31 147 Production processes 313 PROFIBUS Interface 162 Signal specification 214 PROFINET Multi Ethernet interface 144 Project planning Electrical project planning 68 Mechanical project planning 59 Protective extra low voltage 35 R RCCB 75 RCD 75 Recycling 313 Reference documentations 25 Refresh Battery SUP E03...

Page 340: ...coder 5 V supply voltage 190 Encoder 12 V supply voltage 191 Standard control panel 230 Standard encoder evaluation EC 181 Standard motors Voltage load 247 State of the art 29 Storing Components 120 SUP E01 MSM BATTERYBOX Battery box 259 SUP E02 MSM BATTERYBOX Battery box 266 SUP E03 DKC CS BATTRY 261 Supplied components 107 Supplied devices 107 Supply With control voltage 24 V 69 with mains volta...

Page 341: ...motor holding brake 138 X8 Encoder emulation 159 Optional encoder 159 X9 Braking resistor 141 X13 Control voltage 24 V 143 X22 P2 X23 P1 Multi Ethernet 161 X24 P2 X25 P1 Communication 144 X26 Engineering interface 146 X30 PROFIBUS PB 162 X31 Digital inputs digital output 147 X32 Analog input 148 X37 Digital inputs outputs 165 X38 Analog inputs outputs 166 X41 Optional safety technology Safe Motion...

Page 342: ...Notes Bosch Rexroth AG DOK INDRV HCS01 PR05 EN P 340 341 Rexroth IndraDrive CsDrive Systems with HCS01 ...

Page 343: ...Notes DOK INDRV HCS01 PR05 EN P Bosch Rexroth AG 341 341 Rexroth IndraDrive CsDrive Systems with HCS01 ...

Page 344: ... Electric Drives and Controls P O Box 13 57 97803 Lohr Germany Bgm Dr Nebel Str 2 97816 Lohr Germany Phone 49 9352 18 0 Fax 49 9352 18 8400 www boschrexroth com electrics R911322210 R911322210 DOK INDRV HCS01 PR05 EN P ...

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