Bosch Rexroth R911306140 IndraDrive Additional Components and Accessories Manual

Rexroth IndraDrive

Additional Components and Accessories

Project Planning Manual

R911306140

Edition 05

Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Type of Documentation

Document Typecode

Internal File Reference

Title Rexroth IndraDrive

Additional Components and Accessories

Project Planning Manual

DOK-INDRV*-ADDCOMP****-PR05-EN

RS-3aee9eb90a6846ac0139e9630b45f9bf-4-en-US-3

Record of Revision

Edition

05

04

Release Date Notes

2016-06

2014-02

See index entry "Edi‐ tions"

See index entry "Edi‐ tions"

Copyright

Liability

Published by

© Bosch Rexroth AG 2016

This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be re‐ produced or given to third parties without its consent.

The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract. All rights are reserved with respect to the content of this docu‐ mentation and the availability of the product.

Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr a. Main, Germany

Phone +49 9352 18 0 ■ Fax +49 9352 18 8400 http://www.boschrexroth.com/

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG I/431

Table of Contents

Table of Contents

1

1.1

1.1.1

1.1.2

1.1.3

Page

Introduction.................................................................................................................... 9

Documentation........................................................................................................................................ 9

General information............................................................................................................................. 9

Editions.............................................................................................................................................. 10

Overview of Documentations............................................................................................................. 12

2

2.1

2.1.1

2.1.2

2.2

Important directions for use......................................................................................... 17

Appropriate use.................................................................................................................................... 17

Introduction........................................................................................................................................ 17

Areas of use and application............................................................................................................. 17

Inappropriate use.................................................................................................................................. 18

3

3.3.3

3.3.4

3.3.5

3.3.6

3.3.7

3.3.8

3.4

3.1

3.2

3.2.1

3.2.2

3.2.3

3.3

3.3.1

3.3.2

Safety instructions for electric drives and controls....................................................... 19

Definitions of terms............................................................................................................................... 19

General information.............................................................................................................................. 20

Using the Safety instructions and passing them on to others............................................................ 20

Requirements for safe use................................................................................................................ 20

Hazards by improper use.................................................................................................................. 21

Instructions with regard to specific dangers.......................................................................................... 22

Protection against contact with electrical parts and housings........................................................... 22

Protective extra-low voltage as protection against electric shock .................................................... 23

Protection against dangerous movements........................................................................................ 24

Protection against electromagnetic and magnetic fields during operation and mounting.................. 25

Protection against contact with hot parts........................................................................................... 25

Protection during handling and mounting.......................................................................................... 26

Battery safety..................................................................................................................................... 26

Protection against pressurized systems............................................................................................ 27

Explanation of signal words and the Safety alert symbol..................................................................... 28

4

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

4.10

4.11

Brief description, use................................................................................................... 29

General information.............................................................................................................................. 29

Applications of the Drive System Rexroth IndraDrive........................................................................... 29

Mains Transformers DST and DLT....................................................................................................... 30

Mains Filters HNF, HNK, NFE, HNS02 and NFD................................................................................. 31

Mains Chokes HNL01 and HNL02........................................................................................................ 32

DC Bus Resistor Unit HLB01................................................................................................................ 33

Braking Resistor HLR01....................................................................................................................... 34

DC Bus Capacitor Unit HLC01............................................................................................................. 35

Motor Filters HMF01............................................................................................................................. 36

Housing for Control Sections HAC01................................................................................................... 37

HSZ01 safety zone module.................................................................................................................. 37

II/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Table of Contents

5

5.1

5.2

5.2.1

5.2.2

5.3

5.3.1

5.3.2

5.3.3

5.3.4

5.4

5.5

Page

General data and specifications................................................................................... 39

Acceptance tests and approvals........................................................................................................... 39

Transport and storage.......................................................................................................................... 41

Transporting the components............................................................................................................ 41

Storing the components..................................................................................................................... 42

Installation conditions........................................................................................................................... 42

Ambient and operating conditions..................................................................................................... 42

Control cabinet design and cooling................................................................................................... 44

Mounting position.............................................................................................................................. 45

Compatibility with foreign matters...................................................................................................... 46

Voltage testing and insulation resistance testing.................................................................................. 46

Control voltage (24V supply) ............................................................................................................... 47

6

6.1

6.2

6.2.1

6.2.2

6.2.3

Transformers................................................................................................................ 49

General Information.............................................................................................................................. 49

Autotransformers for Drive Controllers................................................................................................. 50

Types................................................................................................................................................. 50

Selection............................................................................................................................................ 51

Technical Data................................................................................................................................... 52

7

7.1

7.3.1

7.3.2

7.3.3

7.3.4

7.3.5

7.4

7.4.1

7.4.2

7.4.3

7.4.4

7.1.1

7.1.2

7.1.3

7.2

7.2.1

7.2.2

7.2.3

7.3

Mains filters.................................................................................................................. 53

Mains Filters NFD / NFE....................................................................................................................... 53

Type Code NFE / NFD...................................................................................................................... 53

Mechanical Data NFE / NFD............................................................................................................. 54

Electrical Data NFE / NFD................................................................................................................. 57

HNF01.1 - mains filter, 3-phase............................................................................................................ 59

Type code HNF01.1.......................................................................................................................... 59

Mechanical data HNF01.1................................................................................................................. 61

Electrical data HNF01.1..................................................................................................................... 66

HNK01.1 - mains filter, with mains choke............................................................................................. 72

Type code HNK01.1.......................................................................................................................... 72

Type plate HNK01.1.......................................................................................................................... 72

Mechanical data HNK01.1................................................................................................................. 74

Electrical data HNK01.1.................................................................................................................... 78

Arranging the components HCS03 drive controller and HNK01 mains filter..................................... 79

HNS02.1 - mains filter, with switch-disconnector.................................................................................. 83

Identification...................................................................................................................................... 83

Mechanical data HNS02.1................................................................................................................. 84

Electrical data HNS02.1.................................................................................................................... 85

Connection points.............................................................................................................................. 85

8

8.1

8.1.1

8.1.2

HNL - mains chokes for supply units and converters................................................... 87

Identification.......................................................................................................................................... 87

Type code.......................................................................................................................................... 87

Type plate.......................................................................................................................................... 88

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG III/431

8.2

8.2.1

8.3

8.3.1

8.3.2

8.4

8.4.1

8.4.2

8.5

8.5.1

8.5.2

Table of Contents

Page

HNL01.1E - mains chokes, feeding...................................................................................................... 88

Technical data................................................................................................................................... 88

HNL01.1R - mains chokes, regenerative.............................................................................................. 93

Safety instruction............................................................................................................................... 93

Technical data................................................................................................................................... 93

HNL01.1*-****-S - mains chokes, current-compensated....................................................................... 95

Function............................................................................................................................................. 95

Technical data................................................................................................................................... 96

HNL02.1 - mains choke........................................................................................................................ 98

Identification...................................................................................................................................... 98

Technical data................................................................................................................................... 99

9

9.1

9.1.1

9.2

9.2.1

9.2.2

9.3

9.4

9.4.1

9.4.2

9.4.3

9.5

HLL01 - DC Bus Choke, Current-Compensated........................................................ 103

Brief Description, Use and Commissioning........................................................................................ 103

Brief Description.............................................................................................................................. 103

Type Code and Identification.............................................................................................................. 103

Type Code....................................................................................................................................... 103

Identification.................................................................................................................................... 104

Scope of Supply.................................................................................................................................. 105

Installation and Mounting.................................................................................................................... 106

General Information......................................................................................................................... 106

Dimensions HLL01.......................................................................................................................... 107

Circuit Diagram HLL01.................................................................................................................... 107

Technical Data.................................................................................................................................... 108

10 HLC01 - DC Bus Capacitor Unit................................................................................ 111

10.1 Application Instructions....................................................................................................................... 111

10.2

10.3

10.3.1

10.3.2

10.4

10.4.1

10.4.2

10.4.3

Identification........................................................................................................................................ 112

Mounting............................................................................................................................................. 112

Notes............................................................................................................................................... 112

Mechanical Data.............................................................................................................................. 114

Installation........................................................................................................................................... 116

Electrical Data................................................................................................................................. 116

Connection Points........................................................................................................................... 116

Touch guard at devices................................................................................................................... 123

11 HLB01.1C and HLB01.1D - DC bus resistor unit....................................................... 127

11.1

11.2

11.3

11.3.1

11.4

11.4.1

11.4.2

11.4.3

Description.......................................................................................................................................... 127

Identification........................................................................................................................................ 127

Mounting HLB01.1.............................................................................................................................. 128

Mechanical data HLB01.1............................................................................................................... 128

Installing HLB01.1............................................................................................................................... 130

Electrical data HLB01.1................................................................................................................... 130

Connection points............................................................................................................................ 132

Touch guard at devices................................................................................................................... 145

IV/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Table of Contents

11.5

Page

Commissioning, operation, diagnostics.............................................................................................. 147

12 HLR01 - Braking Resistors........................................................................................ 151

12.1

12.2

12.2.1

12.2.2

12.3

12.4

12.4.1

12.4.2

12.4.3

12.5

12.5.1

12.5.2

12.5.3

Braking Resistor HLR01..................................................................................................................... 151

Type Code and Identification.............................................................................................................. 151

Type Code....................................................................................................................................... 151

Identification.................................................................................................................................... 152

Scope of Supply.................................................................................................................................. 153

Technical Data.................................................................................................................................... 154

Technical Data HLR01 for HCS02.1................................................................................................ 154

Technical Data HLR01 for HCS03.1E............................................................................................. 156

Technical Data HLR01 for HCS04.2................................................................................................ 162

Installation and Mounting.................................................................................................................... 163

Notes on Installation and Mounting................................................................................................. 163

Braking Resistors HLR01.1, Type of Construction A (Version for Device Mounting)...................... 164

Braking Resistors HLR01.1, Type of Construction N (Version for Free Assembly)......................... 173

13 HLT01 - Braking Unit................................................................................................. 177

13.1 Use..................................................................................................................................................... 177

13.2

13.3

13.3.1

13.3.2

13.3.3

Identification........................................................................................................................................ 178

Braking Unit HLT01.1A ...................................................................................................................... 179

Technical Data................................................................................................................................. 179

Braking Unit HLT01.1A -200K......................................................................................................... 180

Braking Unit HLT01.1A -400K......................................................................................................... 186

14 HMF01 - motor filter................................................................................................... 191

14.1

14.2

14.3

14.4

14.4.1

14.5

14.6

Type code........................................................................................................................................... 191

Type plate........................................................................................................................................... 192

Electrical data..................................................................................................................................... 193

Mechanical data.................................................................................................................................. 195

Dimensions, mass........................................................................................................................... 195

Arranging the components HCS03.1 with HMF motor filter................................................................ 198

Arranging the components HCS03.1 with motor filter and mains filter............................................... 202

15 HAC01 - Housing for Control Sections...................................................................... 207

15.1 Identification........................................................................................................................................ 207

15.1.1

15.1.2

15.2

15.3

15.3.1

15.3.2

Type Code....................................................................................................................................... 207

Type Plate....................................................................................................................................... 207

Use..................................................................................................................................................... 208

Mechanical and Electrical Data.......................................................................................................... 209

Dimensional Drawings HAC01.1..................................................................................................... 209

Connections at HAC01.................................................................................................................... 210

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG V/431

Table of Contents

Page

16 HAT01 - control module for holding brake................................................................. 213

16.1 Brief description, use and design........................................................................................................ 213

16.2

16.2.1

16.2.2

16.3

16.4

16.5

16.6

16.6.1

16.6.2

16.6.3

16.6.4

Type code and identification............................................................................................................... 213

Type code........................................................................................................................................ 213

Identification.................................................................................................................................... 214

Scope of supply.................................................................................................................................. 214

Dimensions......................................................................................................................................... 215

Technical data.................................................................................................................................... 215

Connection points............................................................................................................................... 217

Front view........................................................................................................................................ 217

X1, 24 V power supply..................................................................................................................... 218

X2, output to brake.......................................................................................................................... 218

X3, signal exchange with control section......................................................................................... 219

17 HAT02 - control module for inductive loads............................................................... 221

17.6.1

17.6.2

17.6.3

17.6.4

17.7

17.7.1

17.7.2

17.7.3

17.1

17.2

17.2.1

17.2.2

17.3

17.4

17.5

17.6

17.7.4

17.7.5

17.8

17.9

Brief description, use and design........................................................................................................ 221

Type code and identification............................................................................................................... 222

Type code........................................................................................................................................ 222

Identification.................................................................................................................................... 223

Scope of supply.................................................................................................................................. 224

Dimensions......................................................................................................................................... 225

Technical data.................................................................................................................................... 227

Connection points............................................................................................................................... 228

Front view........................................................................................................................................ 228

XG3, 24 V power supply, brake connection.................................................................................... 229

XG48, signal exchange with control section, brake control input.................................................... 231

XG49, switching state signal input................................................................................................... 233

Rotary coding switches S1, S2, S3, S4.............................................................................................. 234

Overview.......................................................................................................................................... 234

S1, withstand voltage...................................................................................................................... 235

S2, overexcitation duration.............................................................................................................. 236

S3, switching state signal evaluation............................................................................................... 237

S4, waiting time............................................................................................................................... 238

X6 adapter (RKL0091, RKL0092)....................................................................................................... 239

LED H1............................................................................................................................................... 240

18 HSZ01 - safety zone module..................................................................................... 243

18.1 Brief description, use, features........................................................................................................... 243

18.2

18.2.1

18.2.2

18.3

18.4

18.4.1

18.4.2

Type code and identification............................................................................................................... 244

Type code........................................................................................................................................ 244

Identification.................................................................................................................................... 245

Scope of supply.................................................................................................................................. 245

Dimensions......................................................................................................................................... 246

Mounted on a top-hat rail................................................................................................................. 246

Mounted with accessories HAS05.1-014-NNN-NN......................................................................... 247

VI/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Table of Contents

18.5

18.6

18.6.1

18.6.2

18.6.3

18.6.4

18.6.5

18.6.6

18.6.7

18.7

18.7.1

18.7.2

18.7.3

18.8

Page

Technical data.................................................................................................................................... 248

Connection points............................................................................................................................... 250

Position of connection points........................................................................................................... 250

X41, digital inputs............................................................................................................................ 251

Pin assignment, function................................................................................................................. 252

X44, digital outputs, control voltage supply..................................................................................... 253

Data................................................................................................................................................. 253

Pin assignment, function................................................................................................................. 254

X42 and X43, Safe Motion safety technology (communication)...................................................... 255

Digital inputs and outputs................................................................................................................... 256

Digital inputs (safety technology S options)..................................................................................... 256

Digital outputs (safety technology S options).................................................................................. 257

Digital outputs (safety technology S options, SDL)......................................................................... 259

LED H2............................................................................................................................................... 260

19 HAB01 Fan Unit......................................................................................................... 261

20 Accessories................................................................................................................ 263

20.1 HAS01, Basic Accessories................................................................................................................. 263

20.2.2

20.2.3

20.2.4

20.2.5

20.2.6

20.2.7

20.3

20.3.1

20.1.1

20.1.2

20.1.3

20.1.4

20.1.5

20.1.6

20.2

20.2.1

20.3.2

20.3.3

20.3.4

20.4

20.4.1

20.4.2

20.4.3

20.4.4

20.4.5

20.4.6

Type Code....................................................................................................................................... 263

Brief Description.............................................................................................................................. 264

Use.................................................................................................................................................. 264

Assignment...................................................................................................................................... 264

Scope of Supply.............................................................................................................................. 266

Mounting the "Bar" and "End Piece" Parts of the HAS01 Accessory.............................................. 296

HAS02, shield connection................................................................................................................... 297

General information......................................................................................................................... 297

Type code........................................................................................................................................ 298

Use.................................................................................................................................................. 299

Assignment of accessory HAS02.................................................................................................... 299

Scope of supply............................................................................................................................... 299

Mounting the accessory HAS02...................................................................................................... 319

Shield connection of the motor cable via mains filter ..................................................................... 327

HAS03, control cabinet adapter.......................................................................................................... 331

Type code........................................................................................................................................ 331

Use.................................................................................................................................................. 331

Assigning HAS03 accessories......................................................................................................... 332

Scope of supply............................................................................................................................... 332

HAS04, capacitor................................................................................................................................ 335

General information......................................................................................................................... 335

Type code........................................................................................................................................ 335

Use.................................................................................................................................................. 335

Assignment...................................................................................................................................... 336

Scope of supply............................................................................................................................... 336

Capacitor......................................................................................................................................... 339

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG VII/431

Table of Contents

Page

20.4.7

20.4.8

20.4.9

20.5

20.5.1

20.5.2

20.5.3

20.5.4

Mounting dimensions....................................................................................................................... 339

Mounting the HAS04.1-001 accessories......................................................................................... 340

Mounting the HAS04.1-002 accessories......................................................................................... 341

HAS05, accessories for connection points......................................................................................... 344

Overview of types............................................................................................................................ 344

Type code........................................................................................................................................ 346

HAS05.1-001, Adapter for Mains and Motor Connection................................................................ 348

HAS05.1-002, Extension................................................................................................................. 352

20.5.5

20.5.6

20.5.7

20.5.8

HAS05.1-003, Signal Level Converter Encoder Emulation............................................................. 354

HAS05.1-004, Adapter DC Bus Connection.................................................................................... 358

HAS05.1-005, Signal Level Converter RS232/RS485..................................................................... 367

HAS05.1-006, Adapter for Controlling Motor Holding Brake........................................................... 373

20.5.9 HAS05.1-007, Adapter From D-Sub to Terminal Connector........................................................... 378

20.5.10 HAS05.1-008, Adapter for Connecting two Cables......................................................................... 385

20.5.11 HAS05.1-009, Coding Pin for Terminal Connector RHS................................................................. 388

20.5.12 HAS05.1-010, Brake Current Monitoring......................................................................................... 389

20.6.1

20.6.2

20.6.3

20.7

20.7.1

20.7.2

20.8

20.8.1

20.8.2

20.5.13 HAS05.1-014, Mounting Plate for Safety Zone Module................................................................... 399

20.5.14 Snap-on ferrite (HAS05.1-015)........................................................................................................ 401

20.5.15 HAS05.1-016, brake module with connectors................................................................................. 404

20.5.16 HAS05.1-017, X6 adapter............................................................................................................... 405

20.5.17 HAS05.1-018, dummy plate for KMS03 encoder connection.......................................................... 406

20.5.18 HAS05.1-019, KNK03 mains voltage.............................................................................................. 407

20.5.19 HAS05.1-020, KMV03 control voltage............................................................................................. 408

20.6 HAS10, mechanical mounting parts................................................................................................... 409

Type code........................................................................................................................................ 409

Use.................................................................................................................................................. 409

Scope of supply............................................................................................................................... 410

Fiber Optic Cable Connections........................................................................................................... 413

Overview of Types........................................................................................................................... 413

Interconnection of Drive Controllers................................................................................................ 414

RKB0001, Extension for Module Bus Connections............................................................................ 418

Use.................................................................................................................................................. 418

Mounting.......................................................................................................................................... 419

21 Environmental protection and disposal ..................................................................... 421

21.1

21.2

Environmental protection.................................................................................................................... 421

Disposal.............................................................................................................................................. 421

22 Service and support................................................................................................... 423

Index.......................................................................................................................... 425

VIII/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 9/431

Introduction

1 Introduction

1.1 Documentation

1.1.1 General information

This documentation This documentation describes the following additional components and ac‐ cessories for Rexroth IndraDrive systems:

● Transformers (DST)

● Mains filters (HNF, HNK, HNS, NFE, NFD)

● Mains chokes (HNL)

● DC bus chokes (HLL)

● DC bus capacitor units (HLC)

● DC bus resistor units (HLB)

● Braking resistors (HLR)

● Braking units (HLT01)

● Motor filters (HMF)

● Housings for control sections (HAC)

● Control module for holding brake (HAT01)

● Control module for inductive loads (HAT02)

● Safety zone module (HSZ)

● Fan unit (HAB)

● Accessories (HAS)

WARNING Personal injury and property damage by in‐ correct configuration of applications, ma‐ chines and installations!

Take the contents of the following documentation into account: "Rexroth

IndraDrive, Drive Systems with HMV01/02, HMS01/02, HMD01, HCS02/03"

(DOK-INDRV*-SYSTEM*****-PRxx-EN-P; mat. no.: R911309636). This docu‐ mentation, among other things, contains:

● General specifications for the components of the drive system

● Configuration of the drive system components

● Arranging the components in the control cabinet

● Electromagnetic compatibility (EMC)

● Types of mains connection

● Requirements on the mains connection

● Control circuits for the mains connection

● Connections of the components in the drive system

● Fusing and selection of the mains contactor

● Calculations (determining appropriate drive controller; mains connec‐ tion; leakage capacitance; operating data of mains filters; selecting the

24V supply; braking behavior when using a DC bus resistor unit)

10/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Introduction

1.1.2 Editions

Edition

05

Notes

●

●

Changes in comparison to previous edition:

New contents

● HAT02 control module for inductive loads

HNF01.1C mains filter

HAS05.1-016, -017, -018, -019, -020 accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 11/431

Introduction

Edition

04

Notes

●

●

●

●

Changes in comparison to previous edition:

New contents

● HSZ safety zone module

● HLT braking unit

● HAB fan unit

Revised contents

● HMF01 motor filter:

●

●

●

●

●

●

–

–

Updated type code

Updated data

Mains filter:

– Updated type code

–

–

HNF01: Added data of connection points

HNK01: Updated data, added connection cross sections

Mains choke:

– Updated type code

–

–

– HNL02: Added data of connection points

HLL DC bus choke:

Removed "Preliminary" note

Updated type code

– Included current characteristic

HLC DC bus capacitor unit:

– Updated data

HLB DC bus resistor unit:

–

–

Updated type code

Updated data

HLR braking resistors:

– Updated type code

–

–

Updated data

Included braking resistors for HCS04

Updated accessories

General data and specifications:

–

–

Included information on control cabinet design and cooling

Removed information regarding motors

Updated overview of documentations

Modified design of safety instructions in accordance with the ANSI Z535.6 standard

Tab. 1-1: Editions

12/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Introduction

1.1.3 Overview of Documentations

Drive Systems, System Components

Title

Rexroth IndraDrive …

Kind of documentation Document typecode 1)

DOK-INDRV*-…

SYSTEM*****-PRxx-EN-P

Material number

R911…

309636 Drive Systems with HMV01/02

HMS01/02, HMD01, HCS02/03

Mi Drive Systems with KCU01, KSM01, KMS01

Mi Drive Systems with KCU02, KSM02, KMS02

Supply Units, Power Sections

HMV, HMS, HMD, HCS02, HCS03

Drive Controllers

Control Sections CSB01, CSH01,

CDB01

Control Sections

CSE02, CSB02, CDB02, CSH02

Additional Components and Accesso‐ ries

1)

Title

Automation Terminals

Of The Rexroth Inline

Product Range

Project Planning Manual

Project Planning Manual

Project Planning Manual

Project Planning Manual

Project Planning Manual

Project Planning Manual

Project Planning Manual

Application Manual

KCU+KSM****-PRxx-EN-P

KCU02+KSM02-PRxx-EN-P

HMV-S-D+HCS-PRxx-EN-P

CSH********-PRxx-EN-P

Cxx02******-PRxx-EN-P

ADDCOMP****-PRxx-EN-P

DOK-CONTRL-ILSYSINS***-

AWxx-EN-P

320924

335703

318790

295012

338962

306140

Tab. 1-2:

In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: PR01 is the first edition of a Project Planning Manual)

Documentations – Overview

Kind of documentation Document typecode 1) Material number

R911…

317021

1)

Tab. 1-3:

In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: AW01 is the first edition of an Application Manual)

Documentations – Overview

Motors

Title

Rexroth IndraDyn …

A Asynchronous Motors MAD / MAF

H Synchronous Kit Spindle Motors

L Synchronous Linear Motors

Kind of documentation

Project Planning Manual

Project Planning Manual

Project Planning Manual

Document typecode 1)

DOK-MOTOR*-…

MAD/MAF****-PRxx-EN-P

MBS-H******-PRxx-EN-P

MLF********-PRxx-EN-P

Material number

R911…

295781

297895

293635

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 13/431

Introduction

Title

Rexroth IndraDyn …

S Synchronous Motors MSK

T Synchronous Torque Motors

Kind of documentation Document typecode 1)

DOK-MOTOR*-…

MSK********-PRxx-EN-P

Material number

R911…

Project Planning Manual 296289

1)

Project Planning Manual

Tab. 1-4:

MBT********-PRxx-EN-P 298798

In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: PR01 is the first edition of a Project Planning Manual)

Documentations – Overview

Cables

Title

Rexroth Connection Cables

IndraDrive and IndraDyn

Kind of documentation

Selection Data

Document typecode 1)

DOK-…

CONNEC-CABLE*INDRV-CAxx-

EN-P

Material number

R911…

322949

1) In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: CA02 is the second ed‐ ition of the documentation "Selection Data")

Documentations – Overview

Firmware

Title

Rexroth IndraDrive …

Firmware for Drive Controllers

MPH-08, MPB-08, MPD-08, MPC-08

Firmware for Drive Controllers

MPH-07, MPB-07, MPD-07, MPC-07

Firmware for Drive Controllers

MPH-06, MPB-06, MPD-06, MPC-06

Firmware for Drive Controllers

MPH-05, MPB-05, MPD-05

Firmware for Drive Controllers

MPH-04, MPB-04, MPD-04

Firmware for Drive Controllers

MPH-03, MPB-03, MPD-03

Firmware for Drive Controllers

MPH-02, MPB-02, MPD-02

Drive Controllers

MPx-02 to MPx-08

MPx-02 to MPx-08 and HMV

Integrated Safety Technology

Tab. 1-5:

Kind of documentation

Functional Description

Functional Description

Functional Description

Functional Description

Functional Description

Functional Description

Functional Description

Parameter Description

Troubleshooting Guide

Functional and Application

Description

Document typecode 1)

DOK-INDRV*-…

MP*-08VRS**-APxx-EN-P

MP*-07VRS**-FKxx-EN-P

MP*-06VRS**-FKxx-EN-P

MP*-05VRS**-FKxx-EN-P

MP*-04VRS**-FKxx-EN-P

MP*-03VRS**-FKxx-EN-P

MP*-02VRS**-FKxx-EN-P

GEN-**VRS**-PAxx-EN-P

GEN-**VRS**-WAxx-EN-P

SI*-**VRS**-FKxx-EN-P

Part number

R911…

332643

328670

326766

320182

315485

308329

299223

297317

297319

297838

14/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Introduction

Title

Rexroth IndraDrive …

Integrated Safety Technology

According to IEC61508

Rexroth IndraMotion MLD

Rexroth IndraMotion MLD

Library

Title

Rexroth IndraDrive

MPx-18

Functions

Rexroth IndraDrive

MPx-18

Version Notes

Rexroth IndraDrive

MPx-16 to MPx-18

Parameters

Rexroth IndraDrive

MPx-16 to MPx-18

Diagnostic Messages

Rexroth IndraDrive

Integrated Safety Technology as of MPx-1x (Safe Torque Off)

Rexroth IndraDrive

Integrated Safety Technology as of MPx-1x (Safe Motion)

Rexroth IndraDrive

Rexroth IndraMotion MLD (2G)

Libraries as of MPx-18

Rexroth IndraDrive

Rexroth IndraMotion MLD (2G) as of MPx-18

Kind of documentation

Functional Description

Document typecode 1)

DOK-INDRV*-…

SI2-**VRS**-FKxx-EN-P

Part number

R911…

327664

Application Manual

Library Description

MLD-**VRS**-AWxx-EN-P

MLD-SYSLIB*-FKxx-EN-P

306084

309224

1)

Tab. 1-6:

In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: FK02 is the second edi‐ tion of a Functional Description)

Documentations – Overview

Kind of documentation Document typecode 1)

Application Manual DOK-INDRV*-MP*-18VRS**-

APxx-EN-P

Material number

R911…

338673

Release Notes

Reference Book

Reference Book

Application Manual

Application Manual

Reference Book

Application Manual

DOK-INDRV*-MP*-18VRS**-

RNxx-EN-P

DOK-INDRV*-GEN1-PARA**-

RExx-EN-P

DOK-INDRV*-GEN1-DIAG**-

RExx-EN-P

DOK-INDRV*-SI3-**VRS**-APxx-

EN-P

DOK-INDRV*-SI3*SMO-VRS-

APxx-EN-P

DOK-INDRV*-MLD-SYSLIB3-

RExx-EN-P

DOK-INDRV*-MLD3-**VRS*-

APxx-EN-P

338658

328651

326738

332634

338920

338916

338914

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 15/431

Introduction

Title Kind of documentation Document typecode 1) Material number

R911…

341708 Rexroth IndraDrive

Rexroth IndraMotion MLD (2G) as of MPx-18

Rexroth IndraMotion

MLD 13VRS

Service Tool

Commissioning Manual

Tab. 1-8:

Reference Book

DOK-INDRV*-MLD3-F*STEP-

COxx-EN-P

DOK-IM*MLD-IMST****V13-RExx-

EN-P

341347

Title

Productivity Agent

Extended Diagnostic Functions with

Rexroth IndraDrive

1)

Tab. 1-7:

In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: RE02 is the second ed‐ ition of a Reference Book)

Documentations – Firmware

Kind of documentation Document typecode 1)

Application Manual DOK-INDRV*-MLD-PAGENT*-

AWxx-EN-P

Material number

R911…

323947

1) In the document typecodes, "xx" is a wild card for the current edition of the documentation (example: AW01 is the first edition of an Application Manual)

Documentations – Overview

16/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 17/431

Important directions for use

2 Important directions for use

2.1 Appropriate use

2.1.1 Introduction

Rexroth products represent state-of-the-art developments and manufacturing.

They are tested prior to delivery to ensure operating safety and reliability.

WARNING Personal injury and property damage caused by incorrect use of the products!

The products have been designed for use in the industrial environment and may only be used in the appropriate way. If they are not used in the appropri‐ ate way, situations resulting in property damage and personal injury can oc‐ cur.

Rexroth as manufacturer is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks.

Before using Rexroth products, make sure that all the pre-requisites for an appropriate use of the products are satisfied:

● Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with their appropriate use.

● If the products take the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes.

● 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 control electric motors and monitor their operation.

Control and monitoring of the Drive controllers may require additional sensors and actuators.

The drive controllers may only be used with the accessories and parts specified in this documentation. If a component has not been specifically named, then it may neither be mounted nor con‐ nected. The same applies to cables and lines.

Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant Functional Descriptions.

Drive controllers have to be programmed before commissioning to ensure that the motor executes the specific functions of an application.

Drive controllers of the Rexroth IndraDrive series have been developed for use in single- and multi-axis drive and control tasks.

18/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Important directions for use

2.2

To ensure application-specific use of Drive controllers, device types of differ‐ ent drive power and different interfaces are available.

Typical applications include, for example:

● Handling and mounting systems

● Packaging and food machines

● Printing and paper processing machines

● Machine tools

Drive controllers may only be operated under the assembly and installation conditions described in this documentation, in the specified position of normal use and under the ambient conditions as described (temperature, degree of protection, humidity, EMC, etc.).

Inappropriate use

Using the Drive controllers outside of the operating conditions described in this documentation and outside of the indicated technical data and specifica‐ tions is defined as "inappropriate use".

Drive controllers may not be used, if …

● they are subject to operating conditions that do not meet the specified ambient conditions. This includes, for example, operation under water, under extreme temperature fluctuations or extremely high maximum temperatures.

● Furthermore, Drive controllers may not be used in applications which have not been expressly authorized by Rexroth. Please carefully follow the specifications outlined in the general Safety Instructions!

Components of the Rexroth IndraDrive system are products of

Category C3 (with restricted distribution) in accordance with

IEC 61800-3. This Category comprises EMC limit values for linebased and radiated noise emission. Compliance with this Catego‐ ry (limit values) requires the appropriate measures of interference suppression to be used in the drive system (e.g., mains filters, shielding measures).

These components are not provided for use in a public low-volt‐ age mains supplying residential areas. If these components are used in such a mains, high-frequency interference is to be expec‐ ted. This can require additional measures of interference suppres‐ sion.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 19/431

Safety instructions for electric drives and controls

3 Safety instructions for electric drives and controls

3.1 Definitions of terms

Application documentation

Component

Control system

Device

Electrical equipment

Electric drive system

Installation

Machine

Manufacturer

Product

Project Planning Manual

Qualified persons

Application documentation comprises the entire documentation used to in‐ form the user of the product about the use and safety-relevant features for configuring, integrating, installing, mounting, commissioning, operating, main‐ taining, repairing and decommissioning the product. The following terms are also used for this kind of documentation: Operating Instructions, Commis‐ sioning Manual, Instruction Manual, Project Planning Manual, Application De‐ scription, etc.

A component is a combination of elements with a specified function, which are part of a piece of equipment, device or system. Components of the elec‐ tric drive and control system are, for example, supply units, drive controllers, mains choke, mains filter, motors, cables, etc.

A control system comprises several interconnected control components placed on the market as a single functional unit.

A device is a finished product with a defined function, intended for users and placed on the market as an individual piece of merchandise.

Electrical equipment encompasses all devices used to generate, convert, transmit, distribute or apply electrical energy, such as electric motors, trans‐ formers, switching devices, cables, lines, power-consuming devices, circuit board assemblies, plug-in units, control cabinets, etc.

An electric drive system comprises all components from mains supply to mo‐ tor shaft; this includes, for example, electric motor(s), motor encoder(s), sup‐ ply units and drive controllers, as well as auxiliary and additional compo‐ nents, such as mains filter, mains choke and the corresponding lines and ca‐ bles.

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.

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 well as control and power circuits, which have been assembled for a specific application. A machine is, for example, intended for processing, treatment, movement or packaging of a material. The term "machine" also covers a combination of machines which are arranged and controlled in such a way that they function as a unified whole.

The manufacturer is an individual or legal entity bearing responsibility for the design and manufacture of a product which is placed on the market in the in‐ dividual's or legal entity's name. The manufacturer can use finished products, finished parts or finished elements, or contract out work to subcontractors.

However, the manufacturer must always have overall control and possess the required authority to take responsibility for the product.

Examples of a product: Device, component, part, system, software, firmware, among other things.

A Project Planning Manual is part of the application documentation used to support the sizing and planning of systems, machines or installations.

In terms of this application documentation, qualified persons are those per‐ sons who are familiar with the installation, mounting, commissioning and op‐ eration of the components of the electric drive and control system, as well as with the hazards this implies, and who possess the qualifications their work

20/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Safety instructions for electric drives and controls

User requires. To comply with these qualifications, it is necessary, among other things,

● to be trained, instructed or authorized to switch electric circuits and devi‐ ces safely on and off, to ground them and to mark them.

● to be trained or instructed to maintain and use adequate safety equip‐ ment.

● to attend a course of instruction in first aid.

A user is a person installing, commissioning or using a product which has been placed on the market.

3.2 General information

3.2.1 Using the Safety instructions and passing them on to others

Do not attempt to install and operate the components of the electric drive and control system without first reading all documentation provided with the prod‐ uct. Read and understand these safety instructions and all user documenta‐ tion prior to working with these components. If you do not have the user doc‐ umentation for the components, contact your responsible Rexroth sales part‐ ner. Ask for these documents to be sent immediately to the person or per‐ sons responsible for the safe operation of the components.

If the component is resold, rented and/or passed on to others in any other form, these safety instructions must be delivered with the component in the official language of the user's country.

Improper use of these components, failure to follow the safety instructions in this document or tampering with the product, including 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 from failure to observe the safety instructions.

● Read the operating, maintenance and safety instructions in your lan‐ guage before commissioning. If you find that you cannot completely un‐ derstand the application documentation in the available language, please ask your supplier to clarify.

● Proper and correct transport, storage, mounting and installation, as well as care in operation and maintenance, are prerequisites for optimal and safe operation of the component.

● Only qualified persons may work with components of the electric drive and control system or within its proximity.

● Only use accessories and spare parts approved by Rexroth.

● Follow the safety regulations and requirements of the country in which the components of the electric drive and control system are operated.

● Only use the components of the electric drive and control system in the manner that is defined as appropriate. See chapter "Appropriate Use".

● The ambient and operating conditions given in the available application documentation must be observed.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 21/431

Safety instructions for electric drives and controls

● Applications for functional safety are only allowed if clearly and explicitly specified in the application documentation "Integrated Safety Technolo‐ gy". If this is not the case, they are excluded. Functional safety is a safe‐ ty concept in which measures of risk reduction for personal safety de‐ pend on electrical, electronic or programmable control systems.

● The information given in the application documentation with regard to the use of the delivered components contains only examples of applica‐ tions and suggestions.

The machine and installation manufacturers must

– make sure that the delivered components are suited for their indi‐ vidual application and check the information given in this applica‐ tion documentation with regard to the use of the components,

– make sure that their individual application complies with the appli‐ cable safety regulations and standards and carry out the required measures, modifications and complements.

● Commissioning of the delivered components is only allowed once it is sure that the machine or installation in which the components are instal‐ led complies with the national regulations, safety specifications and standards of the application.

● Operation is only allowed if the national EMC regulations for 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 specified in the respective application documentations and must be followed at all times.

National regulations which the user has to comply with

● European countries: In accordance with European EN standards

● United States of America (USA):

– National Electrical Code (NEC)

– National Electrical Manufacturers Association (NEMA), as well as local engineering regulations

– Regulations of the National Fire Protection Association (NFPA)

● Canada: Canadian Standards Association (CSA)

● Other countries:

– International Organization for Standardization (ISO)

– International Electrotechnical Commission (IEC)

3.2.3 Hazards by improper use

● High electrical voltage and high working current! Danger to life or seri‐ ous injury by electric shock!

● High electrical voltage by incorrect connection! Danger to life or injury by electric shock!

● Dangerous movements! Danger to life, serious injury or property dam‐ age by unintended motor movements!

22/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Safety instructions for electric drives and controls

● Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electric drive systems!

● Risk of burns by hot housing surfaces!

● Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!

● Risk of injury by improper handling of batteries!

● Risk of injury by improper handling of pressurized lines!

3.3 Instructions with regard to specific dangers

3.3.1 Protection against contact with electrical parts and housings

This section concerns components of the electric drive and con‐ trol system with voltages of more than 50 volts.

Contact with parts conducting voltages above 50 volts can cause personal danger and electric shock. When operating components of the electric drive and control system, it is unavoidable that some parts of these components conduct dangerous voltage.

High electrical voltage! Danger to life, risk of injury by electric shock or seri‐ ous injury!

● Only qualified persons are allowed to operate, maintain and/or repair the components of the electric drive and control system.

● Follow the general installation and safety regulations when working on power installations.

● Before switching on, the equipment grounding 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 electric components from the mains or from the power supply unit. Secure the electric component from reconnec‐ tion.

● With electric components, observe the following aspects:

Always wait 30 minutes after switching off power to allow live capacitors to discharge before accessing an electric component. Measure the elec‐ trical voltage of live parts before beginning to work to make sure that the equipment is safe to touch.

● Install the covers and guards provided for this purpose before switching on.

● Never touch any electrical connection points of the components while power is turned on.

● Do not remove or plug in connectors when the component has been powered.

● Under specific conditions, electric drive systems can be operated at mains protected by residual-current-operated circuit-breakers sensitive to universal current (RCDs/RCMs).

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 23/431

Safety instructions for electric drives and controls

● Secure built-in devices from penetrating foreign objects and water, as well as from direct contact, by providing an external housing, for exam‐ ple a control cabinet.

High housing voltage and high leakage current! Danger to life, risk of injury by electric shock!

● 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 an equipment grounding connection with a minimum cross section according to the table below. With an outer conductor cross sec‐ tion smaller than 10 mm 2 (8 AWG), the alternative connection of two equipment grounding conductors is allowed, each having the same cross section as the outer conductors.

Cross section outer con‐ ductor

1.5 mm 2 (16 AWG)

2.5 mm 2 (14 AWG)

4 mm 2 (12 AWG)

6 mm 2 (10 AWG)

10 mm 2 (8 AWG)

16 mm 2 (6 AWG)

25 mm 2 (4 AWG)

35 mm 2 (2 AWG)

50 mm 2 (1/0 AWG)

70 mm 2 (2/0 AWG)

...

Minimum cross section equipment grounding conductor

Leakage current ≥ 3.5 mA

1 equipment grounding conductor

2 equipment grounding conductors

2 × 1.5 mm 2 (16 AWG)

10 mm 2 (8 AWG)

2 × 2.5 mm 2 (14 AWG)

2 × 4 mm 2 (12 AWG)

2 × 6 mm 2 (10 AWG)

-

-

16 mm

25 mm

35 mm

2

2

2

(6 AWG)

(4 AWG)

(2 AWG)

...

-

-

-

-

...

Tab. 3-1: Minimum cross section of the equipment grounding connection

3.3.2 Protective extra-low voltage as protection against electric shock

Protective extra-low voltage is used to allow connecting devices with basic in‐ sulation to extra-low voltage circuits.

On components of an electric drive and control system provided by Rexroth, all connections and terminals with voltages up to 50 volts are PELV ("Protec‐ tive Extra-Low Voltage") systems. It is allowed to connect devices equipped with basic insulation (such as programming devices, PCs, notebooks, display units) to these connections.

24/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Safety instructions for electric drives and controls

Danger to life, risk of injury by electric shock! High electrical voltage by incor‐ rect connection!

If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g., the mains connection) are connected to Rexroth products, the connected extra-low voltage circuits must comply with the re‐ quirements for PELV ("Protective Extra-Low Voltage").

3.3.3 Protection against dangerous movements

Dangerous movements can be caused by faulty control of connected motors.

Some common examples are:

● Improper or wrong wiring or cable connection

● Operator errors

● Wrong input of parameters before commissioning

● Malfunction of sensors and encoders

● Defective components

● Software or firmware errors

These errors can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation.

The monitoring functions in the components of the electric drive and control system will normally be sufficient to avoid malfunction in the connected drives. Regarding personal safety, especially the danger of injury and/or property damage, this alone cannot be relied upon to ensure complete safety.

Until the integrated monitoring functions become effective, it must be as‐ sumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of 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 assessment, the user must provide for monitoring func‐ tions and higher-level measures on the installation side for personal safety.

The safety regulations applicable to the installation or machine must be taken into consideration. Unintended machine movements or other malfunctions are possible if safety devices are disabled, bypassed or not activated.

To avoid accidents, injury and/or property damage:

● Keep free and clear of the machine’s range of motion and moving ma‐ chine parts. Prevent personnel from accidentally entering the machine’s range of motion by using, for example:

– Safety fences

– Safety guards

– Protective coverings

– Light barriers

● Make sure the safety fences and protective coverings are strong enough to resist maximum possible kinetic energy.

● Mount emergency stopping switches in the immediate reach of the oper‐ ator. Before commissioning, verify that the emergency stopping equip‐

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 25/431

Safety instructions for electric drives and controls ment works. Do not operate the machine if the emergency stopping switch is not working.

● Prevent unintended start-up. Isolate the drive power connection by means of OFF switches/OFF buttons or use a safe starting lockout.

● Make sure that the drives are brought to safe standstill before accessing or entering the danger zone.

● Additionally secure vertical axes against falling or dropping after switch‐ ing off the motor power by, for example,

– mechanically securing the vertical axes,

– adding an external braking/arrester/clamping mechanism or

– ensuring sufficient counterbalancing of the vertical axes.

● The standard equipment motor holding brake or an external holding brake controlled by the drive controller is not sufficient to guarantee per‐ sonal safety!

● Disconnect electrical power to the components of the electric drive and control system using the master switch and secure them from reconnec‐ tion ("lock out") for:

– Maintenance and repair work

– Cleaning of equipment

– Long periods of discontinued equipment use

● Prevent the operation of high-frequency, remote control and radio equip‐ ment near components of the electric drive and control system and their supply leads. If the use of these devices 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 magnetic fields during opera‐ tion and mounting

Electromagnetic and magnetic fields!

Health hazard for persons with active implantable medical devices (AIMD) such as pacemakers or passive metallic implants.

● Hazards for the above-mentioned groups of persons by electromagnetic and magnetic fields in the immediate vicinity of drive controllers and the associated current-carrying conductors.

● Entering these areas can pose an increased risk to the above-men‐ tioned groups of persons. They should seek advice from their physician.

● If overcome by possible effects on above-mentioned persons during op‐ eration of drive controllers and accessories, remove the exposed per‐ sons from the vicinity of conductors and devices.

3.3.5 Protection against contact with hot parts

Hot surfaces of components of the electric drive and control system. Risk of burns!

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Rexroth IndraDrive Additional Components and Accessories

Safety instructions for electric drives and controls

● Do not touch hot surfaces of, for example, braking resistors, heat sinks, supply units and drive controllers, motors, windings and laminated cores!

● According to the operating conditions, temperatures of the surfaces can be higher than 60 °C (140 °F) during or after operation.

● Before touching motors after having switched them off, let them cool down for a sufficient period of time. Cooling down can require up to 140 minutes! The time required for cooling down is approximately five times the thermal time constant specified in the technical data.

● After switching chokes, supply units and drive controllers off, wait 15 mi‐ nutes to allow them to cool down before touching them.

● Wear safety gloves or do not work at hot surfaces.

● For certain applications, and in accordance with the respective safety regulations, the manufacturer of the machine or installation must take measures to avoid injuries caused by burns in the final application.

These measures can be, for example: Warnings at the machine or in‐ stallation, guards (shieldings or barriers) or safety instructions in the ap‐ plication documentation.

3.3.6 Protection during handling 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 equipment (hard hat, safety goggles, safety shoes, safety gloves, for example).

● Do not stand under hanging loads.

● Immediately clean up any spilled liquids from the floor due to the risk of falling!

3.3.7 Battery safety

Batteries consist of active chemicals in a solid housing. Therefore, improper handling can cause injury or property damage.

Risk of injury by improper handling!

● Do not attempt to reactivate low batteries by heating or other methods

(risk of explosion and cauterization).

● Do not attempt to recharge the batteries as this may cause leakage or explosion.

● Do not throw batteries into open flames.

● Do not dismantle batteries.

● When replacing the battery/batteries, do not damage the electrical parts installed in the devices.

● Only use the battery types specified for the product.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 27/431

Safety instructions for electric drives and controls

Environmental protection and disposal! The batteries contained in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regula‐ tions. Dispose of used batteries separately from other waste. Ob‐ serve the national regulations of your country.

3.3.8 Protection against pressurized systems

According to the information given in the Project Planning Manuals, motors and components cooled with liquids and compressed air can be partially sup‐ plied with externally fed, pressurized media, such as compressed air, hy‐ draulics oil, cooling liquids and cooling lubricants. Improper handling of the connected supply systems, supply lines 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).

● Immediately clean up any spilled liquids from the floor due to the risk of falling!

Environmental protection and disposal! The agents (e.g., fluids) used to operate the product might not be environmentally friendly.

Dispose of agents harmful to the environment separately from other waste. Observe the national regulations of your country.

28/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Safety instructions for electric drives and controls

3.4 Explanation of signal words and the Safety alert symbol

The Safety Instructions in the available application documentation contain specific signal words (DANGER, WARNING, CAUTION or NOTICE) and, where required, a safety alert symbol (in accordance with ANSI

Z535.6-2011).

The signal word is meant to draw the reader's attention to the safety instruc‐ tion and identifies the hazard severity.

The safety alert symbol (a triangle with an exclamation point), which 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 could occur.

NOTICE

In case of non-compliance with this safety instruction, property damage could occur.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

4

4.1

4.2

Bosch Rexroth AG 29/431

Brief description, use

Brief description, use

General information

In terms of "Appropriate use", cases of operation and applications not men‐ tioned in this chapter are not allowed.

Applications of the Drive System Rexroth IndraDrive

The digital, intelligent drive system Rexroth IndraDrive is the cost-efficient solution with a high degree of functionality for single-axis and multi-axis drive and control tasks.

The drive system Rexroth IndraDrive fulfills a large number of drive tasks in the most varied applications.

Typical applications are the industrial sectors:

● Printing and paper converting

● Packaging and food

● Mounting and handling

● Wood machining

● Machine tools

● Metal forming

● General automation

For these applications there are different device types of graduated perform‐ ance.

30/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Brief description, use

4.3 Mains Transformers DST and DLT

DST and DLT transformers are used to transform mains voltages to the al‐ lowed nominal voltages of the devices.

DLT transformers are used to

● prevent overvoltage between outer conductor and ground

● protect other loads against leakage currents

Type

DST autotransformer

DLT isolating transformer

Tab. 4-1:

Usage

Adjusting voltage range in grounded mains

Adjusting voltage range in ungrounded mains

Usage of Transformers

As a matter of principle, DLT isolating transformers have to be used at ungrounded mains.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

4.4

Bosch Rexroth AG 31/431

Brief description, use

Mains Filters HNF, HNK, NFE, HNS02 and NFD

Mains filters reduce radio interference and mains pollution.

When using mains filters HNF01, NFD03, HNS02 and HNK01 at mains grounded via outer conductor, use an isolating transformer between mains and mains filter.

Type

NFE01.1

NFE02.1

NFD03.1

HNF01.1

HNK01.1

HNS02

Tab. 4-2:

Usage

Interference suppression of power supply units up to

230 V

Interference suppression of single-phase drive controllers up to 230 V

Interference suppression of three-phase drive controllers up to 480 V for 1-6 axes and motor cable lengths up to max. 75 m single-axis / 120 m multi-axis

Interference suppression of three-phase drive controllers up to 480 V for drive systems with a high number of axes and long motor cables

Interference suppression of three-phase drive controllers

HCS03.1E up to 500 V

Interference suppression of three-phase drive controllers up to 480 V for drive systems with a maximum of 12 axes and a maximum of 200 m motor cable length

Integrated switch-disconnector

Usage of Mains Filters

Only operate expressly allowed components at the mentioned mains filters. Operating, for example, blowers, pumps etc. at HNF mains filters is not allowed.

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Rexroth IndraDrive Additional Components and Accessories

Brief description, use

4.5 Mains Chokes HNL01 and HNL02

(Standard) mains chokes HNL01.1E, HNL01.1R and HNL02.1R

● reduce harmonics in the mains current

● increase the allowed DC bus continuous power of certain converters

● allow operating regenerative supply units at the mains

Current-compensated mains chokes HNL01.1E-****-S and HNL01.1R-****-S reduce asymmetric currents (leakage currents) in the mains connection phase of the drive system.

The different types may be used exclusively as follows:

Type

HNL01.1R

HNL01.1E

HNL01.1*-****-S

HNL02.1R

Tab. 4-3:

Usage

For connection to components with regeneration to the supply mains (HMV01.1R)

For connection to components without regeneration to the supply mains (HMV01.1E, HCS02.1E, HCS03.1E)

Current-compensated chokes for use with HNL01.1 mains chokes to reduce asymmetric currents (leakage currents) in the mains connection phase of the drive system

(HMV01.1E, HMV01.1R, HCS02.1E, HCS03.1E)

Mains chokes in housing for control cabinet mounting for connection to components with regeneration to the supply mains (HMV02.1R)

Usage of Mains Chokes

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Rexroth IndraDrive Additional Components and Accessories

4.6

Bosch Rexroth AG 33/431

Brief description, use

DC Bus Resistor Unit HLB01

DC bus resistor units HLB01

● Convert generated kinetic energy into thermal energy

● Increase the continuous regenerative power in the drive system

● Increase the peak regenerative power in the drive system

● Allow the DC bus short circuit function ("ZKS") in the drive system

Type

HLB01.1C

HLB01.1D

Tab. 4-4:

Usage

In drive systems of the Rexroth IndraDrive C product range with a de‐ vice mounting depth of 265 mm.

In drive systems of the Rexroth IndraDrive M product range with a de‐ vice mounting depth of 322 mm.

DC Bus Resistor Units HLB

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Rexroth IndraDrive Additional Components and Accessories

Brief description, use

4.7 Braking Resistor HLR01

HLR01.1N-xxxx-Nxxx-A-007-NNNN braking resistors convert generated ki‐ netic energy into thermal energy. For this purpose, the line covers a wide range of continuous power and energy absorption capacity.

Type

HLR01.1A

HLR01.1N

Usage

Type of construction A (version for device mounting): To be mounted to drive controllers of the Rexroth IndraDrive

C product range. For this purpose, the drive controllers must be equipped with a brake chopper.

Type of construction N (version for free assembly): For free assembly in the installation, operated by drive control‐ ler of the Rexroth IndraDrive C product range. For this pur‐ pose, the drive controllers must be equipped with a brake chopper.

Tab. 4-5: Braking Resistors HLR

Designs of type of construction N:

● Fixed resistor IP 20 type A

Cement-coated, wire-wound, tube-type fixed resistors; screwed on side walls; perforated cover; connections in terminal box with PG gland

● Steel-grid fixed resistor IP 20 type B

Fixed resistor in steel-grid design; connection depending on type

● Steel-grid fixed Resistor IP 20 type C

Fixed resistor in steel-grid design; connection depending on type

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Rexroth IndraDrive Additional Components and Accessories

4.8

Bosch Rexroth AG 35/431

Brief description, use

DC Bus Capacitor Unit HLC01

DC bus capacitor units HLC01 store energy in the DC bus of the drive sys‐ tem.

Type

HLC01.1C

HLC01.1D

Tab. 4-6:

Usage

In drive systems of the product ranges Rexroth

IndraDrive C and Rexroth IndraDrive M

In drive systems of the product ranges Rexroth

IndraDrive C and Rexroth IndraDrive M

DC Bus Capacitor Units HLC

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Rexroth IndraDrive Additional Components and Accessories

Brief description, use

4.9 Motor Filters HMF01

HMF01 motor filters

● reduce the rise of the output voltage of drive controllers

● reduce leakage currents of the motor lines

● reduce interference voltage on the motor lines

Type

HMF01.1

Tab. 4-7:

Usage

At the motor output of HCS drive controllers

Usage of HMF01 Motor Filters

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 37/431

Brief description, use

4.10 Housing for Control Sections HAC01

Additional components HAC01 are used to

● insert control sections in them

● supply control sections with 24V control voltage

Type Usage

HAC01.1-002-NNN-NN To insert CDB control sections in it

Tab. 4-8: HAC01 Type

4.11 HSZ01 safety zone module

Type Use

HSZ01 The safety zone module HSZ01 belongs to the Rexroth IndraDrive product range and provides the following safety functions:

●

●

Safety Zone Acknowledge (SZA)

Safety Zone Error (SZE)

●

●

Safety Zone Input (SZI)

Safe Door Locking (SDL)

Tab. 4-9: Use

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Rexroth IndraDrive Additional Components and Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 39/431

5

5.1

General data and specifications

General data and specifications

Acceptance tests and approvals

Declaration of conformity Declarations of conformity confirm that the components comply with the valid

EN standards and EC directives. If required, our sales representative can provide you with the declarations of conformity for components.

C-UL-US listing

CE conformity regarding

Low-Voltage Directive

Drive controllers,

Supply units

EN 61800-5-1:2007

Motors

EN 60034-1:2010+Cor.:2010

EN 60034-5:2001+A1:2007

CE conformity regarding

EMC product standard

EN 61800-3:2004 + A1:2012

Tab. 5-1: CE - applied standards

The components are listed by UL (Underwriters Laboratories Inc.®).

Proof of certification can be found online: www.ul.com/database

Under "UL File Number" enter the file number or under "Company Name" en‐ ter the company name "Bosch Rexroth AG".

Tab. 5-2: C-UL listing

●

●

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 components:

E134201

E227957

The control sections are part of the listed components.

The HAB01.1-0350-1640-NN fan unit is part of the lis‐ ted components HMV01.1R-W0210 and HMS01.1N-

W0350.

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Rexroth IndraDrive Additional Components and Accessories

General data and specifications

UL ratings

When using the component in the scope of CSA/UL, observe the

UL ratings for each component.

Only the following components have been approved in the scope of CSA/UL for supplying HMS, HMD, KCU, KSM and KMS com‐ ponents:

● HMV01.1E

● HMV01.1R

● HMV02.1R

● HCS02.1E

● HCS03.1E

Make sure that the indicated SCCR short-circuit rating is not ex‐ ceeded, e.g., by using appropriate fuses in the mains connection of the supply unit.

Wiring material UL

In the scope of CSA / UL, use copper 60/75 °C only; class 1 or equivalent only.

C-UR-US listing

Allowed pollution degree

Comply with the permitted pollution degree of the components

(see "Ambient and operating conditions").

The components are listed by UL (Underwriters Laboratories Inc.®).

Proof of certification can be found online: www.ul.com/database

Under "UL File Number" enter the file number or under "Company Name" en‐ ter the company name "Bosch Rexroth AG".

Tab. 5-3:

●

●

UL standard: UL 1004-1

CSA standard: Canadian National

Standard C22.2 No. 100

Company Name

BOSCH REXROTH ELECTRIC DRIVES &

CONTROLS GMBH

Category Name:

Servo and Stepper Motors - Component

File numbers

MSK, MSM motors: E335445

C-UR listing

Wiring material UL (ready-made cables by Rexroth)

In the scope of CSA / UL, use copper 60/75 °C only; class 6 or equivalent only.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 41/431

General data and specifications

CCC (China Compulsory Certifica‐ tion)

Allowed pollution degree

Comply with the permitted pollution degree of the components

(see "Ambient and operating conditions").

The CCC mark 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 responsible for certification guidelines. When a product is imported in China, the certification will be checked at customs using the entries in a database. Three criteria are typically critical for certifica‐ tion being required:

1.

Customs tariff number (HS code) according to CNCA document "Appli‐ cation Scope for Compulsory Certification of Products acc. first Cata‐ logue".

2.

Area of application according to CNCA document "Application Scope for

Compulsory Certification of Products acc. first Catalogue".

3.

For the IEC product standard used, a corresponding Chinese GB stand‐ ard must exist.

For the drive components by Rexroth described in this documentation, certifi‐ cation is currently not required, so they are not CCC certified. Negative certifi‐ cations will not be issued.

5.2 Transport and storage

5.2.1 Transporting the components

Ambient and operating conditions for transport

Description

Temperature range

Relative humidity

Absolute humidity

Climatic category (IEC 721)

Moisture condensation

Icing

Symbol

T a_tran

Tab. 5-4:

Unit

°C

% g/m 3

Value

-20 … +70

5 … 95

1 … 60

2K3

Not allowed

Not allowed

Ambient and operating conditions for transport

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Rexroth IndraDrive Additional Components and Accessories

General data and specifications

5.2.2 Storing the components

NOTICE Risk of damage to components from longterm storage!

Some components contain electrolytic capacitors which may deteriorate dur‐ ing 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 U

LN

● Inverters and DC bus capacitor units: Operated with DC bus voltage

U

DC

Ambient and operating conditions for storage

Description

Temperature range

Relative humidity

Absolute humidity

Climatic category (IEC 721)

Moisture condensation

Icing

Symbol

T a_store

Unit

°C

% g/m 3

Value

-20 … +55

5 … 95

1 … 29

1K3

Not allowed

Not allowed

Ambient and operating conditions for storage Tab. 5-5:

5.3 Installation conditions

5.3.1 Ambient and operating conditions

Check that the ambient conditions, in particular the control cabi‐ net temperature, are complied with by calculating the heat levels in the control cabinet. Afterwards, make the corresponding meas‐ urements to verify that the ambient conditions have actually been complied with.

The power dissipation is indicated in the technical data of the indi‐ vidual components as an important input value for calculating the heat levels.

Description

Conductive dirt contamination

Ambient and operating conditions (HCS, HMV, HMS, HMD, HCQ, HCT, KCU,

HLC)

Degree of protection of the device (IEC529)

Use within scope of CSA / UL

Symbol Unit Value

Not allowed

Protect the devices against conductive dirt contami‐ nation by mounting them in control cabinets with the degree of protection IP54 (in accordance with

IEC529).

IP20

For use in NFPA 79 Applications only.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 43/431

General data and specifications

Description

Temperature during storage

Temperature during transport

Symbol Unit Value see

chapter 5.2.2 "Storing the components" on page

42

see chapter 5.2.1 "Transporting the components" on page 41

G1 3) Allowed mounting position

Definition of mounting positions: See

chapter

"Mounting positions of components" on page

45

Installation altitude

Ambient temperature range

Derating vs. ambient temperature:

The performance data are reduced by the fac‐ tor F

T

Ta

in the ambient temperature range a_work_red

:

F

Ta

= 1 - [(T a

- 40) × f

Ta

]

Example: With an ambient temperature

T a

= 50 °C and a capacity utilization factor f

Ta

= 2 %/K, the rated power is reduced to

P

DC_cont_red

= P

DC_cont

x F

Ta

=

P

DC_cont

x (1 - [(50 - 40) x 0.02]) = P

DC_cont

x 0.8

Operation at ambient temperatures outside of

T a_work

and T a_work_red

is not allowed!

T h nenn a_work m

°C

1000

0 … 40

T a_work_red f

Ta

°C

%/K

40 … 55

2.0

Exception HMV02.1R-W0015-A-07-NNNN:

2.7

Derating vs. installation altitude:

At an installation altitude h > h nenn

, the perform‐ ance data reduced by factor f 2) are available.

At an installation altitude in the range h max_ohne tion.

to h max

, an isolating transformer has to be installed at the drive system mains connec‐

Operation above h max

is not allowed!

Simultaneous derating for ambient temperature and installation altitude

Relative humidity

Absolute humidity

Climatic category (IEC 60721-3-3)

Allowed pollution degree (EN 50178)

Resistance to chemically active substances

(IEC 60721-3-3) h max_ohne h max m m

2000

4000

Allowed; reduce performance data with the product f × F

Ta

% g/m 3

5 … 95

1 … 29

3K3

2

Class 3C1

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Rexroth IndraDrive Additional Components and Accessories

General data and specifications

Description

Vibration sine: Amplitude (peak-peak) at

10 … 57 Hz 1)

Vibration sine: Acceleration at 57 … 150 Hz 1)

Overvoltage category

1)

2)

3)

Symbol Unit mm

Value

0.15

g 1

III (according to IEC 60664-1)

According to EN 60068-2-6

Reduced performance data for drive controllers: allowed DC bus continuous power, braking resistor continuous power, con‐ tinuous current; additionally for HCS01, HCQ, HCT drive con‐ trollers: allowed mains voltage

Some components can be operated in mounting positions oth‐ er than G1. The allowed mounting positions are specified in the technical data of the component.

5.3.2 Control cabinet design and cooling

The only mounting position allowed for supply units and drive controllers to be installed in control cabinets is G1.

Closed control cabinet with air circulation

Tab. 5-6:

Possibilities of heat dissipation

Closed control cabinet with heat exchanger

Control cabinet with fan Closed control cabinet with air conditioning unit

P

Q

~ 400 W

Requirements for control cabinets with fan

P

Q

~ 1700 W P

Q

~ 2700 W

P

Q

Tab. 5-7:

Dissipated heat output

Possibilities of heat dissipation

The section below describes the "control cabinet with fan".

P

Q

~ 4000 W

NOTICE Risk of damage by unclean air in the control cabinet!

Operating a control cabinet with a fan, but without the corresponding filters, can damage the devices or cause malfunction.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 45/431

Control cabinet ventilation (sche‐ matic diagram)

General data and specifications

● 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 switched off, because otherwise the fan sucks in the dirt coming off the filter and the dirt gets into the control cabinet.

3

4

1

2

5

6

Fig. 5-1:

Control cabinet

Air outlet opening

Heat discharge

Device in control cabinet

Control cabinet fan

Filter at air intake opening

Control cabinet ventilation (schematic diagram)

Only clean air gets into the control cabinet through the filter at the air intake opening. The control cabinet fan behind the air intake opening conveys the air into the control cabinet and generates overpressure in the control cabinet.

The overpressure prevents unclean air from getting into the control cabinet through possibly existing leaky points (leaky cable ducts, damaged seals, etc.).

5.3.3 Mounting position

Mounting positions of components

NOTICE Risk of damage to the components by incor‐ rect mounting position!

Only operate the components in their allowed mounting positions. The al‐ lowed mounting positions are specified in the technical data of the compo‐ nents.

For supply units and drive controllers installed in control cabinets, only the mounting position G1 is usually allowed.

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Rexroth IndraDrive Additional Components and Accessories

General data and specifications

Mounting positions

Some components can also be operated in mounting positions other than G1.

The allowed mounting positions are specified in the technical data of the component.

The allowed mounting positions are specified with G1, G2, G3, G4 or G5 in the technical data of the components.

Mounting position

G1

Description

Normal mounting position

The air heated inside the component can flow unimpe‐ ded vertically upward. In the case of components with integrated fans, the natural convection supports the forced cooling air current.

1.

Mounting surface

2.

Outgoing, heated air

3.

Component

4.

Fan within the component (forces the cooling air current)

5.

Cooling air

180° to normal mounting position

90° to normal mounting position bottom mounting; mounting surface on the bottom top mounting; mounting surface at the top

G2

G3

G4

G5

Tab. 5-8: Mounting positions

5.3.4 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 any reactions with the materials we use might occur.

For this reason, before using the respective material a compatibility test has to be carried out for new lubricants, cleaning agents etc. and our housings/ materials.

5.4 Voltage testing and insulation resistance testing

According to standard, the components of the Rexroth IndraDrive range are tested with voltage.

Testing

Voltage testing

Insulation resistance testing

Tab. 5-9: Applied standards

Test rate

100% (EN 61800-5-1)

100% (EN 60204-1)

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 47/431

General data and specifications

5.5 Control voltage (24V supply)

PELV

1) for 24V power supply unit

For the 24V supply of the devices of the Rexroth IndraDrive 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 V peak

or 30 V ac

● Max. output power: 10000 VA

Description

Control voltage for drive systems without operation of motor holding brakes in

Rexroth motors

The data in the table below generally apply to the 24V supply of the devices of the Rexroth IndraDrive range. For other data, such as power consumption and inrush currents, see the technical data for each device.

The specified values apply at the connections (+24V, 0V) to the "24V supply" of the devices!

Control voltage for drive systems with op‐ eration of motor holding brakes in

Rexroth motors

External control voltage at HCS02 devi‐ ces of "NNNV" design

(see HCS02 type code; other design:

DC 24 V power supply from the DC bus and external)

Max. ripple content

Symbol

U

N3

U

N3

U

N3 w

Unit Value

V

V

V

20.4 … 28.8 (24 +20% -15%)

When using HMV01.1E, HMV01.1R, HMV02.1R,

HLB01.1D supply units:

22.8 … 27.3 (24 -5%, 26 +5%)

Depending on the motor cable length, the control voltage has to be within the following voltage ranges:

● Motor cable length < 50 m: 22.8 … 25.2 (24 ±5%)

● Motor cable length > 50 m: 24.7 … 27.3 (26 ±5%)

Take the data of the corresponding motor holding brake into account.

26 … 28.8

The output voltage of the internal switching power supply unit is 24 ±10%.

Maximum allowed overvoltage U

N3max

Tab. 5-10:

-

V

The amplitudes of the alternating component on U

N3 be within the specified voltage range.

must

33 (max. 1 ms)

Control voltage

1)

Protective Extra Low Voltage

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Rexroth IndraDrive Additional Components and Accessories

General data and specifications

Description

Control voltage for drive systems without operation of motor holding brakes in

Rexroth motors

Control voltage for drive systems with op‐ eration of motor holding brakes in

Rexroth motors

Max. ripple content

Maximum allowed overvoltage

Symbol

U

N3

Unit

V

Value

19.2 … 30 (see also "Max. ripple content")

U

N3 w

V

-

V

Observe the following aspects when selecting the control voltage:

● Voltage drop on the line between drive controller and motor (current consumption, copper cross sec‐ tion, cable length)

● Allowed voltage tolerance of the brake (see data sheet of brake)

When using Rexroth cables up to a cable length of 40 m:

24 V ±5%

The amplitudes of the alternating component on U

N3 must be within the specified voltage range.

33 (max. 1 ms)

Control voltage

U

N3max

Tab. 5-11:

Overvoltage

Overvoltage greater than 33 V has to be discharged by means of the appropriate electrical equipment of the machine or installation.

This includes:

● 24V power supply units that reduce incoming overvoltage to 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.

Applies to all devices except HCS01 and HMV02:

Insulation monitoring impossible

The input 0 V is connected in conductive form to the housing po‐ tential. Insulation monitoring at +24 V and 0 V against housing is impossible.

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Rexroth IndraDrive Additional Components and Accessories

6

6.1

Bosch Rexroth AG 49/431

Transformers

Transformers

General Information

Grounded Mains

Ungrounded Mains

Transformers are only needed when the mains voltage is outside of the al‐ lowed nominal voltage of the drive controller.

For grounded mains, the mains voltage is adjusted to the nominal voltage of the device by means of autotransformers which have been sized for a specif‐ ic output voltage range.

For voltage adjustment of ungrounded mains, always connect isolating trans‐ formers to prevent overvoltages between outer conductor and ground.

50/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Transformers

6.2 Autotransformers for Drive Controllers

6.2.1 Types

Fig. 6-1: Type Code DST

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

6.2.2 Selection

Bosch Rexroth AG 51/431

Transformers

Select the autotransformer according to the mains voltage and the power re‐ quirements of the installation. For the selection, proceed as follows:

1. By means of the required nominal mains voltage range from the dia‐ gram "Classification of the Three-Phase Current Autotransformers in

Type Groups", determine the type group and read the transformation ra‐ tio "i".

2. Calculate the actual transformer output voltage by means of the given nominal mains voltage and the transformation ratio "i".

3. Check the drive data. The output voltage of the transformer has an ef‐ fect on the drive data.

4. Select the three-phase current autotransformer for the determined mains connected load S

LN

.

Determining the mains connected load: See Project Planning Manual

"Rexroth IndraDrive, Drive System" → "Calculations" → "Calculations for the Mains Connection" → "Calculating the Mains-Side Phase Current"

The nominal power of the transformer must at least equal the mains connected load S

LN

.

For DST transformers, the nominal power is identical to the throughput rating.

Fig. 6-2: Classification of the Three-Phase Current Autotransformers in Type

Groups

52/431 Bosch Rexroth AG

Transformers

6.2.3 Technical Data

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 6-3:

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

7 Mains filters

7.1 Mains Filters NFD / NFE

7.1.1 Type Code NFE / NFD

NFE01.1 - Mains Filter, Single-Phase

Bosch Rexroth AG 53/431

Mains filters

Fig. 7-1:

NFE02.1 - Mains Filter, Single-Phase

Type Code NFE01.1

Fig. 7-2: Type Code NFE02.1

54/431 Bosch Rexroth AG

Mains filters

NFD03.1 - Mains Filter, Three-Phase

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 7-3: Type Code NFD03.1

7.1.2 Mechanical Data NFE / NFD

NFE01.1

Allowed Mounting Positions

Fig. 7-4: Single-Phase Filter NFE01.1-250-006 for Interference Suppression of Power Supply Unit NTM

Every mounting position is allowed.

The mains filter is connected by means of tab receptacles

(b = 6.3 mm, d = 1 mm).

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

NFE02.1

Bosch Rexroth AG 55/431

Mains filters

Allowed Mounting Positions

Type

Fig. 7-5:

NFE02.1-230-008 (with 3 terminal connectors)

Single-Phase Filter NFE02.1 for Drives

Every mounting position is allowed.

56/431 Bosch Rexroth AG

Mains filters

NFD03.1

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mains filter type

NFD 03.1-480-007

NFD 03.1-480-016

NFD 03.1-480-030

NFD 03.1-480-055

NFD 03.1-480-075

NFD 03.1-480-130

NFD 03.1-480-180

NFE 02.1-230-008

NFE 01.1-250-006

Fig. 7-6: Three-Phase Current Filter NFD03.1 for Drives

Tolerance limits for NFD03.1:

● The dimensions B, C, D, K are maximum values. They can be reduced up to 15 mm.

● The ground studs M can also be arranged horizontally (protruding from the mounting flange), instead of vertically (as illustrated above).

A B C D E F G H J K L M M

AE

M

AKl

190 90 50 160 180 20 5,4

250 90 55 220 235 25 5,4

270 100 60 240 255 30 5,4

250 105 90 220 235 60 5,4 -

-

-

190 -

250 -

270 -

260 -

M5 2,2 0,8

M5 2,2 0,8

M5 2,2 2

M6 4 2,2

270 145 90 240 255 60 6,5

270 160 100 240 255 65 6,5 -

-

380 180 130 350 365 102 6,5 455 M10 18 20

90 210 60 60 80 40 5,3 40 0,75 15 10 0,8 0,8

See drawing

280 M6 4 4,5

330 M10 18 8

M

M

AE

AKl

Tab. 7-1:

Maximum tightening torque of the ground stud in Nm

Maximum tightening torque of the terminal in Nm

Dimensions of the Mains Filters NFD/NFE

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 57/431

Mains filters

Allowed Mounting Positions

Mounting posi‐ tion

G1

G2

G3

G4

G5

Note

Allowed without restrictions

Allowed without restrictions

Mains filter may only be loaded with 80% of the maximum allowed continuous current

Allowed without restrictions

Mains filter may only be loaded with 80% of the maximum allowed continuous current

Tab. 7-2:

7.1.3 Electrical Data NFE / NFD

Allowed Mounting Positions

Using mains filters in mains grounded via outer conductor

When using mains filters NFD03 in mains grounded via outer con‐ ductor, use an isolating transformer between mains and mains fil‐ ter.

Maximum mains con‐ nection voltage of mains 50…60 Hz

U

N

In V

Nominal mains

I current nenn

(1)

Number of pha‐ ses

In A

Mains filter type

AC 480V +10% 7 3

Terminal connectors (3)

Flexible

[mm 2 ]

4 (3)

Rigid

[mm 2 ]

AWG

6 (3) AWG 12

AC 480V +10%

AC 480V +10%

AC 480V +10%

AC 480V +10%

AC 480V +10%

AC 480V +10%

16

30

55

75

130

180

3

3

3

3

3

3

NFD

03.1-480-007

NFD

03.1-480-016

NFD

03.1-480-030

NFD

03.1-480-055

NFD

03.1-480-075

NFD

03.1-480-130

NFD

03.1-480-180

4 (3)

10

16

25

50

95

6 (3)

16

25

35

50

95

AWG 12

AWG 6

AWG 4

AWG 3

AWG 1/0

AWG 4/0

Power dissipa‐ tion ap‐ prox.

Weig ht

W

3,9

6,4

11,9

25,9

30,4

38

61 kg

0,7

1,0

1,4

2,0

3,5

4,7

10

Type of construc‐ tion

Vertical

Vertical

Vertical

Vertical

Vertical

Vertical

Vertical

58/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mains filters

Maximum mains con‐ nection voltage of mains 50…60 Hz

U

N

AC 230V +10%

Nominal mains

I current nenn

(1)

Number of pha‐ ses

7,5

Mains filter type

AC 230V +10% 4,7

Terminal connectors (3) Power dissipa‐ tion ap‐ prox.

Weig ht

Type of construc‐ tion

1

1

NFD

NFE

(1)

(2)

(3)

NFE

02.1-230-008

NFE01.1-250-00

6 (2)

Tab. 7-3:

4 (3) 6 (3) AWG 10

Tab connectors 6.3 × 0.8 mm

7,2

4

1,1 Vertical

0,245 Horizontal

Three-phase filter

Single-phase filter

Mains-side maximum continuous current at 45 °C ambient tem‐ perature

Only use for interference suppression of the power supply unit

NTM

For the equipment grounding conductor, connect a conductor cross section of 10 mm2 by means of terminal pin or ring cable lug

Technical data

Operating frequency From 0-60 Hz at 45 °C

Power dissipation Measured 2 or 3 × RI 2

Nenn DC

Temperature range

Overload

-25 … +85 ℃

1.5 × I

Nenn

for 1 minute per hour or

4 × I

Nenn

for 10 seconds per hour

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

See formula for reduction in chapter "Calculations" Current reduction in the case of overtem‐ perature

Leakage current at

50 Hz

Symmetrical three-phase operation: Typ. 30 mA

Single-phase operation or in the case of tripped fuses of a phase: Typ. 175 … 190 mA

Degree of protection IP 20

NFE01.1-250-006: IP 10

Tab. 7-4: Technical Data

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 59/431

Mains filters

7.2 HNF01.1 - mains filter, 3-phase

7.2.1 Type code HNF01.1

HNF01.1

Short type designation 1 2 3 4 5 6 7 8 9

Example:

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

H N F 0 1 . 1 A - F 2 4 0 - R 0 0 9 4 - A - 4 8 0 - N N N N

①

①

Product:

② ③④

HNF = HNF

⑤ ⑥ ⑦ ⑧ ⑨ ⑩

②

③

④

⑤

⑥

⑦

⑧

Series:

01 = 1

Design:

1 = 1

EMC area in accordance with DIN EN 61800-3:

A = industrial areas C3

B = residential areas C1/C2

C = residential areas C2

H = residential areas, harmonic filter 1)

Applications:

A075 = 1 axis, max. cable length 75 m

A100 = 1 axis, max. cable length 100 m

F240 = 6 axes, max. cable length 240 m

H350 = 8 axes, max. cable length 350 m

M240 = 15 axes, max. cable length 240 m

M750 = 15 axes, max. cable length 750 m

M900 = 15 axes, max. cable length 900 m

N1K0 = 22 axes, max. cable length 1000 m

P2K0 = 45 axes, max. cable length 2000 m

Supply system:

E = For feeding devices only

R = For regenerative devices only

Nominal current:

0094 = e.g. 94 A

Degree of protection:

A = IP20

N = IP00

60/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mains filters

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:

⑨

H N F 0 1 . 1 A - F 2 4 0 - R 0 0 9 4 - A - 4 8 0 - N N N N

① ② ③④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩

⑩

Mains connection voltage:

415 = 3 × AC 380 … 415V - 15 + 10%, 50/60 Hz 1)

480 = 3 × AC 400 … 480V - 15 + 10%, 50/60 Hz

500 = 3 × AC 400 … 500V - 15 + 10%, 50/60 Hz

530 = 3 × AC 230 … 530V - 15 + 10%, 50/60 Hz

69A = 3 × AC 500 V - 15% … 3 × AC 690V + 10%, 50/60 Hz

Other design:

NNNN = None

NNNT = For IT mains

1)

Tab. 7-5:

EMC area "H" is only available with mains connection voltage

"415"

HNF01.1, type code

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 61/431

Mains filters

7.2.2 Mechanical data HNF01.1

Dimensions

Mounting position and distances

Mount HNF01 in the control cabinet in normal mounting position

G1 and allow cooling by natural convection. For this purpose, keep at least 80 mm free from mounted parts, at the top side and bottom side of HNF.

Fig. 7-7: Dimensions

F240-R0026

F240-E0051

M900-E0051

M900-R0026

F240-R0065

M900-R0065

F240-R0094

M900-R0094

F240-E0125

M900-E0125

F240-E0202

M900-E0202

H350-R0180

62/431 Bosch Rexroth AG

Mains filters

HNF01.1A-…

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

A

[mm]

B

[mm]

480

480

480

480

480

480

480

480

480

262

262

262

262

262

262

262

262

262

C

[mm]

D

[mm]

E

[mm]

100

100

150

150

150

150

150

250

250

440

440

440

440

440

440

440

440

440

-

-

-

40

40

40

40

40

40

-

-

-

F

[mm]

110

110

110

110

G

[mm]

26

33

26

40

45

45

67

[mm]

M6×23

M6×16

M6×20

M6×16

M10×30

M10×30

110 63.5

M10×30

110 63.5

M10×30

M10×30

H

[Nm] *)

3.15

8.6

8.6

8.6

25

25

25

25

25

L1, L2, L3

L1.1, L2.1, L3.1

[Nm] *)

25

4 AWG

50

1 AWG

50

1 AWG

150

5/0 AWG

[mm 2 ] **)

[AWG]

10

8 AWG

16

6 AWG

10

8 AWG

150

5/0 AWG

150

5/0 AWG

1.8

2.3

1.8

4.5

8

8

30

30

30

*)

**)

Tab. 7-6:

Maximum tightening torque

Maximum connection cross section

HNF01.1A, dimensions

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HNF01.1C-…

F240-E0055

F240-E0080

F240-E0130

F240-E0150

F240-E0225

Bosch Rexroth AG 63/431

Mains filters

A

[mm]

B

[mm]

330

330

330

330

480

200

200

200

200

258

C

[mm]

D

[mm]

80

80

80

80

199

298

298

298

298

440

E

[mm]

F

[mm]

-

-

-

-

-

-

-

-

-

-

G

[mm]

43

43

43

[mm]

38.5

M10×39

M10×39

M10×39

M10×39

H

50.5 M10×38.5

[Nm] *)

11

11

11

11

11

L1, L2, L3

L1.1, L2.1, L3.1

[Nm] *) [mm 2 ] **)

[AWG]

25

4 AWG

50

1 AWG

50

1 AWG

50

1 AWG

95

3/0 AWG

4.5

8

8

8

20

*)

**)

Tab. 7-7:

Maximum tightening torque

Maximum connection cross section

HNF01.1C, dimensions

64/431 Bosch Rexroth AG

Mains filters

Drilling pattern

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 7-8: Drilling pattern

HNF01.1A- …

F240-E0051

M900-E0051

F240-E0125

M900-E0125

F240-E0202

M900-E0202

H350-R0180

F240-R0026

M900-R0026

F240-R0065

M900-R0065

F240-R0094

M900-R0094

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HNF01.1C- …

F240-E0055

F240-E0080

F240-E0130

F240-E0150

F240-E0225

Bosch Rexroth AG 65/431

Mains filters

K [mm]

50

L [mm]

466

M [mm]

25

N [mm]

7

P [mm]

13

R [mm]

6.5

50

100

100

125

125

125

150

466

466

466

466

466

466

466

12.5

12.5

50

25

25

25

12.5

7

7

7

7

7

7

7

13

13

13

13

13

13

13

6.5

6.5

6.5

6.5

6.5

6.5

6.5

Tab. 7-8: HNF01.1A

Tab. 7-9:

K [mm]

55

55

55

55

150

HNF01.1C

L [mm]

315

315

315

315

465

M [mm]

10.5

10.5

10.5

10.5

22.5

N [mm]

7.5

7.5

7.5

7.5

2.5

P [mm]

-

-

-

-

13

R [mm]

6.5

6.5

6.5

6.5

6.5

66/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mains filters

7.2.3 Electrical data HNF01.1

HNF01.1A

HNF01.1A-xxxx-Exxxx-A-480-NNNN data for feeding supply systems

Using mains filters in mains grounded via outer conductor

When using HNF01 mains filters in mains grounded via outer con‐ ductor, use an isolating transformer between mains and mains fil‐ ter.

Operation at a lower voltage than the specified voltage is not al‐ lowed, since this causes saturation phenomena in the input choke due to asymmetric currents. The filter thereby loses its effect, par‐ ticularly in the higher frequency range.

Description

Technical data - currents, voltages, power

Symbol Unit

HNF01.1

A-F240-

E0051-

A-480-

NNNN

HNF01.1

A-F240-

E0125-

A-480-

NNNN

HNF01.1

A-F240-

E0202-

A-480-

NNNN

HNF01.1

A-M900-

E0051-

A-480-

NNNN

HNF01.1

A-M900-

E0125-

A-480-

NNNN

HNF01.1

A-M900-

E0202-

A-480-

NNNN

Degree of protection according to

IEC 60529

Listing in accordance with UL standard

Listing in accordance with CSA standard

Mass

Three-phase mains voltage at TN-

S, TN-C, TT mains

Three-phase mains voltage at

Corner-grounded-Delta mains 1)

Three-phase mains voltage at IT mains 2)

Tolerance rated input voltage U

LN

Mains frequency

Mains frequency tolerance

Nominal current

Maximum allowed peak current 3)

Power dissipation at continuous current and continuous DC bus power respectively 4)

I

IP

U

U

U

I f m

LN

LN

LN

LN

LN

L_max

P

Diss_cont kg

V

V

V

%

Hz

Hz

A

A

W

15.00

51.00

77.00

Less than 89

18.00

125.00

188.00

29.00

IP20

UL1283

C22.2 No. 8

380...480

Not allowed

Not allowed

202.00

303.00

±10

50...60

±2

51.00

77.00

Less than 127

Less than 373

15.00

Less than 91

30.00

125.00

188.00

37.00

202.00

303.00

Less than 174

Less than 373

Last modification: 2007-11-28

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 67/431

Mains filters

Description

Insulation resistance at 500 V DC

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 5)

Symbol

R is

Unit

MOhm

HNF01.1

A-F240-

E0051-

A-480-

NNNN

HNF01.1

A-F240-

E0125-

A-480-

NNNN

HNF01.1

A-F240-

E0202-

A-480-

NNNN

1.18

HNF01.1

A-M900-

E0051-

A-480-

NNNN

HNF01.1

A-M900-

E0125-

A-480-

NNNN

HNF01.1

A-M900-

E0202-

A-480-

NNNN

A

LN

AWG 6 1 4/0 6 1 4/0

1) 2)

3)

4)

5)

Tab. 7-10:

Last modification: 2007-11-28

Mains voltage > U

LN

: Use a transformer with grounded neutral point, do not use autotransformers!

R-types: t = 0.3 s; T = 1.42 s; K = 2.5; E-types: t = 0.3 s;

T = 0.67 s; K = 2.5

Plus dissipation of braking resistor and control section

Copper wire; PVC-insulation (conductor temperature 90 °C;

T a

≤ 40 °C) in accordance with NFPA 79 chapter 12 and

UL 508A chapter 28

HNF - technical data - currents, voltages, power

Exemplary profile

Fig. 7-9:

I

I

K = I peak

/ I base peak

≤ I

L_max rms

≤ I

L_cont

Exemplary profile

HNF01.1A-xxxx-Rxxxx-A-480-NNNN data for regenerative supply sys‐ tems

Using mains filters in mains grounded via outer conductor

When using HNF01 mains filters in mains grounded via outer con‐ ductor, use an isolating transformer between mains and mains fil‐ ter.

68/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mains filters

Description

Technical data - currents, voltages, power

Symbol Unit

HNF01

.1A-

F240-

R0026

-

A-480-

NNNN

HNF01

.1A-

F240-

R0065

-

A-480-

NNNN

HNF01

.1A-

F240-

R0094

-

A-480-

NNNN

HNF01

.1A-

H350-

R0180

-

A-480-

NNNN

HNF01

.1A-

M900-

R0026

-

A-480-

NNNN

HNF01

.1A-

M900-

R0065

-

A-480-

NNNN

HNF01

.1A-

M900-

R0094

-

A-480-

NNNN

Degree of protection according to

IEC 60529

Listing in accordance with UL standard

Listing in accordance with CSA standard

Mass

Three-phase mains voltage at TN-

S, TN-C, TT mains

Three-phase mains voltage at

Corner-grounded-Delta mains 1)

Three-phase mains voltage at IT mains 2)

Tolerance rated input voltage U

LN

Mains frequency

Mains frequency tolerance

Nominal current

Maximum allowed peak current 3)

Power dissipation at continuous current and continuous DC bus power respectively 4)

Insulation resistance at 500 V DC

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 5)

I

U

U

U

I f

IP

LN

LN

LN

LN

L_max

P

Diss_cont

R

A m

LN is

LN kg

V

V

V

%

Hz

Hz

A

A

W

MOhm

AWG

UL1283

C22.2 No. 8

IP20

-

UL1283

C22.2 No. 8

14.00

25.00

28.00

45.00

17.00

26.00

29.00

±10

50...60

±2

26.00

65.00

94.00 180.00 26.00

65.00

94.00

65.00 163.00 235.00 270.00 65.00 163.00 235.00

Less than

73

0.17

Less than

163

Less than

135

1.18

305.00 77.00 157.00 146.00

1.33

0.17

10 6 3

380...480

Not allowed

Not allowed

4/0 10 6 3

1) 2)

3)

4)

5)

Tab. 7-11:

Last modification: 2007-11-28

Mains voltage > U

LN

: Use a transformer with grounded neutral point, do not use autotransformers!

R-types: t = 0.3 s; T = 1.42 s; K = 2.5; E-types: t = 0.3 s;

T = 0.67 s; K = 2.5

Plus dissipation of braking resistor and control section

Copper wire; PVC-insulation (conductor temperature 90 °C;

T a

≤ 40 °C) in accordance with NFPA 79 chapter 12 and

UL 508A chapter 28

HNF - technical data - currents, voltages, power

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 69/431

Mains filters

HNF01.1C

HNF01.1C-xxxx-Exxxx-A-480-NNNN data for feeding supply systems

Using mains filters in mains grounded via outer conductor

When using HNF01 mains filters in mains grounded via outer con‐ ductor, use an isolating transformer between mains and mains fil‐ ter.

Operation at a lower voltage than the specified voltage is not al‐ lowed, since this causes saturation phenomena in the input choke due to asymmetric currents. The filter thereby loses its effect, par‐ ticularly in the higher frequency range.

Description

Technical data - currents, voltages, power

Symbol

IP

Unit HNF01.1C

-F240-

E0055-

A-480-

NNNN

HNF01.1C-

F240-

E0080-

A-480-

NNNN

HNF01.1C-

F240-

E0130-

A-480-

NNNN

IP20

HNF01.1C-

F240-

E0150-

A-480-

NNNN

HNF01.1C-

F240-

E0225-

A-480-

NNNN

Degree of protection according to

IEC 60529

Listing in accordance with UL standard

Listing in accordance with CSA standard

Mass

Three-phase mains voltage at TN-

S, TN-C, TT mains

Three-phase mains voltage at

Corner-grounded-Delta mains 1)

Three-phase mains voltage at IT mains 2)

Tolerance rated input voltage U

LN

Mains frequency

Mains frequency tolerance

Nominal current

Maximum allowed peak current

(for 3 minutes per hour)

Maximum allowed peak current

(for 30 seconds per hour)

Power dissipation at continuous current and continuous DC bus power respectively 3)

I

I

U

U

U

I f m

LN

LN

LN

LN

LN

L_max

L_max

P

Diss_cont kg

V

V

V

%

Hz

Hz

A

A

A

W

5.50

55.00

82.50

137.50

34

8.00

80.00

120.00

200.00

29

UL1283

C22.2 No. 8

14.50

400 … 480

Not allowed

Not allowed

±10

50 … 60

±2

130.00

195.00

325.00

76

17.00

150.00

225.00

375.00

51

18.50

225.00

337.50

562.50

76

70/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mains filters

Description

Insulation resistance at 500 V DC

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 4)

Filter type

HNF01.1C-F240-…

E0055

E0055

E0080

E0130

E0150

E0225

1) 2)

3)

4)

Mains voltage > U

LN

: Use a transformer with grounded neutral point, do not use autotransformers!

Plus dissipation of braking resistor and control section

Copper wire; PVC-insulation (conductor temperature 90 °C;

T a

≤ 40 °C) in accordance with NFPA 79 chapter 12 and

UL 508A chapter 28

HNF - technical data - currents, voltages, power Tab. 7-12:

Allowed leakage capacitance in nF at 4 kHz chopper frequency

230 V with mains choke

230 V without mains choke

400 V with mains choke

400 V without mains choke

500 V with mains choke

500 V without mains choke

-

-

-

200

-

-

Symbol

R is

A

LN

Unit HNF01.1C

-F240-

E0055-

A-480-

NNNN

MOhm

AWG 4

HNF01.1C-

F240-

E0080-

A-480-

NNNN

1

HNF01.1C-

F240-

E0130-

A-480-

NNNN

1.3

1

HNF01.1C-

F240-

E0150-

A-480-

NNNN

1

HNF01.1C-

F240-

E0225-

A-480-

NNNN

3/0

-

-

-

180

-

-

120

110

70

190

800

190

120

110

110

110

800

110

120

110

110

110

800

110

Tab. 7-13: Allowed leakage capacitance [nF] at 4 kHz chopper frequency

Allowed leakage capacitance in nF at 8/12/16 kHz chopper frequency

70

800

110

60

50

70

Filter type

HNF01.1C-F240-…

E0055

E0055

E0080

E0130

E0150

E0225

230 V with mains choke

-

-

-

200

-

-

230 V without mains choke

400 V with mains choke

400 V without mains choke

500 V with mains choke

500 V without mains choke

Tab. 7-14:

-

-

-

120

-

-

120

110

70

70

40

110

70

40

70

-

-

110

70

80

70

120

110

110

70

40

70

-

-

70

Allowed leakage capacitance [nF] at 8/12/16 kHz chopper frequency

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Filter type

HNF01.1C-F240-…

E0055

E0080

E0130

E0150

E0225

Bosch Rexroth AG 71/431

Mains filters

Nominal power, filter [kW] with choke

400 V

33

48

78

96

136

Tab. 7-15:

500 V

41

60

98

121

170

Nominal power, filter [kW]

400 V

25

36

59

72

101 without choke

500 V

31

45

73

90

127

All values apply with

HAS04

accessories connected (capacitor

2 × 470 nF).

72/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mains filters

7.3 HNK01.1 - mains filter, with mains choke

7.3.1 Type code HNK01.1

Fig. 7-10:

7.3.2 Type plate HNK01.1

Type code HNK01.1

Each mains filter is identified by a type designation. There is a type plate at‐ tached to all components.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 73/431

Mains filters

3

4

1

2

Fig. 7-11:

Type designation

Material number

Serial number

Production date

Example of type plate HNK01.1

Position of type plate:

1)

Fig. 7-12:

Type plate

Type plate arrangement

74/431 Bosch Rexroth AG

Mains filters

7.3.3 Mechanical data HNK01.1

Dimensions

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 7-13: Mains filter dimensions HNK01.1A-A075-E0050

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 75/431

Mains filters

Fig. 7-14: Mains filter dimensions HNK01.1A-A075-E0050 with HAS02

76/431 Bosch Rexroth AG

Mains filters

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 7-15: Mains filter dimensions HNK01.1A-A075-E0080/0106

Fig. 7-16: Mains filter dimensions HNK01.1A-A075-E0080/0106 with HAS02

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 77/431

Mains filters

Fig. 7-17: Mains filter dimensions HNK01.1A-A075-E0146

Fig. 7-18: Mains filter dimensions HNK01.1A-A075-E0146 with HAS02

78/431 Bosch Rexroth AG

Mains filters

7.3.4 Electrical data HNK01.1

Circuit diagram

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Description

Degree of protection according to

IEC 60529

Listing in accordance with UL standard

Listing in accordance with CSA standard

Minimum distance on the bottom of the device 1)

Minimum distance on the top of the device 2)

Mass

Three-phase mains voltage at TN-

S, TN-C, TT mains

Three-phase mains voltage at

Corner-grounded-Delta mains 3)

Three-phase mains voltage at IT mains 4)

Tolerance rated input voltage U

LN

Mains frequency

Mains frequency tolerance

Continuous current

I

Typical inductance per winding at cont

C1, C2, C3 approx. 3.3 µF

C4

Fig. 7-19: approx. 0.5 µF

Block diagram HNK01

Technical data - currents, voltages, power

Symbol Unit

HNK01.1A-

A075-E0050-

A-500-NNNN

HNK01.1A-

A075-E0080-

A-500-NNNN

HNK01.1A-

A075-E0106-

A-500-NNNN

HNK01.1A-

A075-E0146-

A-500-NNNN

IP IP20 d bot d top m

U

LN

U

LN

U

LN f

LN

I

L_cont

L typ mm

V

V

%

Hz

Hz

A mm kg

V

µH

15.00

50

571

Listed as optional part of HCS03

80

362

-

100

Mounted to HCS03

20.00

400...500

-

400...500

+10 -15

50...60

±2

106

28.00

146

240 170

Last modification: 2010-06-14

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 79/431

Mains filters

Description Symbol Unit

HNK01.1A-

A075-E0050-

A-500-NNNN

HNK01.1A-

A075-E0080-

A-500-NNNN

HNK01.1A-

A075-E0106-

A-500-NNNN

HNK01.1A-

A075-E0146-

A-500-NNNN

Power dissipation at continuous current and continuous DC bus power respectively 5)

Insulation resistance at 500 V DC

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 6)

P

Diss_cont

R is

A

LN

W

MOhm

AWG

55

8 AWG

90

4 AWG

>15

120

2 AWG

140

1/0 AWG

Connection cross sections

1) 2)

3) 4)

5)

6)

Last modification: 2010-06-14

See fig. "Air intake and air outlet at device"

Mains voltage > U

LN

: Use a transformer with grounded neutral point, do not use autotransformers!

Plus dissipation of braking resistor and control section

Copper wire; PVC-insulation (conductor temperature 90 °C;

T a

≤ 40 °C) in accordance with NFPA 79 chapter 12 and

UL 508A chapter 28

HNK - technical data - currents, voltages, power Tab. 7-16:

HNK01.1A-A075

Maximum connection cross section

Unit mm²

AWG

E0050 E0080 E0106 E0146

16

6

35

2

50

1

70

2/0

Tab. 7-17: Connection cross sections

7.3.5 Arranging the components HCS03 drive controller and HNK01 mains filter

WARNING Lethal electric shock from live parts with more than 50V!

Establish equipment grounding connection between HNK01 mains filter and

HCS03 drive controller. Screw joint bars to guide bar.

The HNK01 mains filters are cooled by the cooling air of the drive controller flowing in.

Arrange HNK01 at HCS03 drive controller as pictured.

80/431 Bosch Rexroth AG

Mains filters

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 7-20:

Fit mains filter to guide bar. Ensure equipment grounding con‐ nection by screwing the mounting link.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 81/431

Mains filters

1)

2)

Fig. 7-21:

Fit mains filter to guide bar

Ensure equipment grounding connection by screwing the mounting link

82/431 Bosch Rexroth AG

Mains filters

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 7-22:

Fit mains filter to guide bar. Ensure equipment grounding con‐ nection by screwing the mounting link.

Arranging HCS03.1E-W0210 device and HNK01.‑***‑E0146 mains filter

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 83/431

Mains filters

7.4 HNS02.1 - mains filter, with switch-disconnector

7.4.1 Identification

Type code

Fig. 7-23: Type code

84/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mains filters

7.4.2 Mechanical data HNS02.1

Dimensions

Mounting position and distances

Mount HNS02.1 in the control cabinet in normal mounting position

G1 and allow cooling by natural convection. Observe the mini‐ mum mounting clearance of the device.

A)

B)

Fig. 7-24:

Data in mm

Minimum mounting clearance

Rear view!

Dimensions HNS02.1

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 85/431

Mains filters

7.4.3 Electrical data HNS02.1

Description

Power dissipation

Phase current (continuous current)

Phase current (peak current 1) )

Maximum leakage current at filter input (mains side) with

12 drive controllers and 200 m motor cable

Leakage current at filter output (load side) with 12 drive con‐ trollers and 200 m motor cable

Tab. 7-18: Data

Symbol

W

A

A

A

A

Value

75

23

55

0.57

0.7

Description

Allowed THD (Total Harmonic Distortion)

Reduction of allowed operating data due to harmonics com‐ ponent

Supply voltage

Sum of leakage currents at filter input with supply unit switched off:

1 phase failed

2 phases failed

Insulation resistance (phase - ground)

(discharging resistances of Y-capacitors)

Degree of protection

Weight

Materials

1)

Tab. 7-19:

7.4.4 Connection points

Symbol

%

-

V

A

A kOhm

Value

See Project Planning Manual "Rexroth

IndraDrive Drive Systems with HMV01/02

HMS01/02, HMD01, HCS02/03"

3 × AC 380 … 480 ±10%, 50/60 Hz ±2%

< 0.8

< 2.0

> 730

kg

-

IP20

14.9

Free of asbestos and silicone

Duration: 300 ms

Duty cycle for feeding devices: 0.67 s

Duty cycle for regenerative devices: 1.42 s

Basic load: 60% continuous current

Data

WARNING Lethal electric shock from live parts with more than 50 V!

Before working on the wiring at filter, mains choke or supply unit:

1. Disconnect the device from the mains voltage

2. Discharge the device-internal capacitors (short-circuit the power con‐ nections at filter output or choke input)

86/431 Bosch Rexroth AG

Mains filters

View

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Description

L1, L2, L3

F1, F2, F3

X41.1, X41.2

X14

(L1.2, L2.2, L3.2)

F4

Significance

Input for supply with mains voltage

Fuses between mains input (L1, L2, L3) and mains output (L1.1,

L2.1, L3.1)

(Mat. no.: R911311988, SICHERUNG-GRC 50A/690V)

Converter (D-Sub ↔ terminal block)

Output to load HMV02 (X14, mains voltage synchronization)

Fuses before output X14

Equipment grounding conductor connection point

L1.1, L2.1, L3.1

Output to load HMV02 (X3, mains connection)

L1, L2, L3

L1.1, L2.1, L3.1

Tab. 7-20:

Tab. 7-21:

Connection points and fuses

L1, L2, L3

Connection cable flexi‐ ble

Connection cable rigid

Tightening torque

Unit mm 2

AWG mm 2

Nm

Data - connection points L1, L2, L3 min.

4

12

4

-

L1.1, L2.1, L3.1

Connection cable flexi‐ ble

Connection cable rigid

Tightening torque

Tab. 7-22:

Unit mm 2

AWG mm 2

Nm min.

4

12

4

-

Data - connection points L1.1, L2.1, L3.1

max.

10

8

16

1.8

max.

25

4

35

4.5

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 87/431

HNL - mains chokes for supply units and converters

8 HNL - mains chokes for supply units and converters

8.1 Identification

8.1.1 Type code

Fig. 8-1: Type code

88/431 Bosch Rexroth AG

HNL - mains chokes for supply units and converters

8.1.2 Type plate

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

17

18

19

Fig. 8-2:

Word mark

Business facility number

CE label

Type designation (two lines, 20 characters each)

Part number

Change release

Production date (YYWww)

Certification label

Nominal voltage / frequency

Nominal current

Number of design specification

Nominal inductance

Temperature

Number and value of additional capacitors

Designation of origin

Approval number

Bar code (39 or 93)

Serial number

Company address

Type plate

8.2 HNL01.1E - mains chokes, feeding

8.2.1 Technical data

Mechanics and mounting

Allowed Mounting Positions Every mounting position is allowed.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 89/431

HNL - mains chokes for supply units and converters

Type 1 dimensions:

Type 2 dimensions:

Fig. 8-3: Type 1 dimensions

Type 3 dimensions:

Fig. 8-4: Type 2 dimensions

Fig. 8-5: Type 3 dimensions

90/431 Bosch Rexroth AG

HNL - mains chokes for supply units and converters

Type 4 dimensions:

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 8-6: Type 4 dimensions

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 91/431

HNL - mains chokes for supply units and converters

Type 5 dimensions:

Mains choke

HNL01.1E-1000-N0012-A-500

HNL01.1E-1000-N0020-A-500

HNL01.1E-0600-N0032-A-500

HNL01.1E-0571-N0050-A-500

HNL01.1E-0400-N0051-A-480

Fig. 8-7: Type 5 dimensions

Typ e

Dimensions [mm]

1

A

120

B

61

C

164

D

81

D1

-

E F 1)

44 6.4 × 11

G

1 150 66.5 184 113 49.5

6.4 × 11

1 150 66.5 185 113 49.5

6.4 × 11

4 153 100 238 127 80 8.5 × 12 400

1 180 112 225 125 80 87 7 × 15 -

-

-

-

H

-

-

-

30

-

S

M5

M5

M5

-

M6

Weight

[kg]

2.7

3.9

4.5

13

13.5

92/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HNL - mains chokes for supply units and converters

Mains choke

HNL01.1E-0362-N0080-A-500

HNL01.1E-0240-N0106-A-500

HNL01.1E-0200-N0125-A-480

HNL01.1E-0170-N0146-A-500

HNL01.1E-0100-N0202-A-480

Mains choke

HNL01.1E-1000-N0012-A-500

HNL01.1E-1000-N0020-A-500

HNL01.1E-0600-N0032-A-500

HNL01.1E-0571-N0050-A-500

HNL01.1E-0400-N0051-A-480

HNL01.1E-0362-N0080-A-500

HNL01.1E-0240-N0106-A-500

HNL01.1E-0200-N0125-A-480

HNL01.1E-0170-N0146-A-500

HNL01.1E-0100-N0202-A-480

Typ e

Dimensions [mm]

A B C D D1 E F 1) G H

3 175 205 180 145 185 8.5 × 12 350 approx.

12

5 See dimensional drawing

1 230 148 295 180 122

3 230 250 205 170 230

1 265 152 350 215 126

8 × 12

15 × 9

15 × 11

-

-

-

-

1400 approx.

12 2)

-

1)

2)

Tab. 8-1:

Long hole in "B" direction

Ring terminal M8

Dimensions, weight

S

M6

-

M8

M8

M8

Weight

[kg]

13

15

24

23

33

U1, V1, W1

[mm 2 ]

16

35

50

70

10

16

4

6

50

150

Tab. 8-2:

Maximum connection cross section

U2, V2, W2

[AWG]

-

-

-

8 AWG

-

6 AWG

1 AWG

-

1/0 AWG

-

Connection cross section, tightening torque a, b

[mm 2 ]

2.5

-

-

2.5

-

2.5

-

4

4

4

Tightening torque

Nm

U1, V1, W1

U2, V2, W2 a, b

Observe the data imprin‐ ted on the component.

Basic data

Mains choke

HNL01.1E-1000-N0012-A-500

HNL01.1E-1000-N0020-A-500

HNL01.1E-0600-N0032-A-500

HNL01.1E-0571-N0050-A-500

HNL01.1E-0400-N0051-A-480

HNL01.1E-0362-N0080-A-500

HNL01.1E-0240-N0106-A-500

U

N

[V]

500

500

500

500

480

500

500

I

N

[A]

12

20

32

50

51

80

106

L

N

[µH]

3 × 1000

3 × 1000

3 × 600

3 × 571

3 × 400

3 × 362

3 × 240

P

V

[W]

40

60

75

50

165

80

100

I max

[A]

25

50

80

100

77

160

212

L min at I max

50% of L

N

50% of L

N

50% of L

N

50% of L

N

50% of L

N

50% of L

N

50% of L

N

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 93/431

HNL - mains chokes for supply units and converters

Mains choke

HNL01.1E-0200-N0125-A-480

HNL01.1E-0170-N0146-A-500

HNL01.1E-0100-N0202-A-480

U

N

[V]

480

500

480

I

N

[A]

125

146

202

L

N

[µH]

3 × 200

3 × 170

3 × 100

P

V

[W]

170

130

200

I max

[A]

188

292

303

L min at I max

50% of L

N

50% of L

N

50% of L

N

Tab. 8-3: Electrical data

Temperature contact a, b

Switching capacity

1 A / AC 250 V

DC 24 V

Tab. 8-4:

Switching temperature

125 °C

HNL01.1E mains chokes of type 1 are equipped with a temperature contact (a, b), types 2, 3 and 4 are not.

Temperature contact

8.3 HNL01.1R - mains chokes, regenerative

8.3.1 Safety instruction

WARNING High electrical voltage! Danger to life, risk of injury by electric shock or serious injury!

● After switch-off, the capacitors in the choke will remain charged for a longer time which can cause electric shock.

● Only operate the choke with connected discharging device or with con‐ nection to "X14, mains voltage synchronization" at a regenerative HMV supply unit (HMV01.1R).

● Unless you use a supply unit with connection "X14, mains voltage syn‐ chronization", operation is only allowed with a connected discharging device, e.g. with HNF mains filter or additional discharging resistors.

● Before accessing the choke, wait up to 30 minutes after switching off power to allow the choke to discharge.

● Verify that energized connections have been isolated from supply before touching the connections.

● Before switching on, read and observe the notes on project planning.

8.3.2 Technical data

Mechanics and mounting

Allowed Mounting Positions Every mounting position is allowed.

94/431 Bosch Rexroth AG

HNL - mains chokes for supply units and converters

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mains choke

HNL01.1R-0980-C0026-A-480

HNL01.1R-0590-C0065-A-480

HNL01.1R-0540-C0094-A-480

HNL01.1R-0300-C0180-A-480

Fig. 8-8: Dimensions

B1

Dimensions [mm]

C D A B E

210

300

340

340

1)

Tab. 8-5:

108

155

174

191

64

50

55

70

245

360

385

400

175

240

290

290

Long hole in "B" direction

Dimensions, weight

85

123

132

147

F 1)

8 × 12

11 × 15

11 × 15

11 × 15

S

M6

M8

M8

M8

Weight [kg]

16

45

65

73

Basic data

Fig. 8-9: Circuit diagram HNL01.1R

Connect the choke inputs U1, V1, W1 to the power grid and the choke out‐ puts U2, V2, W2 to the input of the supply unit.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 95/431

HNL - mains chokes for supply units and converters

Mains choke

HNL01.1R-0980-C0026-A-480

HNL01.1R-0590-C0065-A-480

HNL01.1R-0540-C0094-A-480

HNL01.1R-0300-C0180-A-480

Tab. 8-6:

Connection cross section mm 2 (AWG) a, b U1, V1, W1

U2, V2, W2

16 (6 AWG)

50 (1 AWG)

70 (2/0 AWG)

Tightening torque

U1, V1, W1

U2, V2, W2

Nm a, b

2.5 (14 AWG) Observe the data imprinted on the

2.5 (14 AWG) component.

2.5 (14 AWG)

95 (3/0 AWG) 2.5 (14 AWG)

Connection cross section, tightening torque

Temperature contact a, b

Switching capacity

1 A / AC 250 V

DC 24 V

Switching temperature

125 °C

150 °C (HNL01.1R-0300-C0180-A-480-NNNN)

Tab. 8-7:

Electrical data

Temperature contact a, b

Mains choke

HNL01.1R-0980-C0026-A-480

HNL01.1R-0590-C0065-A-480

HNL01.1R-0540-C0094-A-480

HNL01.1R-0300-C0180-A-480

U

N

[V]

1)

Tab. 8-8:

480

480

480

480

I

N

[A]

P

V

[W]

L

N

[µH]

I max

1)

[A]

L min at I max

26

65

94

180

225

310

420

800

3 × 980

3 × 590

3 × 540

3 × 300

65

163

235

360

80% of L

N

80% of L

N

80% of L

N

80% of L

N

For 300 ms at 1.42 s duty cycle and 60% basic load

Electrical data

CΔ

[µF]

3 × 10

3 × 20

3 × 20

3 × 30

8.4 HNL01.1*-****-S - mains chokes, current-compensated

8.4.1 Function

Arranging the components

Current-compensated mains chokes

● reduce asymmetric currents (leakage currents) in the mains connection phase of the drive system by high asymmetric inductance values

● are operated in series with conventional mains chokes

In mains in which it is not allowed to operate HNF mains filters (e.g., in mains grounded via outer conductor), current-compensated mains chokes

HNL01.1*-****-S make it possible to operate HMV01 supply units in conjunc‐ tion with specific mains filters (not HNF) and HNL01 mains chokes.

With feeding supply units

● Mains → specific mains filter → HNL01.1E mains choke → current-com‐ pensated mains choke HNL01.1E-****-S → HMV**.*E supply unit

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Rexroth IndraDrive Additional Components and Accessories

HNL - mains chokes for supply units and converters

8.4.2 Technical data

With regenerative supply units

● Mains → specific mains filter → HNL01.1R mains choke → current-com‐ pensated mains choke HNL01.1R-****-S → HMV**.*R supply unit

Mechanics and mounting

Allowed Mounting Positions Every mounting position is allowed.

Mains choke

HNL01.1E-5700-S0051-A-480

HNL01.1E-2800-S0125-A-480

HNL01.1E-3400-S0202-A-480

HNL01.1R-4200-S0026-A-480

Fig. 8-10:

A

230

340

340

230

B

200

280

280

200

Dimensions

8.4

8.4

6.5

C

Dimensions [mm 2 ]

D E

6.5

30 105

83

83

30

150

185

125

F

600

600

600

600

G

25 1)

1/0 2)

5/0 2)

16 1)

Weight

[kg]

11

26

30

12

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 97/431

HNL - mains chokes for supply units and converters

Mains choke

HNL01.1R-6300-S0065-A-480

HNL01.1R-3000-S0094-A-480

1)

2)

Tab. 8-9:

A

250

340

B

200

280

C

6.5

8.4

Dimensions [mm 2 ]

D

55

83

E

155

170 mm2

AWG

Dimensions, weight

F

600

600

G

25 1)

50 1)

Weight

[kg]

14

24

Basic data

Degree of protection

Materials

Certification

Supply voltage

Inductance L

N

Minimum inductance, L min

Nominal current

Peak current 1)

Total leakage current at power connection

Allowed power dissipation at nominal current and maximum leakage current

1)

Tab. 8-10:

A

A

A

W

Unit E-5700-

S0051

E-2800-

S0125

E-3400-

S0202

IP10

R-4200-

S0026

R-6300-

S0065

R-3000-

S0094

Free of asbestos and silicone

Acc. to UL 508 and CSA C22.2 No. 14-M91

V 3 × AC 380 … 480 ±10%, 50/60 Hz ±2% mH 3 × 5.7

3 × 2.8

3 × 3.4

3 × 4.2

3 × 6.3

3 × 3.0

51

77

< 2

83

125

188

< 2.2

179

0.8 × L

N

202

303

< 2.2

320

at I max

26

65

< 2

80

65

163

< 2

138

94

235

< 2

142

Duration: 300 ms; duty cycle: for feeding devices: 0.67 s; for regenerative devices: 1.42 s; basic load: 60%

Basic data

1)

Fig. 8-11:

3 × 6.3 mH

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Rexroth IndraDrive Additional Components and Accessories

HNL - mains chokes for supply units and converters

As a matter of principle, the current-compensated mains choke is connected between the conventional mains choke and the mains input of the supply unit.

8.5 HNL02.1 - mains choke

8.5.1 Identification

Type code

Fig. 8-12: Type code

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 99/431

HNL - mains chokes for supply units and converters

8.5.2 Technical data

Mechanics and mounting

Mounting position

Dimensions

G1

Basic data

Degree of protection

Operation temperature

Weight

A)

B)

Fig. 8-13:

Data in mm

Minimum mounting clearance

Rear view!

Dimensions HNL02.1

HNL02.1R-0980-N0023-A-480-NNNN

12.5 kg

Tab. 8-11: Weight

HNL02.1R-0980-C0023-A-480-NNNN

13 kg

Unit

°C

HNL02.1R-0980-N0023-

A-480-NNNN

IP20

0 … 55

HNL02.1R-0980-C0023-

A-480-NNNN

100/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HNL - mains chokes for supply units and converters

Nominal operating temperature

Certification

Materials

Rated voltage U

LN

Nominal frequency f

LN

Inductance L

N

Minimum inductance, L min

Capacitors at mains input

Nominal current

Peak current I max

1)

Total leakage current at power connection with

12 drive controllers and 200 m motor cable

Power dissipation at nominal current and maxi‐ mum leakage current

Maximum allowed fusing of fan or temperature contact connection

Temperature contact switching capacity (N/C)

Trigger temperature

Power consumption of internal fan

1)

2)

Tab. 8-12:

Unit

°C

Hz mH

C x

A

A

V

A

HNL02.1R-0980-N0023-

A-480-NNNN

HNL02.1R-0980-C0023-

A-480-NNNN

40

UL 506 and CAN/CSA C22.2

No. 66

UL 508 C and CSA C22.2

No. 14-M91

Free of asbestos and silicone

3 AC 380 … 480 ±10%

50/60 Hz ±2%

3 × 0.98

0.8 × L

N

at I max

3 × 10 µF

23

55

< 0.7

W 95

A 4

V AC 30 2)

AC 30

DC 24

A

°C

W

3

130

2.7

Duration: 300 ms

Duty cycle for feeding devices: 0.67 s

Duty cycle for regenerative devices: 1.42 s

Basic load: 60%

In the scope of UL, operation with direct voltage is not allowed

Specific data

Connection points

WARNING Lethal electric shock from live parts with more than 50 V!

If wiring work is to be carried out at filter, mains choke or supply unit, dis‐ charge the device-internal capacitors after disconnecting the mains voltage.

(Short-circuit the power connections at filter output or choke input)

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 101/431

HNL - mains chokes for supply units and converters

Connection

U1, V1, W1

U2, V2, W2

24V

L

0V

L

Fig. 8-14:

Significance

Input from power grid

Output to supply unit HMV02

Supply voltage internal fan

Connection points

Max. connection cross sec‐ tion mm 2 / AWG

Stranded wire: 16 / 6 AWG

Solid wire: 10 / 6 AWG

Stranded wire: 4 / 10 AWG

Max. tightening torque

Nm

1.8

0.8

Temperature contact

Switching capacity: 1 A / DC 24 V

Switching temperature: 125 °C

Equipment grounding conductor

Connection points Tab. 8-13:

M6 × 25 6

102/431 Bosch Rexroth AG

HNL - mains chokes for supply units and converters

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Rexroth IndraDrive Additional Components and Accessories

C x

Fig. 8-15:

Capacitors in HNL02.1E-0980-C0023-A-480-NNNN design

Circuit diagram

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 103/431

HLL01 - DC Bus Choke, Current-Compensated

9 HLL01 - DC Bus Choke, Current-Compensated

9.1 Brief Description, Use and Commissioning

9.1.1 Brief Description

HLL01 DC bus chokes connect Rexroth IndraDrive systems to supply units.

The DC bus choke connects the DC bus of the supply unit to the DC bus of the drive system.

9.2 Type Code and Identification

9.2.1 Type Code

The figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of availa‐ ble versions.

104/431 Bosch Rexroth AG

HLL01 - DC Bus Choke, Current-Compensated

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Rexroth IndraDrive Additional Components and Accessories

9.2.2 Identification

Fig. 9-1: Type Code of DC Bus Choke HLL01.1

Each DC bus choke is marked by a type designation. There is a type plate attached to all components.

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Rexroth IndraDrive Additional Components and Accessories

Type Plate Arrangement

Bosch Rexroth AG 105/431

HLL01 - DC Bus Choke, Current-Compensated

Type Plate

1

Fig. 9-2:

Type plate

Position of Type Plate

9.3

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

17

18

19

Fig. 9-3:

Word mark

Business facility number

CE label

Type designation (two lines, 20 characters each)

Material number

Change release

Production date (YYWww)

Certification label

Nominal voltage / frequency

Nominal current

Number of design specification

Nominal inductance

Temperature

Number and value of additional capacitors

Designation of origin

Approval number

Bar code (39 or 93)

Serial number

Company address

Type Plate

Scope of Supply

DC bus choke HLL01

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Rexroth IndraDrive Additional Components and Accessories

HLL01 - DC Bus Choke, Current-Compensated

9.4 Installation and Mounting

9.4.1 General Information

WARNING Lethal electric shock by live parts with more than 50 V!

Connect the DC bus choke to the equipment grounding system of the control cabinet.

Check the continuity of the equipment grounding conductors from the mains connection to the connected motors.

For the equipment grounding conductor, run stationary lines with the cross section of the lines of the DC bus choke power connections, but at least

10 mm 2 .

● Mount HLL01 to a bare metal mounting plate which has been connected to the equipment grounding system of the control cabinet.

● Twist the connection lines.

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Rexroth IndraDrive Additional Components and Accessories

9.4.2 Dimensions HLL01

Bosch Rexroth AG 107/431

HLL01 - DC Bus Choke, Current-Compensated

Fig. 9-4:

9.4.3 Circuit Diagram HLL01

Dimensions in mm

Dimensions of DC Bus Choke HLL01.1

Risk of short circuit, observe correct polarity

Connect the positive pole of the DC bus at the supply unit to the positive pole at the drive system via the HLL01 connections +1,

+2.

108/431 Bosch Rexroth AG

HLL01 - DC Bus Choke, Current-Compensated

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Rexroth IndraDrive Additional Components and Accessories

9.5

Description

In +1, -1 Input (from supply unit)

Out +2, -2 Output (to drive system) a, b

PE

Fig. 9-5:

Temperature contact

Connection point of equipment grounding conductor

Circuit Diagram HLL01.1

Technical Data

Technical Data - Currents, Voltages, Power

Degree of protection according to IEC529

Allowed ambient temperature range

Allowed ambient temperature range during operation with reduced nominal data

Reduced nominal current at

T a_work

< T a

< T a_work_red

Symbol

T a_work

T a_work_red f

Ta

Unit

°C

°C

%/K

HLL01.1N-10M0-S0100-

A-007-05A0-NNNN

IP20

0 … 40

0 … 55

2,0

Allowed mounting position

Horizontally or vertically on mount‐ ing surface

Minimum distance on the bottom of the device

Minimum distance on the top of the device

Horizontal spacing on the device

Mass (weight)

Nominal inductance

Nominal voltage

Tolerance U

LN

Nominal current

Maximum allowed peak current 6)

Maximum allowed leakage current d bot d top d hor m

L nenn

U

LN

I

L_cont

I

L_max

I ab mm mm mm kg mH

V

A

A

All around 80; allow free convection

35

10

DC 540 … 750

±10%

100

250

5 at 70% × I

L_cont

2 at 100% × I

L_cont

Power dissipation at continuous current and continuous DC bus power respectively

Required wire size according to IEC 60364-5-52; at I

L_cont

9)

P

Diss_cont

A

LN

W mm²

300

50

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 109/431

HLL01 - DC Bus Choke, Current-Compensated

Description Symbol Unit

HLL01.1N-10M0-S0100-

A-007-05A0-NNNN

Required wire size according to UL 508 A (internal wiring); at I

L_cont

(UL) 10)

Recommended fuse at operation under rated conditions

Allowed range tightening torque

Temperature contact

Typical switching temperature of temperature contact

Switching capacity of temperature contact

Cross section of connection cable

Cross section of connection cable

Allowed range tightening torque

6)

9)

10)

Tab. 9-1:

A

LN

M

T schalt

A

A

A

Nm

°C mm²

AWG 2

125; gL

6,0 … 6,5

150

1 A / 250V AC; 24 V DC

1 … 2,5

AWG 18 … 14

M Nm 0,5 … 0,6 t = 0.3 s; T = 1.42 s; K = 2.5

Copper wire; PVC-insulation (conductor temperature 70 °C); in‐ stallation method B2; table B52-4; T

Copper wire; PVC-insulation (conductor temperature 90 °C); table 13.5.1; T a

≤ 40 °C a

≤ 40 °C

HLL - Technical Data - Currents, Voltages, Power

Operation Current vs. Leakage

Current

I

HLL

I ab

Fig. 9-6:

Allowed operation current of DC bus choke

Allowed leakage current

Current Characteristic of the DC Bus Choke

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Rexroth IndraDrive Additional Components and Accessories

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 111/431

HLC01 - DC Bus Capacitor Unit

10 HLC01 - DC Bus Capacitor Unit

10.1 Application Instructions

NOTICE Damage to the drive controller!

In operating cycles of more than 30 cycles per minute or in the case of falling mains voltage, the DC bus capacitors in the drive controller can be overloa‐ ded when the mains connection voltage decreases.

Additionally use DC bus capacitor units.

Using a DC bus capacitor unit can increase the storable energy in the DC bus. This makes sense in the following cases:

● Applications with short cycle times (> approx. 30 cycles per minute) or when stable mains voltage is not available. Voltage and current ripples on the DC bus capacitors are reduced which results in a longer service life of the DC bus capacitors. In addition, the continuous power of a braking resistor will be reduced and with it the dissipation heat gener‐ ated in the control cabinet.

● Applications which need a certain amount of energy, also in case of mains failure (e.g. for return motions)

● Systems with DC bus connections > 2 m between the drive controllers to back up the DC bus

112/431 Bosch Rexroth AG

HLC01 - DC Bus Capacitor Unit

10.2 Identification

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Rexroth IndraDrive Additional Components and Accessories

Fig. 10-1: Type Code

10.3 Mounting

10.3.1 Notes

● Always mount the DC bus capacitor unit directly next to the drive con‐ troller with the highest DC bus continuous power.

● To compensate the different mounting depths of a DC bus capacitor unit

HLC01.1C and IndraDrive M drive controllers, there are suitable dis‐

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 113/431

HLC01 - DC Bus Capacitor Unit tance bolts (accessory HAS03.1-002-NNN-NN; contains 2 distance bolts). You are only allowed to use the distance bolts when the DC bus capacitor unit is mounted directly next to the drive controller. In this case you also have to connect the contact bars for DC bus and control volt‐ age connection to the DC bus capacitor unit.

● Mount the distance bolts to the bare metal mounting surface of the con‐ trol cabinet.

A

B

Fig. 10-2:

Distance bolts

Mounting surface in control cabinet

How to Use the Distance Bolts

114/431 Bosch Rexroth AG

HLC01 - DC Bus Capacitor Unit

10.3.2 Mechanical Data

Dimensions HLC01.1C

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Rexroth IndraDrive Additional Components and Accessories

A)

B)

Fig. 10-3:

Minimum mounting clearance

Rear view

Dimensions HLC01.1C

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Rexroth IndraDrive Additional Components and Accessories

Dimensions HLC01.1D

Bosch Rexroth AG 115/431

HLC01 - DC Bus Capacitor Unit

Weight

Mounting Position

A)

B)

Fig. 10-4:

Minimum mounting clearance

Rear view

Dimensions HLC01.1D

Type

HLC01.1C-01M0-A-007-NNNN

HLC01.1C-02M4-A-007-NNNN

HLC01.1D-05M0-A-007-NNNN

Tab. 10-1: Weight

Allowed mounting position: G1

Weight [kg]

3,2

4,3

8,6

116/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLC01 - DC Bus Capacitor Unit

10.4 Installation

10.4.1 Electrical Data

Description Symbol

Allowed input voltage

Nominal DC bus capacitance

Maximum discharge time from 820 V to 50 V

Power dissipation (at 750 V DC bus voltage)

Insulation resistance

Maximum current (at 55 °C ambient temperature)

Cooling

U

DC

C

DC

T

P v

R is

I

Crms

Tab. 10-2:

Unit

V mF s

W

Mohm

A

Type

HLC01.1C-01M0 HLC01.1 C-02M4 HLC01.1D-05M0

DC 254 … 750 V

1

228

2,4

274

5

748

8,5

20

16,5

> 25

50

13

60

Electrical Data

Natural convection

As the mains connection voltage increases, the storable energy in the DC bus decreases, because the differential voltage between braking resistor threshold and DC bus voltage (peak value of sup‐ ply voltage) is reduced.

10.4.2 Connection Points

General Information

WARNING Lethal electric shock by live parts with more than 50 V!

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

When using HMV supply units, the discharge time of the DC bus capacitors can be reduced by activating the function "ZKS".

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Rexroth IndraDrive Additional Components and Accessories

Overview

Bosch Rexroth AG 117/431

HLC01 - DC Bus Capacitor Unit

X1 in, X1 out Module bus

24V, 0V

L+, L-

1)

Control voltage

DC bus

Connection point of equipment grounding conductor

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Rexroth IndraDrive Additional Components and Accessories

HLC01 - DC Bus Capacitor Unit

2)

Fig. 10-5:

Ground connection

Connections - Overview

X1, module bus

Function, pin assignment

View

The module bus is an internal system connection and is used to exchange data between the devices.

Identification Function

X1 in Receives the module bus connector

X1 out Passes the module bus connection to the neigh‐ boring device

Installation instructions

Control Voltage (+24 V, 0 V)

Tab. 10-3: X1, Module Bus

● Keep the ribbon cable in the parking position, if the connection to the neighboring device is not established.

● If used for the module bus, extension cables must be shielded. Their to‐ tal length may not exceed a maximum of 40 m. The module bus connec‐ tion can be extended by means of accessory RKB0001.

● When using DC bus capacitor units:

Do not establish this connection at the DC bus capacitor unit, if the DC bus capacitor unit is the last device in the drive system.

When using DC bus capacitor units: Do not establish this connec‐ tion at the DC bus capacitor unit, if the DC bus capacitor unit is the last device in the drive system.

View

Technical Data of the Connection Point

Identifica‐ tion

+24V

Function

0V

Power supply

Connection to neighboring devices with contact bars from accessory HAS01.1

Reference potential for power supply

Connection to neighboring devices with contact bars from accessory HAS01.1

Screw connection

M6 thread at device (terminal block)

Unit Min.

Max.

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Bosch Rexroth AG 119/431

HLC01 - DC Bus Capacitor Unit

Tightening torque

Polarity reversal protection

Nm 5,5 6,5

Within the allowed voltage range by internal protective diode

Current carrying capacity "looping through" from 24V to 24V, 0V to 0V

(contact bars in scope of supply of accessory HAS01)

With contact bars -072 A 220

Tab. 10-4: Function, Pin Assignment, Properties

L+ L-, DC Bus Connection

WARNING Lethal electric shock by live parts with more than 50 V!

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

Function, Pin Assignment

View

The DC bus connection connects

● several drive controllers to one another

● a drive controller to additional components

HCS02.1E-W0012 drive controllers do not have a DC bus con‐ nection.

Technical Data of the Connection Point

Identifica‐ tion

L+

L-

Function

Connection points for connecting DC bus connections

Screw connection

M6 thread at device (terminal block)

Unit Min.

Max.

Tightening torque

Short circuit protection

Nm 5,5 6,5

Via fusing elements connected in the incoming circuit to the mains connection

Current carrying capacity "looping through" from L+ to L+, L- to L-

(contact bars in scope of supply of accessory HAS01)

120/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLC01 - DC Bus Capacitor Unit

With contact bars -072

Additionally with contact bars -042 and end piece

Tab. 10-5:

A

A

Function, Pin Assignment, Properties

220

245

Notes on Installation

Fig. 10-6: DC Bus Connection with Contact Bars

If in special cases it is not possible to use the contact bars provided to estab‐ lish the connection, the connection must be established using the shortest possible twisted wires.

NOTICE

Make sure the polarity is correct.

Risk of damage by reversing the polarity of the DC bus connections L+ and L-

Length of twisted wire

Line cross section

Line protection

Dielectric strength of single strand against ground

Tab. 10-6: DC Bus Line

Max. 2 m

Min. 10 mm er

2 , but not smaller than cross section of supply feed‐

By means of fuses in the mains connection

≥ 750 V (e.g.: strand type - H07)

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Bosch Rexroth AG 121/431

HLC01 - DC Bus Capacitor Unit

Connection of equipment grounding conductor

WARNING Lethal electric shock by live parts with more than 50 V!

Connect the drive controller to the equipment grounding system of the control cabinet.

Supplying device with connection for joint bar:

● Via the joint bar on the front, connect the drive controller to the supply‐ ing device.

Supplying device without connection for joint bar:

● Via a separate connection line, connect the drive controller to the equip‐ ment grounding system of the control cabinet.

Via the joint bar on the front, connect the drive controller to the neighboring drive controller.

Connect the equipment grounding conductor connection of the supplying unit to the equipment grounding system of the control cabinet.

Check the continuity of the equipment grounding conductors from the mains connection to the connected motors.

Equipment grounding conductor: Material and cross section

For the equipment grounding conductor, use the same metal (e.g.

copper) as for the outer conductors.

For the connections from the equipment grounding conductor connection of the device to the equipment grounding conductor system in the control cabinet, make sure the cross sections of the lines are sufficient.

Cross sections of the equipment grounding connections:

● For HCS03.1E drive controllers, HMV01 and HMV02 supply units at least 10 mm 2 (AWG 8), but not smaller than the cross sections of the outer conductors of the mains supply feeder

● For HCS02.1E drive controllers, at least 4 mm but not smaller than the cross sections of the outer conduc‐ tors of the mains supply feeder

2 (AWG 10),

Additionally, mount the housing of HCS02.1E to a bare met‐ al mounting plate. Connect the mounting plate, too, with at least the same cross section to the equipment grounding conductor system in the control cabinet.

For outer conductors with a cross section greater than 16 mm², you can reduce the cross section of the equipment grounding connection according to the table "Equipment Grounding Conduc‐ tor Cross Section".

122/431 Bosch Rexroth AG

HLC01 - DC Bus Capacitor Unit

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Rexroth IndraDrive Additional Components and Accessories

Cross-sectional area A of outer conduc‐ tors

Tab. 10-7:

A ≤ 16 mm²

16 mm² < A ≤ 35 mm²

35 mm² < A

Minimum cross-sectional area A

PE equipment grounding connection

of

A

16

A / 2

Equipment grounding conductor cross section

The line for the connection of the equipment grounding conductor must have at least the cross section of the mains supply feeder.

With cross sections of the mains supply feeder smaller than

10 mm 2 (AWG 8), the equipment grounding conductor must have at least 10 mm 2 (AWG 8).

1

2

Fig. 10-7:

Joint bar

Connection to equipment grounding system

Design, tightening torque

1

2

Fig. 10-8:

Joint bar

Connection to equipment grounding system

Equipment Grounding Conductor Connection for Supply via HCS02

The joint bars are connected by means of screws:

Tab. 10-8:

Design

M6 × 25

Tightening torque

6 Nm

Data of Connection Point

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 123/431

HLC01 - DC Bus Capacitor Unit

Ground connection

The ground connection of the housing is used to provide functional safety of the drive controllers and protection against contact in conjunction with the equipment grounding conductor.

Ground the housings of the drive controllers:

1. Connect the 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.

See Project Planning Manual of the drive system (index entry "Mains connection → Project planning").

10.4.3 Touch guard at devices

Cutouts

WARNING Lethal electric shock caused by live parts with more than 50 V!

● The appropriate touch guard must be mounted for each device following connection work.

● Never mount a damaged touch guard.

● Immediately replace a damaged touch guard by an undamaged touch guard.

● Keep the cutouts at the touch guard as small as possible. Only remove the cutouts if necessary.

124/431 Bosch Rexroth AG

HLC01 - DC Bus Capacitor Unit

Type 1

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Rexroth IndraDrive Additional Components and Accessories

Type 2

Tab. 10-9: Cutouts at the Touch Guard

● If the DC bus and the control voltage are connected by means of con‐ tact bars, only cutout A may be removed from the touch guard.

● If the DC bus and the control voltage are connected by means of cables

(e.g. in the case of multiple-line arrangement), the cutouts A, B and C may be removed from the touch guard.

● At the first and last device in a line of interconnected devices, you must not remove any cutout at the outer side of the touch guard.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mounting

Bosch Rexroth AG 125/431

HLC01 - DC Bus Capacitor Unit

Tightening torque

Fig. 10-9: Touch Guard at Device

The touch guard is fixed to the device with screws.

Max. 2.8 Nm

126/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 127/431

HLB01.1C and HLB01.1D - DC bus resistor unit

11 HLB01.1C and HLB01.1D - DC bus resistor unit

11.1 Description

The DC bus resistor unit can be advantageously used for

● increasing the available continuous regenerative power

● increasing the available peak regenerative power

● DC bus short circuit (ZKS) for quickly discharging the DC bus

11.2 Identification

Fig. 11-1: Type code

128/431 Bosch Rexroth AG

HLB01.1C and HLB01.1D - DC bus resistor unit

11.3 Mounting HLB01.1

11.3.1 Mechanical data HLB01.1

Dimensions HLB01.1C-…-NNNN

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Rexroth IndraDrive Additional Components and Accessories

A)

B)

Fig. 11-2:

Minimum mounting clearance

Rear view!

Dimensions HLB01.1C-…-NNNN

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Rexroth IndraDrive Additional Components and Accessories

Dimensions HLB01.1D-…-NNNN

Bosch Rexroth AG 129/431

HLB01.1C and HLB01.1D - DC bus resistor unit

A)

B)

Fig. 11-3:

Minimum mounting clearance

Rear view!

Dimensions HLB01.1D

130/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLB01.1C and HLB01.1D - DC bus resistor unit

Weight

Type

HLB01.1C

HLB01.1D

Tab. 11-1: Weight

Mounting Position

Allowed mounting position: G1

11.4 Installing HLB01.1

11.4.1 Electrical data HLB01.1

Technical data - currents, voltages, power

Weight [kg]

5.8

12.2

Description

Rated control voltage input

Rated power consumption control voltage input at U

N3

Max. inrush current at 24-V-supply

Pulse width of I

EIN3

Braking resistor continuous power

Braking resistor peak power

Regenerative power to be absorbed

Nominal braking resistance

Braking resistor switch-on threshold - independent of mains voltage 1)

Braking resistor switch-on threshold - depending on mains voltage 2)

Balancing factor for P

BD

DC bus)

(for parallel operation at common

DC bus voltage

Listing in accordance with UL standard

UL files

Minimum distance on the top of the device 3)

Minimum distance on the bottom of the device 4)

1) 2)

3) 4)

Tab. 11-2:

Symbol

U

N3

P

N3

I

EIN3_max t

EIN3Lade

P

BD

P

BS

W

R_max

R

DC_Bleeder

U

R_DC_On_f

U

R_DC_On_v f

U

DC

-

d top d bot

Unit ms kW kW kWs ohm

V

W

A

V

V

V

-

mm mm

HLB01.1C-01K0

-N06R0-A-007-

NNNN

24V ±20%

14

3

HLB01.1D-02K0

-N03R4-A-007-

NNNN

1

100

100

6

50

820

-

0.8

254 ... 750

UL 508C

E134201

300

2

180

500

3.4

80 100

Last modification: 2014-02-13 (m)

Factory setting

See fig. "Air intake and air outlet at device"

HLB - technical data - currents, voltages, power

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 131/431

HLB01.1C and HLB01.1D - DC bus resistor unit

C d

A

B d top d bot hor

Fig. 11-4:

Air intake

Air outlet

Mounting surface in control cabinet

Distance top

Distance bottom

Distance horizontal

Air intake and air outlet at device

132/431 Bosch Rexroth AG

HLB01.1C and HLB01.1D - DC bus resistor unit

11.4.2 Connection points

Overview HLB01.1C

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Rexroth IndraDrive Additional Components and Accessories

1)

2)

Fig. 11-5:

Equipment grounding conductor connection point

Ground connection

Connections HLB01.1C

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Rexroth IndraDrive Additional Components and Accessories

Overview HLB01.1D

Bosch Rexroth AG 133/431

HLB01.1C and HLB01.1D - DC bus resistor unit

1)

2)

Fig. 11-6:

Equipment grounding conductor connection point

Ground connection

Connections HLB01.1D

134/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLB01.1C and HLB01.1D - DC bus resistor unit

L+ L-, DC bus connection

WARNING Lethal electric shock by live parts with more than 50 V!

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

Function, pin assignment

View

The DC bus connection connects

● several drive controllers to one another

● a drive controller to additional components

HCS02.1E-W0012 drive controllers do not have a DC bus con‐ nection.

Technical Data of the Connection Point

Identifica‐ tion

L+

L-

Function

Connection points for connecting DC bus connections

Screw connection

M6 thread at device (terminal block)

Tightening torque

Short circuit protection

Overload protection

Unit

Nm

Current carrying capacity "looping through" from L+ to L+, L- to L-

(contact bars in scope of supply of accessory HAS01)

With contact bars -072

Additionally with contact bars -042 and end piece

A

A

Min.

Max.

5,5 6,5

Via fusing elements connected in the incoming circuit to the mains connection

Via fusing elements connected in the incoming circuit to the mains connection

220

245

Tab. 11-3: Function, Pin Assignment, Properties

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 135/431

HLB01.1C and HLB01.1D - DC bus resistor unit

Notes on installation

Fig. 11-7: DC Bus Connection with Contact Bars

If in special cases it is not possible to use the contact bars provided to estab‐ lish the connection, the connection must be established using the shortest possible twisted wires.

NOTICE Risk of damage by reversing the polarity of the DC bus connections L+ and L-

Make sure the polarity is correct.

Length of twisted wire

Line cross section

Line protection

Dielectric strength of single strand against ground

Tab. 11-4: DC Bus Line

Max. 2 m

Min. 10 mm 2 , but not smaller than cross section of supply feed‐ er

By means of fuses in the mains connection

≥ 750 V (e.g.: strand type - H07)

136/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLB01.1C and HLB01.1D - DC bus resistor unit

Connection of equipment grounding conductor

WARNING Lethal electric shock by live parts with more than 50 V!

Connect the drive controller to the equipment grounding system of the control cabinet.

Supplying device with connection for joint bar:

● Via the joint bar on the front, connect the drive controller to the supply‐ ing device.

Supplying device without connection for joint bar:

● Via a separate connection line, connect the drive controller to the equip‐ ment grounding system of the control cabinet.

Via the joint bar on the front, connect the drive controller to the neighboring drive controller.

Connect the equipment grounding conductor connection of the supplying unit to the equipment grounding system of the control cabinet.

Check the continuity of the equipment grounding conductors from the mains connection to the connected motors.

Equipment grounding conductor: Material and cross section

For the equipment grounding conductor, use the same metal (e.g.

copper) as for the outer conductors.

For the connections from the equipment grounding conductor connection of the device to the equipment grounding conductor system in the control cabinet, make sure the cross sections of the lines are sufficient.

Cross sections of the equipment grounding connections:

● For HCS03.1E drive controllers, HMV01 and HMV02 supply units at least 10 mm 2 (AWG 8), but not smaller than the cross sections of the outer conductors of the mains supply feeder

● For HCS02.1E drive controllers, at least 4 mm tors of the mains supply feeder

2 (AWG 10), but not smaller than the cross sections of the outer conduc‐

Additionally, mount the housing of HCS02.1E to a bare met‐ al mounting plate. Connect the mounting plate, too, with at least the same cross section to the equipment grounding conductor system in the control cabinet.

For outer conductors with a cross section greater than 16 mm², you can reduce the cross section of the equipment grounding connection according to the table "Equipment Grounding Conduc‐ tor Cross Section".

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 137/431

HLB01.1C and HLB01.1D - DC bus resistor unit

Cross-sectional area A of outer conduc‐ tors

Tab. 11-5:

A ≤ 16 mm²

16 mm² < A ≤ 35 mm²

35 mm² < A

Minimum cross-sectional area A

PE equipment grounding connection

of

A

16

A / 2

Equipment grounding conductor cross section

The line for the connection of the equipment grounding conductor must have at least the cross section of the mains supply feeder.

With cross sections of the mains supply feeder smaller than

10 mm 2 (AWG 8), the equipment grounding conductor must have at least 10 mm 2 (AWG 8).

1

2

Fig. 11-8:

Joint bar

Connection to equipment grounding system

Design, tightening torque

1

2

Fig. 11-9:

Joint bar

Connection to equipment grounding system

Equipment Grounding Conductor Connection for Supply via HCS02

The joint bars are connected by means of screws:

Tab. 11-6:

Design

M6 × 25

Tightening torque

6 Nm

Data of Connection Point

138/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLB01.1C and HLB01.1D - DC bus resistor unit

Ground connection

The ground connection of the housing is used to provide functional safety of the drive controllers and protection against contact in conjunction with the equipment grounding conductor.

Ground the housings of the drive controllers:

1. Connect the 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.

See Project Planning Manual of the drive system (index entry "Mains connection → Project planning").

X13 at HLB01, control voltage

Pin assignment Signal name Function Connec‐ tion

4

3

2

1

+24V

+24V

0V

0V

Power supply and "looping through"

Reference potential for pow‐ er supply and "looping through"

Spring terminal (connector)

Connection cable, solid wire

Connection cable, stranded wire

Connection cable

Power consumption

Voltage load capacity

Current carrying capacity "looping through" from

+24V to +24V, 0V to 0V

Continuous current P

N3

/U

N3

Current carrying capacity "looping through" from

+24V to +24V, 0V to 0V

Inrush current I

EIN3

Polarity reversal protection

Notes on installation

Unit mm 2 mm 2

AWG

W

V

A

A min.

1

1

18

P

N3

(see technical data)

U

N3

(see technical data) max.

1.5

1.5

16

6

12

Within the allowed voltage range by internal protective diode

Tab. 11-7: Function, pin assignment, properties

Requirements on the connection to the 24V supply:

● Minimum cross-section: 1 mm 2

● Maximum allowed inductance: 100 µH (2 twisted single strands, 75 m long)

● Parallel line routing where possible

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 139/431

HLB01.1C and HLB01.1D - DC bus resistor unit

Control voltage HLB01.1D

Technical Data of the Connection Point

View Identifica‐ tion

+24V

Function

0V

Power supply

Connection to neighboring devices with contact bars from accessory HAS01.1

Reference potential for power supply

Connection to neighboring devices with contact bars from accessory HAS01.1

Screw connection

M6 thread at device (terminal block)

Tightening torque

Power consumption

Voltage load capacity

Unit

Nm

W

V

Min.

5,5

Max.

6,5

Polarity reversal protection Within the allowed voltage range by internal protective diode

Current carrying capacity "looping through" from 24V to 24V, 0V to 0V

(contact bars in scope of supply of accessory HAS01)

With contact bars -072 A 220

P

N3

(see technical data)

U

N3

(see technical data)

Tab. 11-8: Function, Pin Assignment, Properties

X1, module bus

Function, pin assignment The module bus is an internal system connection and is used to exchange data between the devices.

View Identification Function

X1 in Receives the module bus connector

X1 out Passes the module bus connection to the neigh‐ boring device

Installation instructions

Tab. 11-9: X1, Module Bus

● Keep the ribbon cable in the parking position, if the connection to the neighboring device is not established.

140/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLB01.1C and HLB01.1D - DC bus resistor unit

● If used for the module bus, extension cables must be shielded. Their to‐ tal length may not exceed a maximum of 40 m. The module bus connec‐ tion can be extended by means of accessory RKB0001.

● When using DC bus capacitor units:

Do not establish this connection at the DC bus capacitor unit, if the DC bus capacitor unit is the last device in the drive system.

X31 at HLB01, ready for operation and prewarning contact

Pin assignment Connec‐ tion

6

5

Signal name / function

●

●

●

Ready for operation contact:

Closes when the following conditions have been fulfilled:

● Control voltage available

Heat sink temperature OK

Load resistor temperature OK

Continuous power is smaller than specified value (see tech‐ nical data)

● Maximum regenerative power is smaller than specified val‐ ue (see technical data) n. c.

4

3

2

1 n. c.

Prewarning contact:

●

●

Opens if one of the following conditions has been fulfilled:

● Heat sink temperature too high

Continuous power > 90%

Regenerative power > 90%

Connect to shield connection XS1 of neighboring drive controller Shields of control lines

Spring terminal (connector)

Connection cable, solid wire

Connection cable, stranded wire

Max. switching voltage

Max. switching current

Max. continuous current

Minimum load of the contacts

Unit mm 2 mm 2

AWG

V

A

A mA

Tab. 11-10: min.

0.5

0.5

20

DC 30

DC 1

DC 1

10

Function, pin assignment, properties max.

1.5

1.5

16

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 141/431

HLB01.1C and HLB01.1D - DC bus resistor unit

X32 at HLB01, DC bus short circuit control, clear error, braking resistor switch-on threshold

NOTICE Risk of fire caused by the "sacrificing behav‐ ior" of the ZKS stage!

The "ZKS" input activates the "DC bus short circuit" function, when the 24V control voltage has not been applied and when there isn't any current flowing to the input. This condition can occur in the following situations:

● Failure of 24V control voltage

● Wire break

● Activation of serially connected contacts (e.g. axis limit switches)

If the kinetic energy of the mechanical axis system regenerated when braking is greater than the energy absorption capacity of HLB, the HLB device re‐ mains active when braking via ZKS takes place, until it is thermally destroyed

(sacrificing behavior). Risk of fire! In this case, braking via ZKS may only come into effect in the case of an emergency (e.g. activation of an axis limit switch causes the mains supply to be cut off and simultaneously causes the

24V supply of the ZKS input to be interrupted).

Install a 24V UPS, if the "sacrificing behavior" of HLB is relevant to your drive system in the case of an emergency. This prevents the braking via ZKS which causes HLB to be destroyed due to the failure of the 24V control volt‐ age. Braking via ZKS then will only take place in cases of emergency.

142/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLB01.1C and HLB01.1D - DC bus resistor unit

Pin assignment

Shields of control lines

DC bus short circuit control

High:

ZKS stage not active, i.e. braking resistor switched off

Voltage at input ZKS1 against ZKS2

(HLB01.1D) or against GND (HLB01.1C)

Low: ZKS stage active, i.e. braking resistor switched on

Delay t d_on on

until braking resistor switches

Delay t d_off off

until braking resistor switches

Input resistance

Polarity reversal protection

Connec‐ tion

9

8

7

6

5

Signal name / function

HLB01.1C

GND

Input ZKS1

Input circuit: see figure "

HLB01.1C input circuit ZKS "

n. c.

n. c.

Input clear error: A negative edge at the input against GND clears all present errors that can be cleared.

Signal name / function

Input ZKS1

HLB01.1D

n. c.

Input circuit: see figure "

HLB01.1D input circuit ZKS "

Input clear error: A negative edge at the input against X32.4

clears all present errors that can be cleared.

4

3

GND Reference potential for input clear error:

Applies to devices with hard‐ ware index ≥ A17 (see type plate) n. c.

Applies to devices with hard‐ ware index ≥ A17 (see type plate)

2 Input braking resistor switch-on threshold:

Input not active; independent of the wiring, the braking resistor is switched on between DC 820 … 850 V (depending on the load)

1 n. c.

Connect ZKS2 (reference po‐ tential for input ZKS1) to 0V

Connect to shield connection XS1 of neighboring drive controller

Unit

V min.

19.2

max.

28.8

V ms ms kOhm

0 approx. 160 approx. 1

2 ±10%

5

Within the allowed input voltage range

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Electrical isolation

Bosch Rexroth AG 143/431

HLB01.1C and HLB01.1D - DC bus resistor unit

HLB01.1C: not electrically isolated, ZKS1 input with reference to

GND

HLB01.1D: ZKS1, ZKS2 inputs are electrically isolated, i.e. both inputs must be connected!

Input circuit ZKS

HLB01.1C

HLB01.1D

Fig. 11-10: HLB01.1C input circuit ZKS

Spring terminal (connector)

Connection cross section solid wire

Connection cross section stranded wire

Connection cross section

Unit mm 2 mm 2

AWG

Tab. 11-11:

X2, serial interface (RS232)

Fig. 11-11: HLB01.1D input circuit ZKS min.

0.5

0.5

28

Function, pin assignment, properties max.

1.5

1.5

14

General information

The serial interface (RS232) is required for programming, parameterization and diagnosis during commissioning and servicing.

Connec‐ tion point

X2

Type

MiniDin, female

(device)

Num‐ ber of poles

8

Stranded wire

[mm²]

0,25-0,5

Description

Serial interface

Figure

Pin assignment

Tab. 11-12:

Pin

4

5

6

1

2

3

Connections

Signal

RTS

CTS

TxD

GND

RxD

V cc

Function

Request to send

Clear to send

Transmit Data

Reference potential

Receive Data

Supply voltage

144/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLB01.1C and HLB01.1D - DC bus resistor unit

Features

Pin

7

8

Signal n. c.

n. c.

Function n. c.

n. c.

n. c.

Tab. 11-13:

Feature not connected

Pin Assignment of Serial Interface

Unit Min.

Number of nodes

Allowed cable length

Transmission rates

Connection

Allowed voltage difference be‐ tween reference potentials of control section and data end device m kBaud

V

9,6

Typ.

Max.

1

15

115

Galvanically connected to control sec‐ tion supply

1

Tab. 11-14: Features

The accessory

HAS05.1-005

makes available a converter from

RS232 to RS485 (see Project Planning Manual for additional components and accessories).

Connection diagrams serial interface to PC

Serial Interface to PC with 9-Pin

D-Sub

Fig. 11-12: Connection of Serial Interface to PC with 9-Pin D‑Sub

For direct connection to the serial interface use our cable

IKB0041.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Serial interface to PC with 25-Pin

D-Sub

Bosch Rexroth AG 145/431

HLB01.1C and HLB01.1D - DC bus resistor unit

Fig. 11-13: Connection of Serial Interface to PC with 25-Pin D‑Sub

X2, RS232 interface

11.4.3 Touch guard at devices

Cutouts

For internal use only.

WARNING Lethal electric shock caused by live parts with more than 50 V!

● The appropriate touch guard must be mounted for each device following connection work.

● Never mount a damaged touch guard.

● Immediately replace a damaged touch guard by an undamaged touch guard.

● Keep the cutouts at the touch guard as small as possible. Only remove the cutouts if necessary.

146/431 Bosch Rexroth AG

HLB01.1C and HLB01.1D - DC bus resistor unit

Type 1

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Type 2

Tab. 11-15: Cutouts at the Touch Guard

● If the DC bus and the control voltage are connected by means of con‐ tact bars, only cutout A may be removed from the touch guard.

● If the DC bus and the control voltage are connected by means of cables

(e.g. in the case of multiple-line arrangement), the cutouts A, B and C may be removed from the touch guard.

● At the first and last device in a line of interconnected devices, you must not remove any cutout at the outer side of the touch guard.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mounting

Bosch Rexroth AG 147/431

HLB01.1C and HLB01.1D - DC bus resistor unit

Tightening torque

Fig. 11-14: Touch Guard at Device

The touch guard is fixed to the device with screws.

Max. 2.8 Nm

11.5 Commissioning, operation, diagnostics

NOTICE Risk of fire caused by the "sacrificing behav‐ ior" of the ZKS stage!

The "ZKS" input activates the "DC bus short circuit" function, when the 24V control voltage has not been applied and when there isn't any current flowing to the input. This condition can occur in the following situations:

● Failure of 24V control voltage

● Wire break

● Activation of serially connected contacts (e.g. axis limit switches)

If the kinetic energy of the mechanical axis system regenerated when braking is greater than the energy absorption capacity of HLB, the HLB device re‐ mains active when braking via ZKS takes place, until it is thermally destroyed

(sacrificing behavior). Risk of fire! In this case, braking via ZKS may only come into effect in the case of an emergency (e.g. activation of an axis limit switch causes the mains supply to be cut off and simultaneously causes the

24V supply of the ZKS input to be interrupted).

Install a 24V UPS, if the "sacrificing behavior" of HLB is relevant to your drive system in the case of an emergency. This prevents the braking via ZKS which causes HLB to be destroyed due to the failure of the 24V control volt‐ age. Braking via ZKS then will only take place in cases of emergency.

148/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLB01.1C and HLB01.1D - DC bus resistor unit

Other braking resistors take effect at the common DC bus. For example, converters (HCS02, HCS03) and supply units (HMV) have integrated braking resistors or operate external HLR braking resistors.

The following parameters are relevant for operating HLB01:

● P-0-0833, Braking resistor threshold

● P-0-0858, Data of external braking resistor

● P-0-0859, Data of internal braking resistor

● P-0-0860, Converter configuration

Braking resistor switch-on thresholds of supply units

● In the case of feeding supply units, the braking resistor switch-on threshold is set depending on the wiring at X32.2

of the supply unit.

A jumper from X32.2 to X32.3, or X32.3 connected to 24 V, activates fixed braking resistor switch-on threshold

820-850 V.

● In the case of regenerative supply units, the braking resistor switch-on threshold is fixed to 820-850 V.

S1 reset button

Fig. 11-15: Diagnostic LEDs and reset button

Is used for resetting errors.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 149/431

HLB01.1C and HLB01.1D - DC bus resistor unit

Diagnostic LED H2 (green)

State Significance

Device is ready for operation and U

ZK

≤ 50 V

Flashing

Device is ready for operation and U

ZK

> 50 V

Diagnostic LED H3 (red)

Continuous light

Tab. 11-16:

State

Diagnostic LED H2 (green)

Significance

●

●

Overload prewarning at 90% load

Overtemperature prewarning

Flashing

Continuous light

Tab. 11-17:

●

●

●

Overload

Overtemperature

Internal error

Diagnostic LED H3 (red)

150/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 151/431

HLR01 - Braking Resistors

12 HLR01 - Braking Resistors

12.1 Braking Resistor HLR01

HLR01.1N-xxxx-Nxxx-A-007-NNNN braking resistors convert generated ki‐ netic energy into thermal energy. For this purpose, the series covers a wide range of continuous power and energy absorption capacity.

To operate HLR01 braking resistors, the drive controller must be equipped with a brake chopper.

Type

HLR01.1A

HLR01.1N

Use

Type of construction A (version for device mounting): To be moun‐ ted to drive controllers of the Rexroth IndraDrive C product range.

For this purpose, the drive controllers must be equipped with a brake chopper.

Type of construction N (version for free assembly): Braking resis‐ tors for free assembly in the installation (some types to be mounted to HCS03), operated by a drive controller of the

Rexroth IndraDrive C product range.

Tab. 12-1: DC Bus Resistor Units HLR

Types of design:

● Fixed resistor IP 20 type A

Cement-coated, wire-wound, tube-type fixed resistors; screwed on side walls; perforated cover; connections in terminal box with PG gland

● Steel-grid fixed resistor IP 20 type B

Fixed resistor in steel-grid design; connection depending on type

● Steel-grid fixed resistor IP 20 type C

Fixed resistor in steel-grid design; connection depending on type

12.2 Type Code and Identification

12.2.1 Type Code

The figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of availa‐ ble versions.

152/431 Bosch Rexroth AG

HLR01 - Braking Resistors

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Rexroth IndraDrive Additional Components and Accessories

12.2.2 Identification

Fig. 12-1: Type Code Braking Resistor HLR01.1

Each braking resistor is identified by a type designation. There is a type plate attached to all components.

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Rexroth IndraDrive Additional Components and Accessories

Type Plate Arrangement

Bosch Rexroth AG 153/431

HLR01 - Braking Resistors

Type Plate

1)

Fig. 12-2:

Type Plate

Position of Type Plate

1)

2)

3)

4)

5)

Fig. 12-3:

Type designation

Material number

Serial number

Production date

Revision index

Type Plate HLR01.1

12.3 Scope of Supply

The scope of supply of HLR braking resistors provided for mounting to drive controllers includes the joint bar for the equipment grounding conductor con‐ nection.

154/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLR01 - Braking Resistors

12.4 Technical Data

12.4.1 Technical Data HLR01 for HCS02.1

Assignment HLR01 to HCS02.1E

Braking Resistors HLR01 for HCS02

Converter

HCS02.1E-W0054-A-03-xNNx

HCS02.1E-W0054-A-03-xNNx

HCS02.1E-W0070-A-03-xNNx

HCS02.1E-W0070-A-03-xNNx

Braking resistor type 1)

HLR01.1N-01K8-N40R0-…

HLR01.1N-03K8-N40R0-…

HLR01.1N-02K4-N28R0-…

HLR01.1N-05K5-N28R2-…

Type of con‐ struction 2)

N

N

N

N

Type

Dimensions 3)

A7

B1

A8

B2

1)

2)

3)

Complete type with: A-007-NNNN

A: Device mounting; N: Version for free assembly

See Project Planning Manual "Rexroth IndraDrive Additional

Components and Accessories", dimension tables HLR

Assignment Braking Resistors HLR ↔ HCS02

HLR01 for HCS02.1E-W0054

Tab. 12-2:

Technical Data - Currents, Voltages, Power

Description Symbol Unit

HLR01.1N-01K8-N40R0-A-007-

NNNN

HLR01.1N-03K8-N40R0-A-007-

NNNN

Degree of protection in accord‐ ance with IEC 60529

Ambient temperature range for operation with nominal data

Mass

Nominal braking resistance

Braking resistor continuous power

Braking resistor peak power

Regenerative power to be absor‐ bed

Maximum allowed on-time duty

IP a_work m

R

DC_Bleed‐ er

P

BD

P

BS

W t

T

R_max on_max

T cycl

Minimum allowed cycle time

Cooling type

Volumetric capacity of forced cool‐ ing

Temperature rise with minimum distances d bot

; d top

; P

BD

Minimum distance on the top of the device 1)

ΔT d

V top

°C kg ohm kW kW kWs s s m 3 /h

K mm

6,60

1,80

72,00

4,00

40,00

300

IP20

0...40

40,00

18,00

n

65

9,50

3,80

300,00

16,67

79,00

600

Last modification: 2012-07-05

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 155/431

HLR01 - Braking Resistors

Description

Minimum distance on the bottom of the device 2)

Horizontal spacing on the device 3)

Allowed range tightening torque

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 4)

Symbol d

A bot d hor

M

LN

Unit mm mm

Nm

AWG

HLR01.1N-01K8-N40R0-A-007-

NNNN

HLR01.1N-03K8-N40R0-A-007-

NNNN

200

200

1,80 2,00

12

1) 2) 3)

4)

Tab. 12-3:

Last modification: 2012-07-05

See fig. "Air Intake and Air Outlet at Device"

Copper wire; PVC-insulation (conductor temperature 90 °C); table 28.1; T a

≤ 40 °C

HLR - Technical Data - Currents, Voltages, Power

NOTICE Property damage due to temperatures higher than 105 ℃!

Observe the indicated minimum distances!

Above the devices there may only be such materials which

● are not combustible

● are insensitive to the occurring high temperatures

HLR01 for HCS02.1E-W0070

Technical Data - Currents, Voltages, Power

Description Symbol Unit

HLR01.1N-02K4-N28R0-A-007-

NNNN

HLR01.1N-05K5-N28R0-A-007-

NNNN

Degree of protection in accord‐ ance with IEC 60529

Ambient temperature range for operation with nominal data

Mass

Nominal braking resistance

T

IP a_work m

R

DC_Bleed‐ er

P

BD

P

BS

Braking resistor continuous power

Braking resistor peak power

Regenerative power to be absor‐ bed

Maximum allowed on-time duty

Minimum allowed cycle time

Cooling type

W t

R_max on_max

T cycl

°C kg ohm kW kW kWs s s

7,90

2,40

100,80

3,88

42,00

IP20

0...40

28,00

26,00 n

13,00

5,50

420,00

16,16

76,40

Last modification: 2012-06-27

156/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLR01 - Braking Resistors

Description

Volumetric capacity of forced cool‐ ing

Temperature rise with minimum distances d bot

; d top

; P

BD

Minimum distance on the top of the device 1)

Minimum distance on the bottom of the device 2)

Horizontal spacing on the device 3)

Allowed range tightening torque

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 4)

Symbol

ΔT d d

A

V top bot d hor

M

LN

Unit m 3 /h

HLR01.1N-02K4-N28R0-A-007-

NNNN

HLR01.1N-05K5-N28R0-A-007-

NNNN

-

K mm mm mm

Nm

AWG

300

1,80

65

200

200

12

600

2,00

1) 2) 3)

4)

Tab. 12-4:

Last modification: 2012-06-27

See fig. "Air Intake and Air Outlet at Device"

Copper wire; PVC-insulation (conductor temperature 90 °C); table 28.1; T a

≤ 40 °C

HLR - Technical Data - Currents, Voltages, Power

NOTICE Property damage due to temperatures higher than 105 ℃!

Observe the indicated minimum distances!

Above the devices there may only be such materials which

● are not combustible

● are insensitive to the occurring high temperatures

12.4.2 Technical Data HLR01 for HCS03.1E

Assignment HLR01 to HCS03.1E

Braking Resistors HLR01 for HCS03

Converter Braking resistor type Type of con‐ struction 1)

HCS03.1E-W0070-A-05-xNBV

HCS03.1E-W0100-A-05-xNBV

HCS03.1E-W0150-A-05-xNBV

HCS03.1E-W0210-A-05-xNBV

HCS03.1E-W0070-A-05-xNBV

HCS03.1E-W0100-A-05-xNBV

HLR01.1N-0300-N17R5-A-007-NNNN

HLR01.1N-0470-N11R7-A-007-NNNN

HLR01.1N-0780-N07R0-A-007-NNNN

HLR01.1N-1K08-N05R0-A-007-NNNN

HLR01.1N-01K6-N18R0-A-007-NNNN

HLR01.1N-01K6-N18R0-A-007-NNNU

HLR01.1N-02K0-N15R0-A-007-NNNN

HLR01.1N-02K0-N15R0-A-007-NNNU

A

N

N

Type

Dimensions 2)

See corresponding di‐ mensional drawing

A5

A9

A6

A10

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 157/431

HLR01 - Braking Resistors

Converter

HCS03.1E-W0150-A-05-xNBV

HCS03.1E-W0210-A-05-xNBV

HCS03.1E-W0070-A-05-xNBV

HCS03.1E-W0100-A-05-xNBV

HCS03.1E-W0150-A-05-xNBV

HCS03.1E-W0210-A-05-xNBV

HCS03.1E-W0070-A-05-xNBV

HCS03.1E-W0100-A-05-xNBV

HCS03.1E-W0150-A-05-xNBV

HCS03.1E-W0210-A-05-xNBV

HCS03.1E-W0070-A-05-xNBV

HCS03.1E-W0100-A-05-xNBV

HCS03.1E-W0150-A-05-xNBV

HCS03.1E-W0210-A-05-xNBV

HCS03.1E-W0070-A-05-xNBV

HCS03.1E-W0100-A-05-xNBV

HCS03.1E-W0150-A-05-xNBV

HCS03.1E-W0210-A-05-xNBV

Braking resistor type

HLR01.1N-04K5-N07R4-A-007-NNNN

HLR01.1N-06K5-N06R1-A-007-NNNN

HLR01.1N-03K5-N19R0-A-007-NNNN

HLR01.1N-05K0-N15R0-A-007-NNNN

HLR01.1N-08K5-N08R0-A-007-NNNN

HLR01.1N-12K5-N05R5-A-007-NNNN

HLR01.1N-04K5-N18R0-A-007-NNNN

HLR01.1N-07K0-N14R0-A-007-NNNN

HLR01.1N-11K0-N07R3-A-007-NNNN

HLR01.1N-17K0-N05R1-A-007-NNNN

HLR01.1N-06K5-N18R0-A-007-NNNN

HLR01.1N-09K5-N13R0-A-007-NNNN

HLR01.1N-15K0-N08R1-A-007-NNNN

HLR01.1N-23K0-N05R5-A-007-NNNN

HLR01.1N-10K0-N18R0-A-007-NNNN

HLR01.1N-14K5-N13R0-A-007-NNNN

HLR01.1N-24K0-N07R2-A-007-NNNN

HLR01.1N-36K0-N05R4-A-007-NNNN

Type of con‐ struction 1)

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

N

B5

B2

B3

B4

B4

B2

B3

B3

Type

Dimensions 2)

B1

B2

B1

B2

B3

C2

B3

B4

C3

C4

1)

2)

A: Device mounting; N: Version for free assembly

See Project Planning Manual "Rexroth IndraDrive Additional

Components and Accessories", dimension tables HLR

Assignment Braking Resistors HLR ↔ HCS03

HLR01 for HCS03.1E-W0070

Tab. 12-5:

Technical Data - Currents, Voltages, Power

Description Symbol Unit

HLR01.1

N-01K6-

N18R0-

A-007-

NNNN

HLR01.1

N-0300-

N17R5-

A-007-

NNNN

HLR01.1

N-03K5-

N19R0-

A-007-

NNNN

HLR01.1

N-04K5-

N18R0-

A-007-

NNNN

HLR01.1

N-06K5-

N18R0-

A-007-

NNNN

HLR01.1

N-10K0-

N18R0-

A-007-

NNNN

Degree of protection in accord‐ ance with IEC 60529

Ambient temperature range for operation with nominal data

Mass

Nominal braking resistance

Braking resistor continuous power

T

IP a_work m

R

DC_Bleed‐ er

P

BD

°C kg ohm kW

5,20

18,00

1,60

3,00

17,50

0,30

9,50

19,00

3,50

IP20

0...40

13,00

18,00

22,00

4,50 6,50 10,00

Last modification: 2007-06-29

158/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLR01 - Braking Resistors

Description Symbol

Braking resistor peak power

Regenerative power to be absor‐ bed

Maximum allowed on-time duty

Minimum allowed cycle time

Cooling type

Volumetric capacity of forced cool‐ ing

Temperature rise with minimum distances d bot

; d top

; P

BD

Minimum distance on the top of the device 1)

Minimum distance on the bottom of the device 2)

Horizontal spacing on the device 3)

Allowed range tightening torque

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 4)

P

BS

W

R_max t on_max

T cycl

ΔT d d

A

V top bot d hor

M

LN

Unit kW kWs s s m 3 /h

K mm mm mm

Nm

AWG

HLR01.1

N-01K6-

N18R0-

A-007-

NNNN

34,00

HLR01.1

N-0300-

N17R5-

A-007-

NNNN

37,00

HLR01.1

N-03K5-

N19R0-

A-007-

NNNN

31,00

HLR01.1

N-04K5-

N18R0-

A-007-

NNNN

HLR01.1

N-06K5-

N18R0-

A-007-

NNNN

33,00

HLR01.1

N-10K0-

N18R0-

A-007-

NNNN

109,00

3,30

37,00

1,00

252,00

8,00

432,00

120,00

13,00

686,00

21,00

1080,00

32,00

n f

200,00 n

>40

1000

200

200

1,80

14

20

80

80

0

1,50

12

>65

10

1000

300

300

2,00

>100

8

1) 2) 3)

4)

Tab. 12-6:

Last modification: 2007-06-29

See fig. "Air Intake and Air Outlet at Device"

Copper wire; PVC-insulation (conductor temperature 90 °C); table 28.1; T a

≤ 40 °C

HLR - Technical Data - Currents, Voltages, Power

NOTICE Property damage due to temperatures higher than 105 ℃!

Observe the indicated minimum distances!

Above the devices there may only be such materials which

● are not combustible

● are insensitive to the occurring high temperatures

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Rexroth IndraDrive Additional Components and Accessories

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HLR01 - Braking Resistors

HLR01 for HCS03.1E-W0100

Technical Data - Currents, Voltages, Power

Description Symbol Unit

HLR01.1

N-02K0-

N15R0-

A-007-

NNNN

HLR01.1

N-0470-

N11R7-

A-007-

NNNN

HLR01.1

N-05K0-

N15R0-

A-007-

NNNN

Degree of protection in accord‐ ance with IEC 60529

Ambient temperature range for operation with nominal data

Mass

Nominal braking resistance

T

IP a_work m

R

DC_Bleed‐ er

P

BD

P

BS

Braking resistor continuous power

Braking resistor peak power

Regenerative power to be absor‐ bed

Maximum allowed on-time duty

Minimum allowed cycle time

Cooling type

Volumetric capacity of forced cool‐ ing

Temperature rise with minimum distances d bot

; d top

; P

BD

Minimum distance on the top of the device 1)

Minimum distance on the bottom of the device 2)

Horizontal spacing on the device 3)

Allowed range tightening torque

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 4)

W t

T

R_max on_max

V

ΔT d d d

A cycl top bot hor

M

LN

°C kg ohm kWs s s kW kW m 3 /h

K mm mm mm

Nm

AWG

6,20

15,00

2,00

40,00

137,00

3,40 n

-

>40

1000

200

200

0,50

12

4,50

11,70

0,47

56,00

56,00

1,00 f

200,00

23

80

80

0

4,00

13,00

15,00

5,00

40,00

360,00

9,00

120,00

16,00

10

HLR01.1

N-07K0-

N14R0-

A-007-

NNNN

IP20

0...40

14,00

7,00

43,00

HLR01.1

N-09K5-

N13R0-

A-007-

NNNN

22,00

HLR01.1

N-14K5-

N13R0-

A-007-

NNNN

9,50

46,00

14,50

672,00 1003,00 1566,00

2,00

n

>65

1000

300

300

8

22,00

13,00

33,00

34,00

3,00

6

1) 2) 3)

4)

Tab. 12-7:

Last modification: 2013-11-14

See fig. "Air Intake and Air Outlet at Device"

Copper wire; PVC-insulation (conductor temperature 90 °C); table 28.1; T a

≤ 40 °C

HLR - Technical Data - Currents, Voltages, Power

160/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLR01 - Braking Resistors

NOTICE Property damage due to temperatures higher than 105 ℃!

Observe the indicated minimum distances!

Above the devices there may only be such materials which

● are not combustible

● are insensitive to the occurring high temperatures

HLR01 for HCS03.1E-W0150

Technical Data - Currents, Voltages, Power

Description Symbol Unit

HLR01.1

N-04K5-

N07R4-

A-007-

NNNN

HLR01.1

N-0780-

N07R0-

A-007-

NNNN

HLR01.1

N-08K5-

N08R0-

A-007-

NNNN

Degree of protection in accord‐ ance with IEC 60529

Ambient temperature range for operation with nominal data

Mass

Nominal braking resistance

Braking resistor continuous power

Braking resistor peak power

Regenerative power to be absor‐ bed

Maximum allowed on-time duty

IP a_work m

R

DC_Bleed‐ er

P

BD

P

BS

W t

T

R_max on_max

T cycl

Minimum allowed cycle time

Cooling type

Volumetric capacity of forced cool‐ ing

Temperature rise with minimum distances d bot

; d top

; P

BD

Minimum distance on the top of the device 1)

Minimum distance on the bottom of the device 2)

Horizontal spacing on the device 3)

ΔT d d d

V top bot hor

°C kg ohm kWs s s kW kW m 3 /h

K mm mm mm

9,50

7,40

4,50

81,00

246,00

3,00

n

>100

1000

300

300

5,50

7,00

0,78

93,00

93,00

1,00 f

200,00

20

80

80

0

8,00

8,50

75,00

HLR01.1

N-11K0-

N07R3-

A-007-

NNNN

IP20

0...40

22,00

7,30

11,00

82,00

8,20

120,00

13,00

33,00

8,10

15,00

74,00

24,00

83,00

612,00 1056,00 1584,00 2592,00

>65

n

1000

300

HLR01.1

N-15K0-

N08R1-

A-007-

NNNN

21,00

HLR01.1

N-24K0-

N07R2-

A-007-

NNNN

80,00

7,20

31,00

>100

300

Last modification: 2007-06-29

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 161/431

HLR01 - Braking Resistors

Description Symbol Unit

HLR01.1

N-04K5-

N07R4-

A-007-

NNNN

3,00

HLR01.1

N-0780-

N07R0-

A-007-

NNNN

4,00

HLR01.1

N-08K5-

N08R0-

A-007-

NNNN

HLR01.1

N-11K0-

N07R3-

A-007-

NNNN

3,00

HLR01.1

N-15K0-

N08R1-

A-007-

NNNN

HLR01.1

N-24K0-

N07R2-

A-007-

NNNN

6,00 Allowed range tightening torque

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 4)

M

A

LN

Nm

AWG 8 6 3 2

1) 2) 3)

4)

Tab. 12-8:

Last modification: 2007-06-29

See fig. "Air Intake and Air Outlet at Device"

Copper wire; PVC-insulation (conductor temperature 90 °C); table 28.1; T a

≤ 40 °C

HLR - Technical Data - Currents, Voltages, Power

NOTICE Property damage due to temperatures higher than 105 ℃!

Observe the indicated minimum distances!

Above the devices there may only be such materials which

● are not combustible

● are insensitive to the occurring high temperatures

HLR01 for HCS03.1E-W0210

Technical Data - Currents, Voltages, Power

Description Symbol Unit

HLR01.1

N-06K5-

N06R1-

A-007-

NNNN

HLR01.1

N-12K5-

N05R5-

A-007-

NNNN

HLR01.1

N-17K0-

N05R1-

A-007-

NNNN

Degree of protection in accord‐ ance with IEC 60529

Ambient temperature range for operation with nominal data

Mass

Nominal braking resistance

T

IP a_work m

R

DC_Bleed‐ er

P

BD

P

BS

Braking resistor continuous power

Braking resistor peak power

Regenerative power to be absor‐ bed

Maximum allowed on-time duty

Minimum allowed cycle time

Cooling type

W t

R_max on_max

T cycl

°C kg ohm kWs s s kW kW

13,00

6,10

6,50

98,00

356,00

3,60

33,00

5,50

12,50

109,00

900,00 1632,00 130,00 2429,00 3888,00

8,30 n

43,00

5,10

17,00

117,00

HLR01.1

N-1K08-

N05R0-

A-007-

NNNN

IP20

0...40

8,00

5,00

1,08

130,00

HLR01.1

N-23K0-

N05R5-

A-007-

NNNN

56,00

5,50

23,00

109,00

HLR01.1

N-36K0-

N05R4-

A-007-

NNNN

93,00

5,40

36,00

111,00

14,00 1,00 22,00 35,00

120,00 f n

Last modification: 2007-06-29

162/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLR01 - Braking Resistors

Description

Volumetric capacity of forced cool‐ ing

Temperature rise with minimum distances d bot

; d top

; P

BD

Minimum distance on the top of the device 1)

Minimum distance on the bottom of the device 2)

Horizontal spacing on the device 3)

Allowed range tightening torque

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 4)

Symbol

V

ΔT d top d bot d hor

M

A

LN

Unit m 3 /h

K mm mm mm

Nm

AWG

HLR01.1

N-06K5-

N06R1-

A-007-

NNNN

HLR01.1

N-12K5-

N05R5-

A-007-

NNNN

HLR01.1

N-17K0-

N05R1-

A-007-

NNNN

HLR01.1

N-1K08-

N05R0-

A-007-

NNNN

HLR01.1

N-23K0-

N05R5-

A-007-

NNNN

HLR01.1

N-36K0-

N05R4-

A-007-

NNNN

200,00 -

6

>100

1000

300

300

2

22

80

6,00

80

0

6

>200

1000

300

300

1/0

1) 2) 3)

4)

Tab. 12-9:

Last modification: 2007-06-29

See fig. "Air Intake and Air Outlet at Device"

Copper wire; PVC-insulation (conductor temperature 90 °C); table 28.1; T a

≤ 40 °C

HLR - Technical Data - Currents, Voltages, Power

NOTICE Property damage due to temperatures higher than 105 ℃!

Observe the indicated minimum distances!

Above the devices there may only be such materials which

● are not combustible

● are insensitive to the occurring high temperatures

12.4.3 Technical Data HLR01 for HCS04.2

Braking resistors for HCS04.2:

● HLR01.1N-22K0-N03R5-B-007-NNNN

● HLR01.1N-44K0-N03R3-B-007-NNNN

● HLR01.1N-66K0-N02R1-B-007-NNNN

Assignment and technical data:

See Project Planning Manual "Rexroth IndraDrive Drive Controllers

HCS04.2E" (material number: R911327334).

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 163/431

HLR01 - Braking Resistors

12.5 Installation and Mounting

12.5.1 Notes on Installation and Mounting

WARNING Lethal electric shock by live parts with more than 50 V!

Connect the braking resistor to the equipment grounding system of the con‐ trol cabinet.

● Braking resistors of type of construction A: For the equipment grounding connection, mount the joint bar on the front between braking resistor and drive controller.

● Braking resistors of type of construction N: Connect the equipment grounding conductor in stationary form to the equipment grounding sys‐ tem of the control cabinet.

Check the continuity of the equipment grounding conductors from the mains connection to the housings of the braking resistors.

Equipment grounding conductor: Material and cross section

For the equipment grounding conductor, use the same metal (e.g.

copper) as for the outer conductors.

For the connections from the equipment grounding conductor connection of the device to the equipment grounding conductor system in the control cabinet, make sure the cross sections of the lines are sufficient.

Cross sections of the equipment grounding connections:

● For HCS03.1E drive controllers, HMV01 and HMV02 supply units at least 10 mm 2 (AWG 8), but not smaller than the cross sections of the outer conductors of the mains supply feeder

● For HCS02.1E drive controllers, at least 4 mm but not smaller than the cross sections of the outer conduc‐ tors of the mains supply feeder

2 (AWG 10),

Additionally, mount the housing of HCS02.1E to a bare met‐ al mounting plate. Connect the mounting plate, too, with at least the same cross section to the equipment grounding conductor system in the control cabinet.

For outer conductors with a cross section greater than 16 mm², you can reduce the cross section of the equipment grounding connection according to the table "Equipment Grounding Conduc‐ tor Cross Section".

Cross-sectional area A of outer conduc‐ tors

A ≤ 16 mm²

16 mm² < A ≤ 35 mm²

35 mm² < A

Tab. 12-10:

Minimum cross-sectional area A

PE equipment grounding connection

of

A

16

A / 2

Equipment grounding conductor cross section

164/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HLR01 - Braking Resistors

CAUTION Hot surface!

The surface and housing parts of the braking resistor can have a temperature of more than 250 °C in operation.

Do not stress and do not touch surfaces and housing parts of braking resis‐ tors.

Before touching the surfaces and housing parts of braking resistors, wait for an adequate time after switching off power to allow the braking resistors to cool down.

NOTICE High temperatures in the proximity of braking resistors!

Mount the braking resistors to temperature-resistant mounting surfaces in such a way that the air can freely enter and escape and heat does not accu‐ mulate.

Take the minimum distances d top

, d bot

and d hor

into account.

Take into account that the temperatures in the range of the indicated mini‐ mum distances can be above 250 °C.

Leave sufficient distance to combustible objects and take into account that braking resistors dissipate a lot of heat.

Make sure there is free cooling air supply at the bottom d bot discharge at the top d top

.

and cooling air

The space must be able to discharge the energy converted by the braking re‐ sistor.

Observe degree of protection!

When mounted outdoor or at the outside of the control cabinet, observe the degree of protection IP20 of the braking resistor.

Protect the devices against intrusion of water.

12.5.2 Braking Resistors HLR01.1, Type of Construction A (Version for De‐ vice Mounting)

General Information

Only HLR01 braking resistors of the type of construction A are suited for

mounting to HCS03 drive controllers (see index entry " HLR01 → For

HCS03

").

The braking resistors provided for mounting above the HCS03 drive controllers are cooled by the cooling air of the drive control‐ ler flowing off.

For other mounting situations, the HLR braking resistors must be separately cooled:

Cooling air current of at least 200 m³/h through the braking resis‐ tor

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HCS03.1E-W0070-xNBV with HLR01.1N-0300-N17R-A-007-NNNN

Dimensions for Mounting

Bosch Rexroth AG 165/431

HLR01 - Braking Resistors d top

, d bot

, d hor

Dimensions in mm

Distances at top and bottom and on the sides; values: see technical data

Fig. 12-4:

166/431 Bosch Rexroth AG

HLR01 - Braking Resistors

Dimensional Drawing

HLR01.1N-0300-N17R5-A-007-

NNNN

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Rexroth IndraDrive Additional Components and Accessories

Fig. 12-5:

Dimensions in mm

Dimensions Braking Resistor HLR01.1N-0300-N17R5-A-007-NNNN

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 167/431

HCS03.1E-W0100-xNBV with HLR01.1N‑0470‑N11R7‑A‑007‑NNNN

Dimensions for Mounting

HLR01 - Braking Resistors d top

, d bot

, d hor

Fig. 12-6:

Dimensions in mm

Distances at top and bottom and on the sides; values: see technical data

Mounting Example Device / Braking Resistor

HLR01.1N‑0780‑N07R7‑A‑007‑NNNN

168/431 Bosch Rexroth AG

HLR01 - Braking Resistors

Dimensional Drawing

HLR01.1N-0470-N11R7-A-007-

NNNN

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Rexroth IndraDrive Additional Components and Accessories

Fig. 12-7:

Dimensions in mm

Dimensions Braking Resistor HLR01.1N‑0470‑N11R7‑A‑007‑NNNN

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 169/431

HCS03.1E-W0150-xNBV with HLR01.1N‑0780‑N07R7‑A‑007‑NNNN

Dimensions for Mounting

HLR01 - Braking Resistors d top

, d bot

, d hor

Fig. 12-8:

Dimensions in mm

Distances at top and bottom and on the sides; values: see technical data

Mounting Example Device / Braking Resistor

HLR01.1N‑0780‑N07R7‑A‑007‑NNNN

170/431 Bosch Rexroth AG

HLR01 - Braking Resistors

Dimensional Drawing

HLR01.1N-0780-N07R0-A-007-

NNNN

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Rexroth IndraDrive Additional Components and Accessories

Fig. 12-9:

Dimensions in mm

Dimensions Braking Resistor HLR01.1N‑0780‑N07R0‑A‑007‑NNNN

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 171/431

HCS03.1E-W0210-xNBV with HLR01.1N‑1K08‑N05R0‑A‑007‑NNNN

Dimensions for Mounting

HLR01 - Braking Resistors d top

, d bot

, d hor

Fig. 12-10:

Dimensions in mm

Distances at top and bottom and on the sides; values: see technical data

Mounting Example Device / Braking Resistor

HLR01.1N‑1K08‑N05R0‑A‑007‑NNNN

172/431 Bosch Rexroth AG

HLR01 - Braking Resistors

Dimensional Drawing

HLR01.1N-1K08-N05R0-A-007-

NNNN

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Rexroth IndraDrive Additional Components and Accessories

Fig. 12-11:

Dimensions in mm

Dimensions Braking Resistor HLR01.1N-1K08-N05R0-A-007-NNNN

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 173/431

HLR01 - Braking Resistors

12.5.3 Braking Resistors HLR01.1, Type of Construction N (Version for Free

Assembly)

Fixed Resistor IP 20 Type A

Type

A8

A9

A10

A5

A6

A7

H

586

686

549

649

649

749

B

185

185

275

275

185

185 d top

, d bot

, d hor

1)

2)

Fig. 12-12:

Distances at top and bottom and on the sides; values: see technical data

Allowed mounting position (terminals at the bottom; on horizon‐ tal surfaces)

Inadmissible mounting position (terminals at the top, to the right and to the left)

Type A5 – A6

Dimensions [mm]

T

120

120

120

120

120

120

H1

526

626

430

530

530

630

Tab. 12-11:

B1

150

150

240

240

150

150

M6

M6

M6

D

M6

M6

M6

Dimension Table Braking Resistor Type A

Weight [kg]

7,9

5,8

6,7

5,2

6,2

6,6

174/431 Bosch Rexroth AG

HLR01 - Braking Resistors

Steel-Grid Fixed Resistor IP 20 Type B

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Rexroth IndraDrive Additional Components and Accessories

Type

B1

B2

B3

B4

B5

B

490

490

490

490

490

T

300

400

600

800

1000 d top

, d bot

, d hor

1)

2)

Fig. 12-13:

Distances at top and bottom and on the sides; values: see technical data

Allowed mounting position (terminals at the bottom; perforated sheet at the top and at the bottom; on horizontal surfaces)

Inadmissible mounting position (terminals at the top, to the right and to the left)

Type B1 – B4

Dimensions [mm]

H B1

270

270

270

270

270

380

380

380

380

380

Tab. 12-12:

T1

270

370

570

770

970

Dimension Table Braking Resistor Type B

D

M10

M10

M10

M10

M10

Weight [kg]

9,5

13

22

33

44

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Rexroth IndraDrive Additional Components and Accessories

Steel-Grid Fixed Resistor IP 20 Type C

Bosch Rexroth AG 175/431

HLR01 - Braking Resistors

Type

C2

C3

C4

B

595

795

995

T

490

490

490 d top

, d bot

, d hor

1)

Fig. 12-14:

Distances at top and bottom and on the sides; values: see technical data

Allowed mounting position (vertically on horizontal surfaces)

Type C1 – C7

Dimensions [mm]

H B1

710 570

710

710

770

970

Tab. 12-13:

T1

380

380

380

D

M10

M10

M10

Dimension Table Braking Resistor Type C

Weight [kg]

56

80

93

176/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 177/431

HLT01 - Braking Unit

13 HLT01 - Braking Unit

13.1 Use

Function An HLT controls an external HLR braking resistor, when no internal braking unit is available in the drive controller.

Drive controller with external braking unit HLT:

Fig. 13-1: External Braking Unit HLT

When the DC bus voltage, due to a deceleration process, exceeds a value to be set, the external braking resistor (as a load) is connected to the DC bus.

The HLR braking resistor converts the generated energy into thermal energy and thereby keeps the DC bus voltage from rising.

178/431 Bosch Rexroth AG

HLT01 - Braking Unit

13.2 Identification

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Rexroth IndraDrive Additional Components and Accessories

Fig. 13-2: Type Code

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 179/431

HLT01 - Braking Unit

13.3 Braking Unit HLT01.1A

13.3.1 Technical Data

Vibrations

Shock

Operating temperature

Storage/transport temperature

Degree of protection

Environment class / humidity

Installation altitude

Allowed pollution

Protection class

Basic standard

EMC immunity

EMC emission

Insulation

In accordance with IEC/EN 60068-2-6

1.5 mm in the range of 3 … 10 Hz, 0.6 g from 10 … 200 Hz

(3M3 in accordance with IEC/EN 60721-3-3)

In accordance with IEC/EN 60068-2-27

4 g for 11 ms (3M2 in accordance with IEC/EN 60721-3-3)

-10 … +40℃

(3K3 in accordance with IEC/EN 60721-3-3)

Up to +55℃ with derating

-25 … +70℃

Lateral, front IP31

Top IP20

Bottom IP00

Class 3K3 in accordance with IEC/EN 60721-3-3 / no moisture condensation, max. 95% relative humidity

Up to 1,000 m; above that, derating by 1% per 100 m up to 3,000 m

Pollution degree 2 in accordance with EN 61800-5-1

3C2 and 3S2 in accordance with EN 60721-3-3

Class 1 in accordance with EN 50178

The devices were developed, built and tested on the basis of EN 50178.

In accordance with EN 61800-3, 1st and 2nd environment

(IEC 1000-4-2; IEC 1000-4-3; IEC 1000-4-4; IEC 1000-4-5; IEC 1000-4-6)

In accordance with product standard EN 61800-3

1st and 2nd environment, category C2, C3

Galvanic isolation in accordance with EN 50178 PELV

(Protective Extra Low Voltage)

Assignment HCS04.2

Peak braking power

Max. continuous braking power

Possible braking power depending on the duty cycle

Cycle time

HLT01.1A-200K-N-007-NNNN

HCS04.2E-W0640

HCS04.2E-W0790

420 kW

200 kW

420 kW for 5%

320 kW for 15%

250 kW for 50%

240 s

HLT01.1A-400K-N-007-NNNN

HCS04.2E-W1010

HCS04.2E-W1240

HCS04.2E-W1540

750 kW

400 kW

750 kW for 5%

550 kW for 15%

440 kW for 50%

240 s

180/431 Bosch Rexroth AG

HLT01 - Braking Unit

Typ. braking power for crane operation

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Rexroth IndraDrive Additional Components and Accessories

HLT01.1A-200K-N-007-NNNN HLT01.1A-400K-N-007-NNNN

Min. braking resistance

Power dissipation at 100% I

N

Cooling air volume

Mass

Mounting

1.05 Ω

550 W

0.7 Ω

1,050 W

100 m 3 /h

30 kg

Attached to the left side wall of the con‐ verter. This increases the device width to 655 mm.

600 m 3 /h

70 kg

Mounted on the left next to the convert‐ er; the connection lines for a distance of 110 mm to the converter housing are included. A distance of up to 1 m is al‐ lowed with adjusted connection lines.

13.3.2 Braking Unit HLT01.1A -200K

Dimensions

Fig. 13-3: Dimensions Braking Unit HLT01.1A -200K

Power connections

Description

HLT01.1A+, HLT01.1A-

PA, PB

Connection

M10

M10

Tightening torque

24 Nm

24 Nm

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Rexroth IndraDrive Additional Components and Accessories

Technical Data

Braking unit

Power dissipation at 100% I

N

Cooling air volume

Peak braking power

Max. continuous braking power

Possible braking power depend‐ ing on the duty cycle

Cycle time

Typ. braking power for crane op‐ eration

Bosch Rexroth AG 181/431

HLT01 - Braking Unit

HLT01.1A-200K-N-007-NNNN

550 W

100 m 3 /h

420 kW

200 kW

420 kW for 5 %

320 kW for 15 %

250 kW for 50%

240 s

Installing HLT01.1A -200

Min. braking resistance

Mass

1.05 Ω

30 kg

Mount the braking unit at the left hand side of the converter. To do this, pro‐ ceed as follows:

1.

Mount the converter.

2.

Remove the cover of the converter; when doing this, take the safety rec‐ ommendations described in this manual into account.

3.

Remove the detachable part A at the left of the converter.

182/431 Bosch Rexroth AG

HLT01 - Braking Unit

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Rexroth IndraDrive Additional Components and Accessories

4.

Mount the braking unit at the left hand side of the converter. There are 5 mounting points (5xM8).

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 183/431

HLT01 - Braking Unit

5.

Connect the bus bar B between the terminals BU- and BU+ of the con‐ verter and the terminals BU- and BU+ of the braking unit.

6.

Connect the braking resistor to PA and PB.

184/431 Bosch Rexroth AG

HLT01 - Braking Unit

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Rexroth IndraDrive Additional Components and Accessories

The bus bar used to connect the braking unit to "IndraDrive

HCS04.2E" (BU+, BU-) is part of the scope of supply.

7.

Connect the control cables:

● Connect the control cable X20 of the braking unit to the cable X20 of the converter.

● Connect the control cable X92 of the braking unit to the plug-in connector X20 of the converter.

● Disconnect the cable X3 of the converter from the plug-in connec‐ tor X3 on the converter circuit board.

● Connect the cable X3 of the converter to the cable X3B of the brak‐ ing unit.

● Connect the cable X3A of the braking unit to the plug-in connector

X3 on the converter circuit board.

8.

Mount the housing of "HLL01.1A" (C) to the wall of the control cabinet.

9.

Remove the detachable part (D) of the DC bus choke housing.

10.

Mount the cover (E) of the braking unit to the DC bus choke housing.

11.

Mount the DC choke(s) of the converter.

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Bosch Rexroth AG 185/431

HLT01 - Braking Unit

186/431 Bosch Rexroth AG

HLT01 - Braking Unit

13.3.3 Braking Unit HLT01.1A -400K

Dimensions

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Rexroth IndraDrive Additional Components and Accessories

Fig. 13-4: Dimensions Braking Unit HLT01.1A -400K

Power connections

Description

BU+, BU-

PA, PB

PE

Connection

M12

M12

M12

Tightening torque

41 Nm

41 Nm

41 Nm

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 187/431

HLT01 - Braking Unit

The bus bars used to connect the braking unit to "IndraDrive

HCS04.2E" (BU+, BU-) are part of the scope of supply. They are provided for a mounting distance of 110 mm. The maximum dis‐ tance is 1 m. The distance between the bars must not be greater than 10 mm!

Technical Data

Braking unit

Power dissipation at 100% I

N

Cooling air volume

Peak braking power

Max. continuous braking power

Possible braking power depend‐ ing on the duty cycle

HLT01.1A -400

1,050 W

600 m 3 /h

750 kW

400 kW

750 kW for 5 %

550 kW for 15 %

440 kW for 50%

240 s Cycle time

Typ. braking power for crane op‐ eration

Installing HLT01.1A -400

Min. braking resistance

Mass

0.7 Ω

70 kg

Mount the braking unit at the left hand side of the converter with a distance of

110 mm (+/- 5 mm). This distance must be complied with due to the bus bars supplied with the braking unit. If you use your own bus bars (63 x 5 x 1 mm), you can extend the distance up to one meter.

The distance between the bus bars of the power section BU+ and

BU- must not exceed 10 mm!

1.

Mechanically install the converter and the braking unit.

2.

Remove the cover of the converter; when doing this, comply with the safety recommendations.

3.

Remove the detachable part A inside the converter.

4.

By means of the bus bars B, connect the terminals BU- and BU+ of the converter to the terminals BU- and BU+ of the braking unit.

188/431 Bosch Rexroth AG

HLT01 - Braking Unit

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Rexroth IndraDrive Additional Components and Accessories

5.

Connect the control cable and supply cable of the fan:

● Connect the control cable X1 coming from the braking unit to the plug-in connector X1 of the converter.

● Connect the supply cable of the fan coming from the braking unit to the plug-in connector X2 of the converter.

Distances to other devices or to the wall

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Bosch Rexroth AG 189/431

HLT01 - Braking Unit

190/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

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Rexroth IndraDrive Additional Components and Accessories

14 HMF01 - motor filter

14.1 Type code

Bosch Rexroth AG 191/431

HMF01 - motor filter

Fig. 14-1: Motor filter HMF01.1 type code

192/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HMF01 - motor filter

14.2 Type plate

Each motor filter is identified by a type designation. There is a type plate at‐ tached to all components.

3

4

1

2

Fig. 14-2:

Type designation

Material number

Serial number

Production date

Type plate

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 193/431

HMF01 - motor filter

14.3 Electrical data

Motor frequency The maximum motor frequency of the motor filters is specified in the type designation.

Example: For an HMF01.1A-N0K2 motor filter, the maximum motor frequency is 200 Hz.

Technical data - currents, voltages, power

Description Symbol Unit

HMF01.1

A-N0K2-

D0045-

A-500-

NNNN

HMF01.1

A-N0K2-

D0073-

A-500-

NNNN

HMF01.1

A-N0K2-

D0095-

A-500-

NNNN

HMF01.1

A-N0K2-

D0145-

A-500-

NNNN

HMF01.1

N-N0K2-

M0012-

A-500-

NNNN

HMF01.1

N-N0K2-

M0028-

A-500-

NNNN

Degree of protection according to

IEC 60529

Listing in accordance with UL standard

Listing in accordance with CSA standard

Mass

Specific inductance

Allowed switching frequencies 1) f

Continuous output current when s

= 4 kHz f

Maximum output current when s

= 4 kHz

Rise of voltage at output with

U

LN_nenn

and 15 m motor cable length phase-ground (10-90%) 2)

Rise of voltage at output with

U

LN_nenn

and 15 m motor cable length phase-phase (10-90%) 3)

Power dissipation at continuous current and continuous DC bus power respectively 4)

IP m

L f s

I out_cont4

I out_max4 dv/dt dv/dt

P

Diss_cont kg

µH kHz

A

A kV/µs kV/µs

W

15.00

3 x 160 3 x 100 3 x 78

20.00

3 x 50

5.10

11.20

3 x 900 3 x 450

4, 8, 12, 16

45.0000

73.0000

95.0000 145.0000 12.0000

28.0000

70.0000 100.0000 150.0000 210.0000 28.0000

70.0000

120.00

UL 508C

C22.2 No. 14-10

160.00

4

190.00

IP10

1.00

1.00

220.00

C22.2 No. 14

25.00

UL 508

50.00

Last modification: 2014-02-24

194/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HMF01 - motor filter

Description

Insulation resistance at 500 V DC

Required wire size in accordance with NFPA 79 and UL 508 A (in‐ ternal wiring); 5)

Symbol

R is

Unit

MOhm

HMF01.1

A-N0K2-

D0045-

A-500-

NNNN

HMF01.1

A-N0K2-

D0073-

A-500-

NNNN

1.00

HMF01.1

A-N0K2-

D0095-

A-500-

NNNN

HMF01.1

A-N0K2-

D0145-

A-500-

NNNN

HMF01.1

N-N0K2-

M0012-

A-500-

NNNN

600.00

HMF01.1

N-N0K2-

M0028-

A-500-

NNNN

A

LN

AWG 6 2 0 4/0 14 10

1)

2) 3)

4)

5)

Tab. 14-1:

Last modification: 2014-02-24

Also depending on firmware and control section; see parame‐ ter description "P-0-0001, Switching frequency of power output stage"; see "P-0-4058, Amplifier type data"

Guide value, see following note

Plus dissipation of braking resistor and control section

Copper wire; PVC-insulation (conductor temperature 90 °C;

T a

≤ 40 °C) in accordance with NFPA 79 chapter 12 and

UL 508A chapter 28

HMF - technical data - currents, voltages, power

Guide value "Rise of voltage at output"

Observe that the voltage load at the motor is almost independent of the power section used.

Especially when using standard motors, make sure that they com‐ ply with the occurring voltage load.

Observe the information on third-party motors at drive controllers

(see documentation "Rexroth IndraDrive Drive Systems With

HMV01/02 HMS01/02, HMD01, HCS02/03", index entry "Thirdparty motors → On drive controllers").

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Rexroth IndraDrive Additional Components and Accessories

14.4 Mechanical data

14.4.1 Dimensions, mass

Bosch Rexroth AG 195/431

HMF01 - motor filter

Fig. 14-3: Motor filter HMF01.1A-N0K2-M0012-A-500-NNNN dimensions

Type

0012

0028

A

155

210

Fig. 14-4:

B

91.5

130

Dimensions [mm]

C D

162

182

130

175

Tab. 14-2:

Motor filter HMF01.1A-N0K2-M0028-A-500-NNNN dimensions

E

71.5

95

Weight [kg] Tightening torque electrical connections

[Nm]

5.1

11.2

Motor filter dimensions

0.6-0.8

12

196/431 Bosch Rexroth AG

HMF01 - motor filter

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Rexroth IndraDrive Additional Components and Accessories

Fig. 14-5:

Dimensions in mm

Motor filter HMF01.1A-N0K2-D0045-A-500-NNNN dimensions

Fig. 14-6: Motor filters HMF01.1A‑N0K2‑D0073‑A‑500‑NNNN,

HMF01.1A‑N0K2‑D0145‑A‑500‑NNNN dimensions

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Rexroth IndraDrive Additional Components and Accessories

Type

0045

0073

0095

0145

Bosch Rexroth AG 197/431

HMF01 - motor filter

B H

Dimensions [mm]

T B H1 see above fig. " Motor filter HMF01.1A-N0K2-D0045-

A-500-NNNN dimensions"

225

225

350

315

315

400

270

270

260

175

175

250

257

257

310

Tab. 14-3:

Weight [kg] Tightening torque electrical connections

[Nm]

15

15

20

20

Motor filter dimensions

1.5

6

6

25

198/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HMF01 - motor filter

14.5 Arranging the components HCS03.1 with HMF motor filter

The HMF01 motor filters are cooled by the cooling air of the drive controller flowing in.

Arrange HMF01 at HCS03 drive controller as pictured.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 199/431

HMF01 - motor filter

Fig. 14-7: Mounting example HCS03.1E-W0070 / HMF01.1A-D0K2-D0045

200/431 Bosch Rexroth AG

HMF01 - motor filter

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Rexroth IndraDrive Additional Components and Accessories

Fig. 14-8: Mounting example HCS03.1E-W0100, -0150, -0210 / HMF01 motor filter

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Rexroth IndraDrive Additional Components and Accessories

HCS03.1E-

W0100

W0150

W0210

Tab. 14-4:

H

720

720

780

B

225

225

350

Bosch Rexroth AG 201/431

HMF01 - motor filter

B1

175

175

250

202/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HMF01 - motor filter

14.6 Arranging the components HCS03.1 with motor filter and mains filter

The HMF01 motor filters and HNK01 mains filters are cooled by the cooling air of the drive controller flowing in.

Arrange HMF01 and HNK01 at HCS03 drive controller as pic‐ tured.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 203/431

HMF01 - motor filter

Fig. 14-9: Arranging HCS03.1E-W0070 / HMF motor filter and HNK01 mains filter + HAS05.1‑001 + HAS05.1-002

For information on the HAS05.1 accessories, see index entry

"

HAS05.1- → 001 " and "

HAS05.1- → 002 "

204/431 Bosch Rexroth AG

HMF01 - motor filter

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Rexroth IndraDrive Additional Components and Accessories

Fig. 14-10: Arranging device 0100, 0150, 0210 / motor filter and mains filter

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Rexroth IndraDrive Additional Components and Accessories

HCS03.1E-

W0100

W0150

W0210

Tab. 14-5:

H

980

980

1090

B1

175

175

250

Bosch Rexroth AG 205/431

HMF01 - motor filter

B

225

225

350

206/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 207/431

HAC01 - Housing for Control Sections

15 HAC01 - Housing for Control Sections

15.1 Identification

15.1.1 Type Code

15.1.2 Type Plate

Fig. 15-1: Type Code HAC01.1

1

2

5

6

3

4

7

8

Fig. 15-2:

Material number

Production week (example: 06W31 meaning year 2006, week

31)

Factory identifier

Type

Bar code

Serial number

Hardware index

Country of manufacture

Type Plate

208/431 Bosch Rexroth AG

HAC01 - Housing for Control Sections

15.2 Use

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Rexroth IndraDrive Additional Components and Accessories

The additional component HAC01 is a housing in which control sections are inserted and loops through the control voltage supply from connection "0V, 24V" to the control sections.

The additional component HAC01 can be optionally sup‐ plied. There is no control section contained in the scope of supply of HAC01.

Make sure that the parameter ""P-0-0860, Converter con‐ figuration" has been set to operation as "SERCOS analog converter" (bit 15 = 1). Wrong setting will generate the error message "F8091 Power section defective".

HAC01

Tab. 15-1: Use

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Rexroth IndraDrive Additional Components and Accessories

15.3 Mechanical and Electrical Data

15.3.1 Dimensional Drawings HAC01.1

HAC01.1-001-NNN-NN

Bosch Rexroth AG 209/431

HAC01 - Housing for Control Sections

E

Fig. 15-3:

All dimensions in mm

Minimum mounting clearance

Dimensions HAC01.1-001-NNN-NN

210/431 Bosch Rexroth AG

HAC01 - Housing for Control Sections

HAC01.1-002-NNN-NN

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Rexroth IndraDrive Additional Components and Accessories

E

Fig. 15-4:

15.3.2 Connections at HAC01

X13, Control Voltage

Assignment

All dimensions in mm

Minimum mounting clearance

Dimensions HAC01.1-002-NNN-NN

Connec‐ tion

4

3

2

1

Signal name

+24V

+24V

0V

0V

Function

Power supply and "looping through"

Reference potential for pow‐ er supply and "looping through"

Spring terminal (connector)

Connection cross section solid wire

Connection cross section stranded wire

Unit mm 2 mm 2

Min.

1,0

1,0

Max.

1,5

1,5

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 211/431

HAC01 - Housing for Control Sections

Connection cross section

Power consumption

Voltage load capacity

Current carrying capacity "looping through" from

+24V to +24V, 0V to 0V

Continuous current P

N3

/U

N3

Current carrying capacity "looping through" from

+24V to +24V, 0V to 0V

Inrush current I

EIN3

Polarity reversal protection

Power Consumption at X13

AWG

W

V

A

A

18 16

P

N3

(see technical data of the device)

U

N3

(see technical data of the device)

6

12

Within the allowed voltage range by internal protective diode

Tab. 15-2: Function, Pin Assignment, Properties

The power consumption at X13 is determined by the control section and op‐ tional modules used.

Specification of Control Voltage

Overvoltage

Overvoltage greater than 33 V has to be discharged by means of the appropriate electrical equipment of the machine or installation.

This includes:

● 24V power supply units that reduce incoming overvoltage to 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.

See chapter

5.5 Control voltage (24V supply) , page 47

212/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 213/431

HAT01 - control module for holding brake

16 HAT01 - control module for holding brake

16.1 Brief description, use and design

Brief description

Use

The HAT01 control module belongs to the Rexroth IndraDrive product range and is used for the "Safe braking and holding system".

HAT01 control modules are mounted on a top-hat rail in the control cabinet.

The types are used as follows:

Type Use

HAT01.1-002-NNN-NN To control an electrically releasing, redundant holding brake.

Tab. 16-1: Use

Operating the HAT01 control module requires components with the firmware MPx-04 … 08, such as Cxx01 control sections.

16.2 Type code and identification

16.2.1 Type code

The figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of availa‐ ble versions.

Fig. 16-1: Type code

214/431 Bosch Rexroth AG

HAT01 - control module for holding brake

16.2.2 Identification

Type plate arrangement

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Rexroth IndraDrive Additional Components and Accessories

Type plate

1

Fig. 16-2:

Type plate

Type plate arrangement

3

4

1

2

5

6

7

Fig. 16-3:

Device type

Material number

Serial number

Bar code

Country of manufacture

Production week, 07W24 meaning year 2007, week 24

Hardware index

Type plate

16.3 Scope of supply

The scope of supply of the HAT01 control module contains:

● Connectors X1, X2, X3

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Rexroth IndraDrive Additional Components and Accessories

16.4 Dimensions

Bosch Rexroth AG 215/431

HAT01 - control module for holding brake

A d top

, d bot

Fig. 16-4:

16.5 Technical data

Technical data

All dimensions in mm

Minimum mounting clearance

See table "Technical data"

Dimensions

Description

Weight

Degree of protection

Allowed mounting position

Minimum distance from the top of the device 5)

Minimum distance from the bottom of the de‐ vice 6)

Minimum distance on the side of the device

Allowed ambient temperature range

Symbol m d top d bot d hor

T a_work

Unit kg mm mm mm

°C

HAT01.1-002-NNN-NN

0.6

IP20

Vertical

50

50

-

0 … 55

216/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HAT01 - control module for holding brake

Description

Cooling type 3)

Listing in accordance with UL standard (UL)

UL files (UL)

Control voltage supply

Rated control voltage input (UL) 1)

Symbol

U

N3

Unit

V

HAT01.1-002-NNN-NN n

UL 508C

E134201

Brake cable length < 50 m: 24 ±5%

Brake cable length > 50 m: 26 ±5%

33 Maximum allowed voltage for 1 ms 2)

Rated power consumption control voltage input at U

N3

(UL)

Inrush current at 24V supply

Pulse width of I

EIN3

Input capacitance

Power dissipation

Output current

1)

2)

3)

5) 6) 7)

Tab. 16-2:

U

N3_max

P

N3

V

W 1.5

I

EIN3 t

EIN3Lade

C

N3

A ms mF

35

4

3.6

P

Diss

W max. 7.5

(brake controlled)

See "X2, output to brake" I

Br

A

Observe supply voltage for holding brake

See following note regarding overvoltage n: natural convection; f: forced cooling

See fig. "Air intake and air outlet at device"

HAT01 - technical data

Overvoltages of more than 33 V have to be discharged using the appropriate electrical equipment of the machine or installation.

This includes:

● 24V power supply units that reduce incoming overvoltages to the allowed value.

● Overvoltage limiters at the control cabinet input that limit ex‐ isting overvoltages to the allowed values. This, too, applies to long 24V lines that are run in parallel to power cables and mains cables and that can absorb overvoltages by inductive or capacitive coupling.

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Distances

Bosch Rexroth AG 217/431

HAT01 - control module for holding brake

C d

A

B d top d bot hor

Fig. 16-5:

16.6 Connection points

16.6.1 Front view

Front view

Air intake

Air outlet

Mounting surface in control cabinet

Distance top

Distance bottom

Distance horizontal

Air intake and air outlet at device

Connection point

X1

X2

X3

A

Description

24 V power supply (24V, 0V)

Output to brake

Signal exchange with control section; connection with ready-made cable RKS0007

Strain relief:

Fix connection cable with cable tie

Tab. 16-3: Connection points

218/431 Bosch Rexroth AG

HAT01 - control module for holding brake

16.6.2 X1, 24 V power supply

Pin assignment Connec‐ tion

X1.1

X1.2

X1.3

X1.4

X1.5

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Rexroth IndraDrive Additional Components and Accessories

Signal name

+24V

+24V

0V

0V

-

Function

Power supply and "looping through"

Reference potential for pow‐ er supply and "looping through"

Housing potential

Screw connection at connector

Tightening torque

Connection cable, stranded wire

Connection cables

Power consumption

Voltage load capacity

Current carrying capacity "looping through" from

+24V to +24V, 0V to 0V

Polarity reversal protection

Tab. 16-4:

16.6.3 X2, output to brake

Pin assignment Connec‐ tion

X2.1

Unit

Nm mm 2

AWG

W

V

A

min.

0.5

1.0

max.

0.6

2.5

18 14

See P

N3

See U

N3

6

(max. 1 other HAT01 for op‐ eration with HMD01)

Within the allowed voltage range by internal protective diode

Function, pin assignment, properties

X2.2

X2.3

Signal name

Br+

Br-

-

Function

Connection to positive pole of holding brake

Connection to negative pole of holding brake

HAT01 housing potential

(connection for cable shield)

Screw connection at connector

Tightening torque

Connection cable, stranded wire

Connection cables

Output current I

Br_cont

Output current I

Br_max

; t ≤ 1 s; I

AV

≤ I

Br_cont

Unit

Nm mm 2

AWG

A

A min.

0.5

1.0

18

0.25

max.

0.6

2.5

14

6

7.5

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 219/431

HAT01 - control module for holding brake

Output voltage U

Br

Output protection

V

-

U

N3

- 0.5 V U

N3

Short-circuit proof and overload-proof within the allowed voltage range

Tab. 16-5: Function, pin assignment, properties

16.6.4 X3, signal exchange with control section

Pin assignment Connec‐ tion

X3.1

X3.2

Signal name

+24V

+24V

Function

X3.3

X3.4

X3.5

X3.6

X3.7

HAT-Steuer

HAT-Diagnose

0V

0V

-

Power supply of isolated in‐ puts/outputs X3.3 and X3.4

with 24 V / 0.1 A

Input for brake control via U

Br

(X2)

HAT-Diagnose output

Reference potential for pow‐ er supply at X3.1

Connection for cable shield

Screw connection at connector

Tightening torque

Connection cable, stranded wire

Connection cables

Allowed cable length

Input X3.3 controls output Br+/Br- (X2)

(dynamized input)

Output voltage at X3.4 shows state of controlled brake

Ready-made connection cable

Unit

Nm mm 2

AWG m

V

min.

0.5

1.0

max.

0.6

2.5

18 14

3

250 Hz ±20%, duty cycle ~50% → "H" level at Br (X2) output

"H" level → "L" level at Br (X2) output

"L" level → error state: "L" level at Br (X2) output

Brake applied: 150 Hz ±20%

Brake released: "H", (max. X3.1 - 0.5 V)

Brake faulty: "L"

RKS0007

Function, pin assignment, properties Tab. 16-6:

220/431 Bosch Rexroth AG

HAT01 - control module for holding brake

Interconnection diagram RKS0007

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Rexroth IndraDrive Additional Components and Accessories

*

Fig. 16-6:

Connection between HAT01 (X3) and control section (X41

[HAT-Diagnose], X32 [HAT-Steuer])

Interconnection diagram RKS0007

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 221/431

HAT02 - control module for inductive loads

17 HAT02 - control module for inductive loads

17.1 Brief description, use and design

Brief description The HAT02 control module belongs to the Rexroth IndraDrive product range and complies with the following "Safety Integrity Level" (SIL) and "Perform‐ ance Level" (PL):

● SIL3 according to EN 61508, IEC EN 62061 and IEC 61800-5-2, with dual-channel selection

● Category 4, PL e according to EN ISO 13849-1, with dual-channel se‐ lection

HAT02 control modules are mounted on a top-hat rail in the control cabinet.

Use

Type Use

HAT02.1-002 Safely controlling an inductive load, such as a self-applying motor holding brake, hydraulic/pneumatic valve, contactor.

HAT02.1-003 Safely controlling an inductive load, such as a self-applying motor holding brake, hydraulic/pneumatic valve, contactor.

Additional functions:

●

●

Safety-related evaluation of up to two signaling contacts

Adjustable withstand voltage (power reduction)

● Adjustable overexcitation time

Tab. 17-1: Use

Commissioning

Replacing the component

Operating the HAT02 control module requries components with the firmware MPx-18 or higher, such as Cxx02 or HCS01 control sections.

The Cxx02 control sections must have been manufactured from production week 14W39 onward (see control section type plate).

The error F8353 occurs with older Cxx02 control sections (pro‐ duction week ≤ 14W38). The error already occurs when the de‐ vice is switched on. The safe state is always ensured.

When the HAT02 control module is commissioned, the overall function with the inductive load (e.g. motor holding brake) has to be checked prior to the first safety-relevant use. The drive has to be able to open and close the in‐ ductive load.

Observe the following aspects when replacing the component:

● The order numbers of the components have to be identical.

● Additionally for HAT02.1-003:

The positions of the rotary coding switches have to be identical.

● After the installation:

Make an acceptance test

222/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HAT02 - control module for inductive loads

17.2 Type code and identification

17.2.1 Type code

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: H A T 0 2 . 1 - 0 0 2 - N N N - N N

① ② ③ ④ ⑤ ⑥

①

②

③

④

⑤

⑥

Product:

HAT = Control module for inductive loads

Series:

02 = 02

Design:

1 = 1

Brake type:

002 = Safe switching of inductive loads

003 = Safe switching of inductive loads with state monitoring and overexcitation

Other properties:

NNN = None

Other design:

NN = None

Tab. 17-2: HAT02 type code

The figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of availa‐ ble versions.

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Rexroth IndraDrive Additional Components and Accessories

17.2.2 Identification

Plates

Bosch Rexroth AG 223/431

HAT02 - control module for inductive loads

Type plate

1

2

Fig. 17-1:

Type plate

Data plate

Plates at device

Data plate

3

4

1

2

5

6

7

Fig. 17-2:

Bar code

Type

Hardware index

Production week (example: 13W38 means: year 2013, week

38)

Material number

Factory identifier

Serial number

Type plate

Fig. 17-3: Data plate

224/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HAT02 - control module for inductive loads

17.3 Scope of supply

The scope of supply of the HAT02 control module contains:

HAT02.1-002

Connector: XG3, XG48

Tab. 17-3: Scope of supply HAT02

HAT02.1-003

Connector: XG3, XG48, XG49

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Rexroth IndraDrive Additional Components and Accessories

17.4 Dimensions

HAT02.1-002

Bosch Rexroth AG 225/431

HAT02 - control module for inductive loads

A

Fig. 17-4:

All dimensions in mm

Minimum mounting clearance

HAT02.1-002, dimensions

226/431 Bosch Rexroth AG

HAT02 - control module for inductive loads

HAT02.1-003

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Rexroth IndraDrive Additional Components and Accessories

A

Fig. 17-5:

All dimensions in mm

Minimum mounting clearance

HAT02.1-003, dimensions

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 227/431

HAT02 - control module for inductive loads

17.5 Technical data

Technical data

Description

Mass

Degree of protection

Allowed mounting position

Minimum distance from the top of the device 1)

Minimum distance from the bottom of the device 2)

Minimum distance on the side of the device

Allowed ambient temperature range

Cooling type

1) 2)

Tab. 17-4:

Distances

Symbol m d top d bot

-

d hor

T a_work

-

Unit g

-

mm mm mm

°C

HAT02

HAT02.1-002: 70

HAT02.1-003: 100

IP20

Vertical

40

40

-

0 … 55

Natural convection

See fig. "Air intake and air outlet at device"

HAT02 - technical data

C d

A

B d top d bot hor

Fig. 17-6:

Air intake

Air outlet

Mounting surface in control cabinet

Distance top

Distance bottom

Distance horizontal

Air intake and air outlet at device

228/431 Bosch Rexroth AG

HAT02 - control module for inductive loads

17.6 Connection points

17.6.1 Front view

HAT02.1-002-NNN-NN HAT02.1-003-NNN-NN

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Connection point Description

XG3

XG48

XG49

24 V power supply

Brake connection

Brake control input

Signal exchange with control sec‐ tion

Switching state signal input

Tab. 17-5: Connection points

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HAT02 - control module for inductive loads

17.6.2 XG3, 24 V power supply, brake connection

WARNING In the case of error, injury and property dam‐ age due to inadmissibly high voltage!

For selection and the 24 V supply of devices with integrated safety technolo‐

gy, use a 24 V power supply unit with protection by SELV 1) in accordance

with IEC 60950-1 or PELV

2) in accordance with IEC 60204-1.

View Connec‐ tion

1

2

3

4

Signal name

Brake+

Brake-

24V_Brake

0V_Brake

Function

Brake connection

Control module and brake power supply

Spring terminal

Connection cable, stranded wire

Connection cable

Stripped length

Description

Voltage input

Internal consumption

Output driver current consumption

Polarity reversal protection

Tab. 17-6: Pin assignment

Mechanical data

Unit mm 2

AWG mm min.

0.2

24

10

Tab. 17-7: Mechanical data

Electrical data (control module and brake power supply)

1)

Tab. 17-8: max.

1.5

16

Symbol

U

24V_Brake

I

24V_Brake

I max

Unit

V

A

A min.

19.2

1) max.

30

0.1

6

Present

Observe allowed voltage tolerance of connected load

Electrical data

The power supply is monitored. The monitored undervoltage threshold is lower than the specified minimum value, and the overvoltage threshold is higher than the specified maximum val‐ ue.

1)

2)

Safety Extra Low Voltage

Protective Extra Low Voltage

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HAT02 - control module for inductive loads

Description

Output voltage On (Brake+/Brake-)

Output current Off

Output current On

Switching frequency at output

Energy content inductive load (f ≤ 0.1 Hz)

Test pulse duration (switching off) 5)

Short circuit protection

Overload protection

1)

Electrical data (brake control Brake+/Brake-)

2)

3)

4)

5)

Tab. 17-9:

Symbol Unit min.

max.

U

On

I

Off

I

On f

E

Ind t

Testpuls

V mA

A

Hz

J

μs

24V_Brake - 1

0.1

4)

100

24V_Brake 1)

5

6

1

18 2) 3)

700

Present

Present

24V_Brake corresponds to the power supply of the user inter‐ face. The voltage is accordingly reduced in the case of opera‐ tion with voltage reduction.

An external connection with < 20 V free-wheeling voltage is re‐ quired for inductive loads with a greater energy content.

A higher switching frequency is possible in the case of a small‐ er energy content.

Reason: Switch-off capability monitoring

Free-wheeling voltage during the test: approx. 1 V

Electrical data

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HAT02 - control module for inductive loads

17.6.3 XG48, signal exchange with control section, brake control input

View

Spring terminal

Connection cable, stranded wire

Connection cable

Stripped length

Description

Voltage input

Internal consumption

Output driver current consumption

Polarity reversal protection

Connec‐ tion

1

2

3

4

5

Signal name

Ext_SI_bSBC_Ch1

0V_EA

Ext_SI_bSBC_Ch2

24V_EA

Ext_Diag_I_Brake min.

19.2

Function

Channel 1 brake control input

Reference potential of diag‐ nostic inputs and output

Channel 2 brake control input

Diagnostic output power sup‐ ply

Channel 1 and channel 2 di‐ agnostic output

Ground connection 6

Tab. 17-10: Pin assignment

Mechanical data

Tab. 17-12:

Symbol

U

24V_EA

I

24V_EA

I max

Unit

V mA mA

Electrical data

GND

Unit mm 2

AWG mm min.

0.2

24

10

Tab. 17-11: Mechanical data

Electrical data (power supply for control section signal exchange) max.

1.5

16

Present max.

30

5

200

The voltage at XG48.4/2 (24V_EA/0V_EA) and the voltage at the drive controller (e.g., X33.1/2) have to be provided by the same voltage source.

Wire the voltage source at the drive controller.

Description

Allowed input voltage

Input voltage high

Input voltage low

Current consumption

Reference potential

Electrical data (Ext_SI_bSBC_Ch1, Ext_SI_bSBC_Ch2 inputs)

Tab. 17-13:

Symbol

U

In

U

In_High

U

In_Low

I

In_High mA

Electrical data

Unit

V

V

V min.

-3

18

-3

4

0V_EA max.

30

30

5

7

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HAT02 - control module for inductive loads

Description

Output voltage On

Output current Off

Output current On

Energy content inductive load (f ≤ 1 Hz)

Short circuit protection

Overload protection

Reference potential

1)

Tab. 17-14:

Electrical data (Ext_Diag_I_Brake output)

Symbol Unit min.

max.

U

On

I

Off

I

On

E

Ind

V mA mA mJ

24V_EA - 1 24V_EA 1)

0.1

200

400

Present

Present

0V_EA

24V_EA corresponds to the device/brake power supply

Electrical data

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HAT02 - control module for inductive loads

17.6.4 XG49, switching state signal input

View Connec‐ tion

1

Signal name

Feedback_1

Function

2 Feedback_2

Input for switching state sig‐ nal 1

Input for switching state sig‐ nal 2

Spring terminal

Connection cable, stranded wire

Connection cable

Stripped length

Description

Allowed input voltage

Input voltage high

Input voltage low

Current consumption 1)

Reference potential

Tab. 17-15: Pin assignment

Mechanical data

Unit mm 2

AWG mm min.

0.2

24

Tab. 17-16: Mechanical data

Electrical data (Feedback_1, Feedback_2 inputs)

1)

Tab. 17-17:

10

Symbol Unit min.

U

In

U

In_High

U

In_Low

I

In_High

V

V

V mA

-3

18

-3

7.5

0V_Brake

With 24 V, the current consumption is > 10 mA

Electrical data max.

1.5

16 max.

30

30

5

12

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HAT02 - control module for inductive loads

17.7 Rotary coding switches S1, S2, S3, S4

17.7.1 Overview

HAT02.1-003, rotary coding switch

S1

S2

S3

S4

Function

Withstand voltage

Overexcitation duration

Switching state signal evaluation

Waiting time

Tab. 17-18: HAT02.1-003, rotary coding switch

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HAT02 - control module for inductive loads

17.7.2 S1, withstand voltage

Overexcitation

Power reduction

The withstand voltage is set with S1. The withstand voltage is the voltage af‐ ter the overexcitation is over.

S1 facilitates 2 functions:

● Overexcitation

● Power reduction

The functions can be combined.

The voltage applied to the inductive load is higher than the one applied to the nominal voltage. Thus, the load reacts faster. After the overexcitation dura‐ tion (rotary coding switch S2), the voltage is reduced to the nominal voltage.

First the nominal voltage is applied to the inductive load for a specified dura‐ tion (rotary coding switch S2). Afterwards, the voltage is set to a value lower than the nominal voltage. Thereby, the power dissipation at the load can be reduced.

The voltage reduction is not a safety function.

View

Tab. 17-19:

7

8

5

6

9

Position Withstand voltage ±20%

0 24V_Brake (XG3.3)

3

4

1

2

2/3 × 24V_Brake (XG3.3)

1/2 × 24V_Brake (XG3.3)

1/3 × 24V_Brake (XG3.3)

1/4 × 24V_Brake (XG3.3)

Reserved

Reserved

Reserved

Reserved

Reserved

S1, withstand voltage

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HAT02 - control module for inductive loads

17.7.3 S2, overexcitation duration

S2 determines how long the voltage of 24V_Brake (XG3.3) is applied to the inductive load.

Prerequisite: Position of switch S1 ≠ 0.

View

Tab. 17-20:

Position Overexcitation duration [s] ±10%

6

7

4

5

8

9

2

3

0

1

0.02

0.04

0.08

0.15

0.3

0.6

1

1.5

2

2.5

S2, overexcitation duration

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HAT02 - control module for inductive loads

17.7.4 S3, switching state signal evaluation

Signaling contacts directly mounted to the mechanics allow checking whether a brake or a valve has really switched or not.

Examples of signaling contacts: Microswitch, proximity switch, Hall sensor

The 24 V power supply of the signaling contacts has to have the same ground reference as 24V_Brake and 0V_Brake.

The S3 position depends on the type (N/C-N/O contact) and state (open/ closed) of the signaling contacts.

A maximum of 2 signaling contacts can be connected at XG49.

View

3

4

1

2

Tab. 17-21:

5

6

7

8

Position Evaluation

0 N/C 3) at Feedback_1, N/O

(closed and open) 1) 4)

3) at Feedback_2

1

2

N/C

N/O

3) at Feedback_1 (closed and open)

3) at Feedback_1 (closed and open)

1)

1)

3 N/C 3) at Feedback_1 and N/O

(closed) 2) 4)

3) at Feedback_2

4 N/C 3) at Feedback_1 (closed) 2)

N/O 3) at Feedback_1 (closed)

Evaluation switched off

Reserved

Reserved

2)

9 Reserved

Evaluation with brake closed (currentless) and with brake open

Evaluation with brake closed (currentless)

N/C-N/O: Contact or PNP output

If two feedback signals are evaluated, the signals have to be antivalent

S3, switching state signal evaluation

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HAT02 - control module for inductive loads

17.7.5 S4, waiting time

During the transition of the inductive load from the inactivated state to the ac‐ tivated state, or vice versa, it is necessary to wait for a certain time before the switching state signals can be evaluated. This time is the waiting time.

The waiting times of self-applying motor holding brakes are as follows:

● (t

V_On_max

+ t

Br_Off_max

) × f

● (t

V_Off_max

+ t

Br_On_max

) × f

The higher one of the two determined values is decisive for the waiting time.

Description t

V_On_max t

V_Off_max t

Br_On_max t

Br_Off_max f

Tab. 17-22:

Significance

Maximum valve ON time (if brake controlled via a hydraulic/ pneumatic valve)

Maximum valve OFF time (if brake controlled via a hydraulic/ pneumatic valve)

Maximum clamping delay of brake

Maximum release delay of brake

Factor (see data sheet of brake)

Data for determining the waiting time

View

Tab. 17-23:

Position Waiting time [s]

6

7

4

5

8

9

2

3

0

1

0.02

0.03

0.05

0.09

0.15

0.3

0.6

1.2

2.5

5

S4, waiting time

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HAT02 - control module for inductive loads

17.8 X6 adapter (RKL0091, RKL0092)

When a motor holding brake is wired via the motor cable, the motor holding brake connections are diverted at the drive controller and connected to the

HAT02 control module via a shielded connection. The shield is connected at one end to the motor cable shield at the drive controller.

K

L

Fig. 17-7:

Standard length: 5 cm

Length: depending on the application

X6 adapter for diverting the motor holding brake connections

Depending on the drive controller performance, there are two types:

Type A

HMS01.1N-W0020 … -W0070

HMS02.1N-W0028, -W0054

HCS02.1E-W0012 … -W0070

HMD01.1N-W0012 … -W0036

HCS03.1E-W0070

Order code:

RKL0091 (R911347795)

Tab. 17-24: X6 adapter, types

Type B

HMS01.1N-W0100 … -W0350

HCS03.1E-W0100 … -W0350

Order code:

RKL0092 (R911369814)

240/431 Bosch Rexroth AG

HAT02 - control module for inductive loads

17.9 LED H1

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LED

Off

Fig. 17-8: LED H1

HAT02.1-002

Significance

24 V voltage is missing

Device defective

Device ready for operation

Action

Check supply voltage

Replace device

Green

Flashing green Supply voltage (24V_Brake) outside of tolerance range

Flashing green-yel‐ low

Overtemperature

Check supply voltage

Check ambient temperature

Yellow Wiring error at Brake+ or Brake-

24V_Brake outside of tolerance range during booting process

Wire break at Brake+/-

Short circuit Brake+ against 0V

Check Brake+/- wiring

Check supply voltage

Check Brake+/- wiring

Check Brake+/- wiring

Short circuit Brake+ against BrakeCheck Brake+/- wiring

Flashing yellow Load current too high Check current consumption at Brake+/-

Device defective Replace device Red

Flashing red

Reset 1)

R

R

PO

Error on interface to drive controller Check XG48 wiring

Error in load control

Device defective

Check Brake+/- wiring

Replace device

1)

Tab. 17-25:

PO

R

PO

R: Reset via drive; PO: "Power Off/On"; switch supply voltage

(24V_Brake) off and on again

LED display (HAT02.1-002)

R

PO

PO

PO

PO

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HAT02 - control module for inductive loads

The error state is displayed as long as the error is present. At least, however, until the SBC function is deselected the next time.

The error state is saved in the drive and has to be acknowledged at the drive.

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HSZ01 - safety zone module

18 HSZ01 - safety zone module

18.1 Brief description, use, features

Brief description, use

Type Use

HSZ01 The safety zone module HSZ01 belongs to the Rexroth IndraDrive product range and provides the following safety functions:

●

●

●

Safety Zone Acknowledge (SZA)

Safety Zone Error (SZE)

Safety Zone Input (SZI)

● Safe Door Locking (SDL)

Features

Tab. 18-1: Use

● 2 × 8 digital inputs for dual-channel collective selection of the safety functions at the safety zone nodes or 16 inputs for single-channel selec‐ tion

● 2 × 1 digital dynamized output (1 output pair) for safety zone acknowl‐ edge, if all safety zone nodes signal safety

● 2 × 1 digital dynamized output (1 output pair) for safety zone error, if at least one safety zone node signals an error

● 2 × 1 digital dynamized output (1 output pair) for monitoring the wiring

● 2 × 1 digital output (1 output pair) for controlling the safe door locking

● Galvanic isolation exists between the inputs and outputs of the safety zone module and the other nodes of a safety zone

244/431 Bosch Rexroth AG

HSZ01 - safety zone module

18.2 Type code and identification

18.2.1 Type code

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Fig. 18-1: Type code

The figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of availa‐ ble versions.

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18.2.2 Identification

Type plate arrangement

Bosch Rexroth AG 245/431

HSZ01 - safety zone module

Type plate (device)

1

Fig. 18-2:

Type plate

Type plate arrangement

1

2

3

6

7

4

5

8

9

Fig. 18-3:

Device type

Part number

Production week; 11W36, for example, means year 2011, week 36

Factory identifier

Bar code

Serial number

Hardware index

Country of manufacture

Identification

Type plate (device)

18.3 Scope of supply

Scope of supply

● HSZ01 safety zone module

● Connector X41

● Connector X44

246/431 Bosch Rexroth AG

HSZ01 - safety zone module

18.4 Dimensions

18.4.1 Mounted on a top-hat rail

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A

B

Fig. 18-4:

All dimensions in mm

Minimum mounting clearance

Top-hat rail (35 mm × 7.5 mm [according to EN50022])

Dimensions

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18.4.2 Mounted with accessories HAS05.1-014-NNN-NN

HSZ01 - safety zone module

A

B

C

Fig. 18-5:

All dimensions in mm

Minimum mounting clearance

Drilling pattern

HAS05.1-014-NNN-NN

Dimensions

See also

chapter 20.5.13 "HAS05.1-014, Mounting Plate for Safety Zone

Module" on page 399

.

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HSZ01 - safety zone module

18.5 Technical data

Technical data

Description

Degree of protection

Conductive dirt contamination

Allowed mounting position

Weight

Minimum distance from the top of the device 1)

Minimum distance from the bottom of the device 2)

Minimum distance from the side of the device 3)

Allowed ambient temperature range

Allowed relative humidity

Cooling type 4)

Control voltage supply

Control voltage input 5)

Internal consumption

Output current 6)

1) 2) 3)

4)

5)

6)

Tab. 18-2:

Symbol Unit HSZ01.1-D08-D04-NNNN

IP20

Not allowed

(You can protect the devices against conductive dirt contamination, e.g., by mounting them in control cabinets with a degree of protection of IP54 in accord‐ ance with IEC529.)

Vertical in a control cabinet

0.65

40 d hor

T a_work m d top d bot kg mm mm mm

°C

40

-

0 … 55

U ext

P ext

I max

%

V

W

5 … 85 n

19.2 … 30

0.5

A 3.4

See fig. "Air intake and air outlet at device" n: natural convection; f: forced cooling

When selecting a control voltage supply, observe the require‐ ments of the door locking device

Sum of all output currents at the outputs (without SDL_Ch2)

HSZ01 - technical data

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Distances

C d

A

B d top d bot hor

Fig. 18-6:

Air intake

Air outlet

Mounting surface in control cabinet

Distance top

Distance bottom

Distance horizontal

Air intake and air outlet at device

Bosch Rexroth AG 249/431

HSZ01 - safety zone module

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HSZ01 - safety zone module

18.6 Connection points

18.6.1 Position of connection points

View Connection point Description

XS1

Shield connection

X41

X42

X43

X44

Digital inputs

Communication, input

Communication, output

Digital outputs

Control voltage supply connection

Equipment grounding conductor

H2 (LED)

Status display (bicolor LED)

Tab. 18-3: Connection points

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18.6.2 X41, digital inputs

Data

View Identifica‐ tion

X41

Bosch Rexroth AG 251/431

HSZ01 - safety zone module

Function

Safe Motion

Spring terminal (connector)

Connection cable

Stranded wire

Stripped length

Time behavior

Unit mm 2

AWG mm max.

1.5

16

10

Tab. 18-4: Data

Maximum delay when selecting and deselecting a digital input: 2.5 ms

The delay results from the addition of the following times:

● Filter time of the digital input

● Time for adjusting the signal

● Transmission time to the drive controller

The reaction time of the drive controller is not contained in the specified time.

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18.6.3 Pin assignment, function

Connection

2.5

2.6

2.7

2.8

2.1

2.2

2.3

2.4

1.5

1.6

1.7

1.8

1.1

1.2

1.3

1.4

Signal name

In_9

In_10

In_11

In_12

In_13

In_14

In_15

In_16

In_5

In_6

In_7

In_8

In_1

In_2

In_3

In_4

Function

Input 9

Input 10

Input 11

Input 12

Input 13

Input 14

Input 15

Input 16

Input 1

Input 2

Input 3

Input 4

Input 5

Input 6

Input 7

Input 8

1)

Tab. 18-5:

Dynamization 1)

DYN_Ch1

DYN_Ch2

DYN_Ch1

DYN_Ch2

DYN_Ch1

DYN_Ch2

DYN_Ch1

DYN_Ch2

DYN_Ch1

DYN_Ch2

DYN_Ch1

DYN_Ch2

DYN_Ch1

DYN_Ch2

DYN_Ch1

DYN_Ch2

Input pair

1

2

3

4

5

6

7

8

Technical data

See

chapter 18.7.1 "Digital inputs

(safety technology S options)" on page 256

Assigned dynamization output of HSZ01 in the case of selec‐ tion via a passive safety unit

Function, pin assignment, properties

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HSZ01 - safety zone module

18.6.4 X44, digital outputs, control voltage supply

18.6.5 Data

View Identifica‐ tion

X44

Function

Safe Motion

Spring terminal (connector)

Connection cable

Stranded wire

Stripped length

Tab. 18-6:

Unit mm 2

AWG mm

Data max.

1.5

16

10

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HSZ01 - safety zone module

18.6.6 Pin assignment, function

Function

Power supply

Power supply

Channel 1 zone error output

Channel 2 zone error output

Channel 1 zone safety output

Channel 2 zone safety output

Safe door locking output, channel 1

Safe door locking output, channel 2

Channel 1 dynamization output

Channel 2 dynamization output

Channel 1 dynamization output

Channel 2 dynamization output

Channel 1 dynamization output

Channel 2 dynamization output

Channel 1 dynamization output

Channel 2 dynamization output

Channel 1 dynamization output

Channel 2 dynamization output

2.3

1.4

2.4

1.5

1.2

2.2

1.3

2.5

1.6

2.6

Connec‐ tion

2.1

1.1

1.7

2.7

1)

2)

1.8

2.8

1.9

2.9

Tab. 18-7:

Signal name Technical data

24V Voltage: DC 19.2 … 30 V 1)

0V Reference potential of power supply

SZE_Ch1

SZE_Ch2

● High on both outputs:

All nodes are without error

● Low on both outputs:

At least one node has an error

See also 2) and

chapter 18.7.2 "Digital outputs (safety technology S options)" on page 257

SZA_Ch1

SZA_Ch2

● High on both outputs:

All nodes are safe

Low on both outputs: ●

At least one node is not safe

See also 2) and

chapter 18.7.2 "Digital outputs (safety technology S options)" on page 257

SDL_Ch1 Output pair for controlling a door locking device.

SDL_Ch2 When the door latch is correctly controlled,

SDL_Ch1 = High and SDL_Ch2 = Low.

See also

chapter 18.7.3 "Digital outputs (safety technol‐ ogy S options, SDL)" on page 259

DYN_Ch1 One output pair for dynamization of the external wiring.

DYN_Ch2

DYN_Ch1

To simplify the wiring, the connection of the output pair exists several times.

DYN_Ch2

See also 2) and

chapter 18.7.2 "Digital outputs (safety technology S options)" on page 257

DYN_Ch1

DYN_Ch2

DYN_Ch1

DYN_Ch2

DYN_Ch1

DYN_Ch2

If the door locking device requires a tighter tolerance of the voltage, the power supply unit used has to comply with the tol‐ erance of the door locking device.

If a relay is used, the minimum withstand voltage of the relay has to be > 2 V (2 V = maximum output voltage OFF of the dig‐ ital output).

Function, pin assignment, properties

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 255/431

HSZ01 - safety zone module

18.6.7 X42 and X43, Safe Motion safety technology (communication)

View Identifica‐ tion

X42

X43

Function

Connection points for connecting the HSZ01 1) safety zone nodes:

safety zone module and the

X42: Input

X43: Output

X42:

X43:

Connection cable ●

●

●

●

Maximum total length of all cables of a safety zone: 2500 m

Maximum length of one cable between two connection points: 100 m

Number of safety zone nodes (without HSZ01):

– Maximum: 35

– Minimum: 1

Ready-made cables that can be ordered:

– RKB0051

Short cables to connect 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; 10 m

Minimum bending radius: 8xD (= 8x6 mm = 48 mm)

Order code for a 5 m long cable: RKB0052/005,0

Flexible installation of the cable is not allowed.

1)

Tab. 18-8:

See Project Planning Manual "IndraDrive Additional Compo‐ nents and Accessories" (R911306140).

X42, X43

256/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HSZ01 - safety zone module

18.7 Digital inputs and outputs

18.7.1 Digital inputs (safety technology S options)

The digital inputs correspond to IEC 61131, type 1.

Data

Allowed input voltage

High

Low

Unit

V

V

V mA min.

-3

2

-3

15

Current consumption

Tab. 18-9:

Time behavior

Digital inputs (safety technology S options)

Description

Test pulse width (t

PL

)

Percentage of High time (T

PH

/T

P

×100%)

Phase shift between two test pulses on both channels

(φ)

Unit

µs

% ms max.

5

5

30

30 min.

max.

0 1000

90

-

100

-

Tab. 18-10: Time behavior

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 257/431

HSZ01 - safety zone module

18.7.2 Digital outputs (safety technology S options)

The digital outputs are compatible with digital inputs of types 1, 2 and 3

(IEC 61131).

Data

Output voltage ON

Output voltage OFF

Allowed output current per out‐ put

Allowed energy content of con‐ nected inductive loads, e.g. re‐ lay coils

Capacitive load

Short circuit protection

Overload protection

Block diagram output:

Unit

V

V mA mJ nF min.

U ext

- 1

Present

Present max.

U ext

2

350

400 1) 2)

320

Error detection

1)

2)

Tab. 18-11:

The following errors 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

At a maximum switching frequency of 1 Hz

In the case of inductive loads with currents > 200 mA or in the case of inductive loads with a greater energy content, an exter‐ nal free-wheeling arm has to be installed. The effective termi‐ nal voltage has to be < 25 V.

Digital outputs

258/431 Bosch Rexroth AG

HSZ01 - safety zone module

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Rexroth IndraDrive Additional Components and Accessories

Time behavior

Description

Test pulse width (t

PL

)

Periodic time (T

P

)

Phase shift between two test pulses on both channels

(φ)

Unit

μs ms ms min.

max.

100 200

500

50

1000

-

Tab. 18-12: Time behavior

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 259/431

HSZ01 - safety zone module

18.7.3 Digital outputs (safety technology S options, SDL)

The digital outputs are compatible with digital inputs of type 1 (IEC 61131).

Data

Output voltage ON SDL_Ch1

Output voltage ON SDL_Ch2

Output current ON

Output current OFF

Allowed energy content of con‐ nected inductive loads, e.g. re‐ lay coils; only allowed as single pulse

Short circuit protection

Overload protection

Unit

V

V mA mA mJ min.

U ext

- 1

typ.

24 max.

U ext

0.5

1250

0.8

2000 1) 2)

Present

Present

1)

2)

Overtemperature protection

Monitoring of internal switches

T_Ch1 and T_Ch_2

Tab. 18-13:

Present

Present

With a maximum switching frequency of 0.5 Hz

In the case of greater inductive loads, an external free-wheel‐ ing arm must be installed. The effective terminal voltage must be < 20 V.

Digital outputs

Fig. 18-7: Safe Door Locking SDL

260/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HSZ01 - safety zone module

18.8 LED H2

LED

H2

Color

Off

Description

●

●

Power supply missing

Device defective

Device functions without error

Permanently lit green

Errors present: See diagnostic display (e. g. F3152) on the drive controller

Fixing: See firmware documentation "Diag. Messages"

Flashing red

Permanently lit red

●

●

Hardware error

Firmware error

● Communication error

Diagnostic display: F7033

Tab. 18-14: LED H2

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Rexroth IndraDrive Additional Components and Accessories

19 HAB01 Fan Unit

Type Code

Bosch Rexroth AG 261/431

HAB01 Fan Unit

Data

Fig. 19-1:

Use

Type Code

Complete designation

Volume flow

Weight

Dimensions

Tab. 19-1:

HAB01 cools

●

●

HMV01.1R-W0120 supply units

HMS01.1N-W0350 power sections

HAB01.1-0350-1640-NN

1,640 m 3 /h

7.5 kg

See dimensional drawing

HAB01 Fan Unit - Data

262/431 Bosch Rexroth AG

HAB01 Fan Unit

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Rexroth IndraDrive Additional Components and Accessories

Mounting

Fig. 19-2: HAB01 Fan Unit - Dimensional Drawing

See also dimensional drawing HMV01.1R-W0120 or HMS01.1N-W0350 in the documentation of the supply units and power sections.

1.

Mount supply unit or power section

2.

Hang up HAB01

3.

Screw on bottom of HAB01

4.

Screw on top of HAB01

5.

Connect HAB01 to X13

1

2

3

Fig. 19-3:

Screws to fix HAB01 to supply unit or power section

Screws to fix HAB01 to mounting plate

Connection X13 for power supply of HAB01 fan unit

HAB01 Fan Unit - Mounting and Connection

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 263/431

Accessories

20 Accessories

20.1 HAS01, Basic Accessories

20.1.1 Type Code

The figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of availa‐ ble versions.

Fig. 20-1: Type Code HAS01.1

264/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.1.2 Brief Description

Accessories for mounting and installing the drive controllers in a group, i.e.

next to each other.

As adjusted to the device widths, we distinguish 3 types:

● HAS01 without contact bars, (-NNN)

● HAS01 with contact bars (-072-) to connect the DC buses

● HAS01 with contact bars (-072-) to connect the DC buses and joint bars to connect the equipment grounding conductors of the devices

Observe that the contact bars of the basic accessories HAS01 are used for connection to the drive controller on the left-hand side.

20.1.3 Use

The HAS01 accessories are used to

● fix the drive controllers to a mounting surface

● connect the DC bus connections of drive controllers

● connect the 24V supply of drive controllers of the Rexroth IndraDrive M range

● connect the equipment grounding conductor from drive controller to drive controller or supply unit

● increase the current carrying capacity of the contact bars in the DC bus for high-performance devices (by means of the parts "end piece" and

"bar" in HAS01; see chapter "Assignment")

● inform the user on safety risks. The HAS01 accessory contains adhe‐ sive labels with notes on safety in the English and French languages.

Place the adhesive labels clearly visibly at the device or in the immedi‐ ate vicinity of the device, if the adhesive labels existing at the device are hidden by neighboring devices.

Using the parts "end piece" and "bar"

For high-performance devices, you have to mount the end pieces and bars contained in the HAS01 accessory (see chapter "As‐ signment").

See sections

"DC Bus Connection (L+, L-)" and "Terminal Block, 24 - 0V

(24V Supply)" in the Project Planning Manual for supply units and power sec‐ tions.

20.1.4 Assignment

The accessories are assigned to the individual devices depending on the de‐

vice width (see section "Type Code"

).

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Device type

HMS01.1N- W0020

W0036

W0054

W0070

W0110

W0150

W0210

W0300

W0350

HMD01.1N- W0012

W0020

W0036

HMS02.1N- W0028

W0054

HLB01.1 D

HLC01.1 D

HMV01.1E- W0030

W0075

W0120

HMV01.1R- W0018

W0045

W0065

W0120

HMV02.1R- W0015

HCS02.1N- W0012

W0028

W0054

W0070

HLB01.1 C

HLC01.1 C

HCS03.1N- W0070

W0100

W0150

W0210

Tab. 20-1: Device Width

105

65

50

125

150

65

65

105

175

250

350

350

75

150

250

350

225

225

350

75

49.5

74.5

100

200

350

50

50

100

125

150

200

50

50

75

Width / mm

Bosch Rexroth AG 265/431

Accessories

150

065

065

105

175

250

350

350

075

150

250

350

075

050

075

100

105

065

050

125

225

225

350

200

350

050

050

100

125

150

200

Accessory HAS01.1-

With "end piece"

050

050

075 -

-

-

-

-

■

■

-

■

-

-

-

-

■

-

-

-

-

-

-

-

-

■

■

-

■

■

■

-

-

-

-

-

-

266/431 Bosch Rexroth AG

Accessories

20.1.5 Scope of Supply

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-2: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 267/431

Accessories

Fig. 20-3: Product Insert

268/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-4: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 269/431

Accessories

Fig. 20-5: Product Insert

270/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

Fig. 20-6: Product Insert HAS01.1-100-072-MN (Page 1)

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 271/431

Accessories

Fig. 20-7: Product Insert HAS01.1-100-072-MN (Page 2)

272/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-8: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 273/431

Accessories

Fig. 20-9: Product Insert

274/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-10: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 275/431

Accessories

Fig. 20-11: Product Insert

276/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-12: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 277/431

Accessories

Fig. 20-13: Product Insert

278/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-14: Product Insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 279/431

Accessories

Fig. 20-15: Product Insert

280/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-16: Product Insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 281/431

Accessories

Fig. 20-17: Product Insert

282/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-18: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 283/431

Accessories

Fig. 20-19: Product Insert

284/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-20: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 285/431

Accessories

Fig. 20-21: Product Insert

286/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-22: Product Insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 287/431

Accessories

Fig. 20-23: Product Insert

288/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-24: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 289/431

Accessories

Fig. 20-25: Product Insert

290/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-26: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 291/431

Accessories

Fig. 20-27: Product Insert

292/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-28: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 293/431

Accessories

Fig. 20-29: Product Insert

294/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-30: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 295/431

Accessories

Fig. 20-31: Product Insert

296/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.1.6 Mounting the "Bar" and "End Piece" Parts of the HAS01 Accessory

The "bar" and "end piece" parts increase the current carrying capacity of the

DC bus connections by reducing the involved contact resistances.

1

2

3

Fig. 20-32:

Bar

End piece (right end)

End piece (left end)

Mounting the Bar and End Piece of HAS01

● Ad 1: Use the bars (-042) contained in all HAS01.1-***-072-** as shown in the figure at L+ and L-.

● Ad 2 and 3: Use the end pieces contained in all HAS01.1-350-***-** and

HAS01.1-200-***-** at the right and left ends of the DC bus connections in the drive system.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 297/431

Accessories

20.2 HAS02, shield connection

20.2.1 General information

Accessories for appropriate connection of the motor cable to the drive con‐ troller, especially the shield connection of the motor cable.

There are appropriate HAS02 accessories for the different drive controllers.

298/431 Bosch Rexroth AG

Accessories

20.2.2 Type code

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-33: Type Code HAS02.1

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 299/431

Accessories

20.2.3 Use

The HAS02 accessories are used to

● provide strain relief of the motor cable

● connect the shield of the motor cable to the drive controller

20.2.4 Assignment of accessory HAS02

See section "Type Code (Device Assignment)"

20.2.5 Scope of supply

For the scope of supply and the components of HAS02, see the correspond‐ ing product inserts.

300/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

Fig. 20-34: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 301/431

Accessories

Fig. 20-35: Product Insert

302/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

Fig. 20-36: Product Insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 303/431

Accessories

Fig. 20-37: Product Insert

304/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-38: Product Insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 305/431

Accessories

Fig. 20-39: Product Insert

306/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-40: Product Insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 307/431

Accessories

Fig. 20-41: Product Insert

308/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-42: Product Insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 309/431

Accessories

Fig. 20-43: Product Insert

310/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-44: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 311/431

Accessories

Fig. 20-45: Product Insert

312/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-46: Product Insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 313/431

Accessories

Fig. 20-47: Product Insert

314/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-48: Product Insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 315/431

Accessories

Fig. 20-49: Product Insert HAS02.1-020-NNF-NN (Page 1)

316/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-50: Product Insert HAS02.1-020-NNF-NN (Page 2)

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 317/431

Accessories

Fig. 20-51: Product Insert HAS02.1-021-NNF-NN (Page 1)

318/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-52: Product Insert HAS02.1-021-NNF-NN (Page 2)

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

20.2.6 Mounting the accessory HAS02

General information

Bosch Rexroth AG 319/431

Accessories

3

4

1

2

5

Fig. 20-53:

Screw in thread XS2

Fixing device of shielding plate

Shielding plate

Shield of motor cable

Clip

Strain Relief and Shield Connection of Motor Cable

● Unscrew bottom or bottom left mounting screw of drive controller.

● Put fixing device of accessories to bottom of drive controller and screw down mounting screw of drive controller again.

NOTICE Risk of damage to the drive controller by too long screws!

Exclusively use screws of a maximum length of 12 mm for the thread of shield connection XS2.

● Screw second screw (M6 × 12) in thread XS2 at bottom of drive control‐ ler.

● Screw shielding plate to sheet metal of accessories according to desired cable routing of motor cable (45° or horizontal). (The figure below illus‐ trates cable routing with 45°.)

● According to diameter of motor cable, fix motor cable at corresponding point of shielding plate (12-18 mm or 19-30 mm) with a clip. Make sure that shield of motor cable has good contact with shielding plate (see fig‐ ure below).

320/431 Bosch Rexroth AG

Accessories

HAS02.1-001 at HMS01.1N-W0054

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mounting

3

4

1

2

Fig. 20-54:

Fixing device

Shielding plate

Clip

Different possibilities of mounting the shielding plate, according to motor cable routing

HAS02.1-001 at Bottom of Drive Controller HMS01.1N‑W0054

1.

By means of supplied screws, fasten fixing device to bottom of drive controller.

2.

Fix shielding plate to fixing device according to desired motor cable rout‐ ing.

3.

Fix shield of cable to shielding plate with appropriate clip.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HAS02.1-002 at HCS02.1E-W0054

Bosch Rexroth AG 321/431

Accessories

Mounting

3

4

1

2

Fig. 20-55:

Fixing device

Shielding plate

Clip

Different possibilities of mounting the shielding plate, according to motor cable routing

HAS02.1-002 at Bottom of Drive Controller HCS02.1E‑W0054

1.

By means of supplied screws, fasten fixing device to bottom of drive controller.

2.

Fix shielding plate to fixing device according to desired motor cable rout‐ ing.

3.

Fix shield of cable to shielding plate with appropriate clip.

322/431 Bosch Rexroth AG

Accessories

HAS02.1-003 at HMS01.1N-W0210/300

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mounting

3

4

1

2

Fig. 20-56:

Fixing device

Shielding plate

Clip

Different possibilities of mounting the shielding plate, according to motor cable routing

HAS02.1-003 at Bottom of Drive Controller HMS01.1N‑W0210/300

1.

By means of supplied screws, fasten fixing device to bottom of drive controller.

2.

Fix shielding plate to fixing device according to desired motor cable rout‐ ing.

3.

Fix shield of cable to shielding plate with appropriate clip.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HAS02.1-004 at HCS03.1E-W0070

Bosch Rexroth AG 323/431

Accessories

Mounting

3

4

1

2

Fig. 20-57:

Fixing device

Shielding plate

Clip

Different possibilities of mounting the shielding plate, according to motor cable routing

HAS02.1-004 at Bottom of Drive Controller HCS03.1E-W0070

1.

By means of supplied screws, fasten fixing device to bottom of drive controller.

2.

Fix shielding plate to fixing device according to desired motor cable rout‐ ing.

3.

Fix shield of cable to shielding plate with appropriate clip.

324/431 Bosch Rexroth AG

Accessories

HAS02.1-005 at HCS03.1E-W0100/150

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Mounting

3

4

1

2

Fig. 20-58:

Fixing device

Shielding plate

Clip

Different possibilities of mounting the shielding plate, according to motor cable routing

HAS02.1-005 at Bottom of Drive Controller HCS03.1E-W0100/0150

1.

By means of supplied screws, fasten fixing device to bottom of drive controller.

2.

Fix shielding plate to fixing device according to desired motor cable rout‐ ing.

3.

Fix shield of cable to shielding plate with appropriate clip.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HAS02.1-008 at HCS03.1E-W0210/280/350

Bosch Rexroth AG 325/431

Accessories

Mounting

3

4

1

2

Fixing device

Shielding plate

Clip

Different possibilities of mounting the shielding plate, according to motor cable routing

Fig. 20-59:

1.

By means of supplied screws, fasten fixing device to bottom of drive controller.

2.

Fix shielding plate to fixing device according to desired motor cable rout‐ ing.

3.

Fix shield of cable to shielding plate with appropriate clip.

326/431 Bosch Rexroth AG

Accessories

HAS02.1-010 at HMS02.1N‑W0028/54

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

1

2

Fig. 20-60:

Fixing device

Shielding plate

HAS02.1-010-NNN-NN at Bottom of Drive Controller

HMS02.1N‑W0028/54

1. Screw fixing device to equipment grounding conductor connection of drive controller.

2. Fix shield of cable with shielding plate to fixing device.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HAS02.1-014 at HMS01.1N-W0350

Bosch Rexroth AG 327/431

Accessories

1

2

3

Fig. 20-61:

Fixing device

Shielding plate

Clip

HAS02.1-014 at Bottom of Drive Controller HMS01.1N‑W0350

1. By means of supplied screws, fasten fixing device to front of fan unit.

2. Fix shielding plate to fixing device.

3. Fix shield of cable to shielding plate with appropriate clip.

20.2.7 Shield connection of the motor cable via mains filter

General information

For shield connection of the motor cable at the drive controller via the mains filter, a special shielding plate is available:

Using the shielding plate guarantees optimum shield contact of the motor cable. You should therefore, where possible, always use the shielding plate.

The shielding plate is only available as an option.

328/431 Bosch Rexroth AG

Accessories

HAS02.1-006 with mains filter

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

3

4

1

2

Fig. 20-62:

Fixing device

Shielding plate (power supply cable)

Clip

Shielding plate (motor cable)

HAS02.1-006 at Bottom of Mains Filter (Rated Current 50 A)

1.Hang up fixing device at bottom of mains filter at threaded bolts and fasten with supplied nuts.

2. Screw shielding plate to fixing device.

3. Fix shield of cable to shielding plate with appropriate clip.

The shield terminals must not be used to provide strain relief.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

HAS02.1-007 with mains filter

Bosch Rexroth AG 329/431

Accessories

3

4

1

2

5

6

Fig. 20-63:

Fixing device

Shielding plate

Clip

Different possibilities of mounting the shielding plate, according to cable routing

Power supply cable

Motor cable

HAS02.1-007 at Bottom of Mains Filter (Rated Current 80 A / 106 A)

1.Hang up fixing device at bottom of mains filter and fasten with supplied screws.

2. Screw shielding plate to fixing device.

According to desired cable routing, the shielding plate can be mounted in dif‐ ferent positions.

3. Fix shield of cable to shielding plate with clip.

The shield terminals must not be used to provide strain relief.

330/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

HAS02.1-009 with power supply cable and mains filter

Mounting

3

4

1

2

5

6

Fig. 20-64:

Fixing device

Shielding plate

Clip

Different possibilities of mounting the shielding plate, according to cable routing

Power supply cable

Motor cable

Shielding Plate HAS02.1-009 at Bottom of Mains Filter (Rated Cur‐ rent 146 A)

1.

By means of supplied screws, fasten fixing device to bottom of drive controller.

2.

Fix shielding plate to fixing device according to desired motor cable rout‐ ing.

3.

Fix shield of cable to shielding plate with appropriate clip.

The shield terminals must not be used to provide strain relief.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

20.3 HAS03, control cabinet adapter

20.3.1 Type code

Bosch Rexroth AG 331/431

Accessories

20.3.2 Use

Fig. 20-65: Type code HAS03.1

The control cabinet adapter is used to compensate different mounting depths of HCS02.1E drive controllers and HLC01.1C and HMS01 / HMD01 when mounted to a common mounting surface.

332/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

A

B

Fig. 20-66:

Control cabinet adapter

Mounting surface in control cabinet

How to use the control cabinet adapters

Observe the maximum allowed tightening torque of 6 Nm at

HAS03.

Mechanical stability of the adapted device requires a rigid con‐ nection via DC bus bars to a neighboring device without adapter.

● Do not operate HAS03 without neighboring device.

● Mount HAS03 to bare metal mounting plate.

20.3.3 Assigning HAS03 accessories

See

"Type code (device assignment)"

.

20.3.4 Scope of supply

Scope of supply For the scope of supply and the parts of HAS03, see the corresponding prod‐ uct insert.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 333/431

Accessories

Fig. 20-67: Product insert

334/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-68: Product insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 335/431

Accessories

20.4 HAS04, capacitor

20.4.1 General information

Capacitors from the DC bus connections L+ and L- against housing.

20.4.2 Type code

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:

①

②

H A S 0 4 . 1 - 0 0 1 - N N N - N N

① ② ③ ④

Product:

HAS = IndraDrive accessories

Series:

04 = Capacitor

⑤ ⑥

③

④

⑤

⑥

Design:

1 = 1

Capacitor:

001 = 2 × 470 nF (HCS02.x)

002 = 2 × 470 nF (HCS03.x)

003 = 2 × 2.5 μF (HLL05)

Other properties:

NNN = None

Other design:

NN = None

Tab. 20-2: HAS04, type code

Using the HAS04 accessories requires additional mounting clear‐ ance at the drive controller.

Take the dimensions of HAS04 into account.

20.4.3 Use

The HAS04 accessories are used to

● operate HCS02 and HCS03 drive controllers at HNF01.1 mains filter

● operate HMS01, HMS02 and HMD01 drive controllers at HCS02 and

HCS03 drive controllers

● operate HMU05 universal inverters at HLL05 DC bus chokes

HAS04 type Use

HAS04.1-001-NNN-NN At DC bus connections of HCS02 drive controllers

HAS04.1-002-NNN-NN At DC bus connections of HCS03 drive controllers

HAS04.1-003-NNN-NN At DC bus connections of HMU05 universal inverters

Further information: See HMU05 Project Planning Manual.

Tab. 20-3: HAS04 type

336/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.4.4 Assignment

Device

HCS02.1E-W0028

HCS02.1E-W0054

HCS02.1E-W0070

HCS03.1E-W0070

HCS03.1E-W0100

HCS03.1E-W0150

HCS03.1E-W0210

HMU05/HLL05

-001

■

-

-

■

■

-

-

-

HAS04.1

-002

-

■

■

-

-

-

■

■

-003

-

-

-

-

-

-

-

■

Tab. 20-4:

20.4.5 Scope of supply

Assigning HAS04 accessories

The HAS04 accessories are available as an option, they are not part of the standard scope of supply.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 337/431

Accessories

Fig. 20-69: Product insert HAS04.1-001

338/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-70: Product insert HAS04.1-002

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

20.4.6 Capacitor

Connection HAS04

Bosch Rexroth AG 339/431

Accessories

Fig. 20-71:

20.4.7 Mounting dimensions

Connection HAS04

Fig. 20-72: Mounting dimensions HAS04

340/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

Device

HAS04.1-001

HAS04.1-002

Min. installation width B

[mm]

30

40

Tab. 20-5: Mounting dimensions

20.4.8 Mounting the HAS04.1-001 accessories

Device height H

[mm]

75

75

Device depth

[mm]

< 150

< 150

WARNING Dangerous contact voltage at device housing!

Lethal electric shock!

Connect the HMx01 drive controllers to the HCS02 drive controller using bus bar 2 (see figure below). Bus bar 2 replaces the equipment grounding con‐ nection 3 at HMx01 (see figure below) to the equipment grounding system.

1

2

3

Fig. 20-73:

HAS04.1-001 accessories mounted with connections to L

+ and L-

Bus bar mounted

Equipment grounding connection at HMx01

HAS04.1-001 at drive system HCS02 with HMx01 without touch guard mounted

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 341/431

Accessories

1

2

Fig. 20-74:

HAS04.1-001 accessories mounted

Bus bar mounted

HAS04.1-001 at drive system HCS02 with HMx01 with touch guard mounted

20.4.9 Mounting the HAS04.1-002 accessories

WARNING Dangerous contact voltage at device housing!

Lethal electric shock!

Connect the HAS04.1-002 accessories to the HCS03 drive controller via the joint bar (see figure below).

342/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

1

2

Fig. 20-75:

HAS04.1-002 accessories mounted with connections to L

+ und L-

Joint bar

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 343/431

Accessories

1

Fig. 20-76:

HAS04.1-002 accessories mounted with connections to L

+ und L-

HAS04.1-002 at drive system HCS03.1E-W0210 with HMx01 without touch guard mounted

Fig. 20-77:

344/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5 HAS05, accessories for connection points

20.5.1 Overview of types

The HAS05 product series includes:

● Cables

● Connectors

● Adapters

HAS05 type Brief description / use

HAS05.1-001-NNN-NN Adapter for mains and motor connection

Is used for electrical connection between output filter

HMF01.1A-D0K2-D0045 and HCS03.1E-W0070, as well as between mains filter HNK01.1A-A075-E0050 and

HCS03.1E-W0070

HAS05.1-002-NNN-NN Extension

Is used for electrical connection between mains filter

HNK01.1A-A075-E0050 and HCS03.1E-W0070, if an out‐ put filter has been mounted between HCS03.1 and mains filter

HAS05.1-003-NNN-NN Encoder emulation signal level converter

Increases voltage level at output of optional module MEM

(encoder emulation) to voltage range 5 … 30 V

HAS05.1-004-NNL-NN

HAS05.1-004-NNR-NN

DC bus connection adapter

With this accessory, you can wire several systems of drive controllers with greater cross sections at DC bus connec‐ tions L+ and L-

NNL: Outgoing direction "left"

NNR: Outgoing direction "right"

HAS05.1-005-NNN-NN Signal level converter RS232/RS485

Converts the serial interface of control sections from

RS232 standard to RS485 standard

HAS05.1-006-NNN-NN Adapter for controlling motor holding brake

HAS05.1-007-NNL-NN

HAS05.1-007-NNR-NN

Adapter from D-Sub to terminal connector

Universal adapter for safety technology for more easily wiring X41 of 2nd channel

NNL: For mounting to double-axis control sections CDB01 at OP ST1

NNR: For mounting to double-axis control sections CDB01 at OP ST2

HAS05.1-008-NNN-NN Adapter for connecting two cables

With this accessory, you can connect 2 ring cable lugs each at connections A1, A2 and A3 of X5 (motor connec‐ tion)

HAS05.1-009-NNN-NN Coding pin for terminal connector RHS

HAS05.1-010-NNN-NN Brake current monitoring

Monitors current and voltage of motor holding brakes

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 345/431

Accessories

HAS05 type Brief description / use

HAS05.1-014-NNN-NN Mounting plate for safety zone module HSZ01

HAS05.1-015-NNN-NN Snap-on ferrite for HLR01.2

HAS05.1-016-NNN-NN Brake module with connectors

HAS05.1-017-NNN-NN X6 adapter ( RKL0091

, RKL0092)

HAS05.1-018-NNN-NN KMS03 (dummy plate for encoder connection)

HAS05.1-019-NNN-NN KNK03 (mains voltage connection accessories)

HAS05.1-020-NNN-NN KMV03 (control voltage connection accessories)

Tab. 20-6: HAS05 types

346/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.2 Type code

The figure illustrates the basic structure of the type code. Our sales representative will help you with the current status of availa‐ ble versions.

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:

①

②

H A S 0 5 . 1 - 0 1 7 - N N N - N N

① ② ③ ④ ⑤

Product:

HAS = IndraDrive accessories

Series:

05 = Cables, connectors, adapters

⑥

③

④

Design:

1 = 1

Device assignment:

001 = HCS03.1E-W0070

002 = HMF01.1 … -0070-

003 = encoder emulation level adjustment

004 = DC bus, 2 × 50 mm 2

005 = RS232/RS485 converter

006 = brake module

007 = X41 adapter

008 = motor connection, 2 × 16 mm 2

009 = coding pin for RHS plug-in connector

010 = brake current monitoring

011 = HCP02.1E-B0070-…-NNNN/NNM2

012 = HMP01.1L-N0126B

013 = HCP02.1E-B0070-…-NNM1

014 = HSZ01.1-D08-D04-NNNN

015 = snap-on ferrite for HLR01.2

016 = brake module with connectors

017 = X6 adapter

018 = KMS03 (dummy plate for encoder connection)

019 = KNK03 (mains voltage)

020 = KMV03 (control voltage)

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 347/431

Accessories

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:

⑤

H A S 0 5 . 1 - 0 1 7 - N N N - N N

① ② ③ ④ ⑤ ⑥

⑥

Other properties:

NHN = Top-hat rail mounting

NNB = Mounting direction: both-way

NNL = Mounting direction: left

NNN = None

NNR = Mounting direction: right

Other design:

NN = None

Tab. 20-7: HAS05, type code

348/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.3 HAS05.1-001, Adapter for Mains and Motor Connection

Brief Description and Use

Brief Description

Assignment

The accessory HAS05.1-001 brings the mains and motor connections from the bottom of the device to the front of an HCS03.1-W0070.

You need this adapter when additional components are mounted to

HCS03.1E-W0070 in order to connect them to the mains and motor input.

HAS05.1-001 can be used at the following drive controllers:

Scope of Supply

Device

HCS03.1E-W0070

HAS05.1-001

■

Tab. 20-8: Assignment Accessory HAS05.1-001

Order this accessory as a separate item. It is not part of the scope of supply of the device.

Parts of the accessory: See product insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 349/431

Accessories

Fig. 20-78: Product Insert

350/431 Bosch Rexroth AG

Accessories

Parts of HAS05.1-001

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-79: Parts of HAS05.1-001

Technical Data

Allowed Cross Sections

Mounting Dimensions

Connection

Examples of Installation

Connection, Mounting Dimensions

The accessory HAS05.1 has been dimensioned to insert lines with ferrules in it.

Allowed connection cross section stranded wire

Allowed connection cross section stranded wire

Unit mm²

AWG

HAS05.1-001

16

6

Tab. 20-9: Connection Cross Section HAS05.1-001

The mounted adapter remains within the outer housing dimensions of the in‐ volved components HMF and HCS03.

● HMF01

Connect input of output filter HMF01 to X5 at HAS05.1-001 (motor out‐ put of HCS03).

● HNK01

Connect output of mains filter HNK01 to X3 at HAS05.1-001 (mains in‐ put of HCS03).

Mounted accessory

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 351/431

Accessories

Fig. 20-80: Arrangement HCS03 / HAS05.1-001 / HMF01

352/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.4 HAS05.1-002, Extension

Brief Description and Use

Brief Description

Assignment

The accessory HAS05.1-002 is an extension which connects the output of the HNK01 mains filter to the mains input of HCS03 (X3).

This adapter is required when the additional components HNK01 and HMF01 are mounted to HCS03.1E-W0070. The adapter is not required without

HMF01.

HAS05.1-002 can be used at the following drive controllers:

Scope of Supply

Device

HCS03.1E-W0070

With HNK01 and HMF01

HAS05.1-002

■

Tab. 20-10: Assignment Accessory HAS05.1-002

Order this accessory as a separate item. It is not part of the scope of supply of the device.

Parts of the accessory: See product insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 353/431

Accessories

Parts of HAS05.1-002

Fig. 20-81:

Fig. 20-82: Parts of HAS05.1-002

354/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.5 HAS05.1-003, Signal Level Converter Encoder Emulation

Usage

Accessories

HAS05.1-003-NNN-NN

Usage

Adjusts voltage level at output of optional module MEM to voltage range 5-30 V

Tab. 20-11: Usage

Scope of Supply

Scope of Supply Order this accessory as a separate item. It is not part of the scope of supply of the device.

Parts of the accessory: See product insert

Dimensions

Fig. 20-83: Dimensions HAS05.1-003

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Parts

Bosch Rexroth AG 355/431

Accessories

1

2

3

Fig. 20-84:

Top shell of connector housing

Bottom shell of connector housing

Electronics circuit board with internal connection point

Parts

356/431 Bosch Rexroth AG

Accessories

Description

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Pin Assignment

Tab. 20-12:

Pin

4

5

6

1

2

3

Tab. 20-13:

Fig. 20-85:

X2

Accessory HAS05.1-003

Connection point Type No. of poles

Screw terminal block

6

Connection

Signal Function

UB

UL

UA2+

0Vext

UA1+

UA0+

Shield

Voltage supply for electronics

Voltage supply for output driver

Incremental encoder track A2

Reference potential

Incremental encoder track A1

Incremental encoder reference track A0

Connect cable shield to connector housing

Assignment

Stranded wire

[mm²]

0,14-1,5

If the required output voltage UL is greater than 7V, it can be used to supply the electronics (UB), too.

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 357/431

Accessories

Electrical Data

Data

Supply voltage UL

(output driver)

Supply current UL

(output driver)

Supply voltage UB

(electronics)

Supply current UB

(electronics)

Output voltage UA0+, UA1+, UA2+

Allowed output current per output

UA0+, UA1+, UA2+

Output resistance

Short circuit protection

Overload protection

Tab. 20-14: Supply and outputs

Unit

V mA

V mA

V mA

Min.

5

7

Typ.

16

17

Max.

30

30

UL

40 kOhm

Present

Present, output voltage is reduced

Example of Connection

SYS

Fig. 20-86:

Target, e.g. PLC; incremental input, counter or trigger function

Example of connection

358/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.6 HAS05.1-004, Adapter DC Bus Connection

Brief Description and Usage

Brief Description

Assignment

The accessory HAS05.1-004-NNR and HAS05.1-004-NNL is an adapter which allows connecting lines with cross sections of up to 2 × 50 mm² to the

DC bus connections.

It is typically used at the DC bus connections of high-performance supply units and inverters, when these devices have not been arranged directly side by side (e.g. with multiple-line arrangement or with decentralized supply con‐ cepts between several control cabinets).

The types "NNR" and "NNL" allow connections with outgoing directions to the right and left (view to front of drive controller).

The use of the HAS05.1-004 accessory is restricted by the width of the drive controllers:

● NNL: Device width is at least 125 mm

● NNR: Can be used independently of the device width

At devices with a width of 50 mm, the outgoing direction to the left can also be used with the type "NNR".

For devices up to a width of 125 mm and for the outgoing direction to the left, you can fix lines with a maximum cross section of 1 × 35 mm² (1 ring cable lug) without fixing device (01) and without bar (05) directly at the terminal block (see

picture 4

).

The accessory can be used at the following drive controllers:

Scope of Supply

Device

HMV01.1E-W0030, -W0075, -W0120

HMV01.1R-W0018, -W0065, -W0120

HMS01.1N: type current < W0110

HMS01.1N: type current ≥ W0110

HMD01.1N-W0012, -W0020, -W0036

HCS03.1E: type current ≥ W0070

HLB01.1D

HLC01.1D

-

-

-

■

NNL

HAS05.1-004-

NNR

-

■

■

■

■

■

■

■

■

■

■

■

Tab. 20-15: Assignment accessory HAS05.1-004

Order this accessory as a separate item. It is not part of the scope of supply of the device.

Parts of the accessory: See product insert

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Product Insert HAS05.1-004-NNR-NN

Bosch Rexroth AG 359/431

Accessories

Fig. 20-87: Product Insert HAS05.1-004-NNR-NN

360/431 Bosch Rexroth AG

Accessories

Product Insert HAS05.1-004-NNL

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-88: Product Insert HAS05.1-004-NNL-NN

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 361/431

Accessories

Technical Data

Allowed Cross Sections, Lengths

Mounting Dimensions

Connection, Mounting Dimensions

The accessory HAS05.1-004 is used to connect lines with ring cable lugs. At each connection point, it is allowed to use 1 or 2 lines of the same cross sec‐ tion.

Allowed connection cross sec‐ tion stranded wire;

1 ring cable lug mounted

Allowed connection cross sec‐ tion stranded wire;

2 ring cable lugs mounted

Maximum tightening torque

Minimum tightening torque

Allowed length, required lengths of lay etc.

Fusing

Unit mm²

AWG mm²

AWG

Nm

Nm

HAS05.1-004-

NNL

35

50

2

1/0

35

50

2

1/0

6,6

5,4

HAS05.1-004-

NNR

35

50

See Project Planning Manual

"Rexroth IndraDrive, Drive Sys‐ tem" → "Connections of the

Components in the Drive Sys‐ tem" → "Connection of the DC

Bus Connections"

Observe requirement on line protection!

See Project Planning Manual

"Rexroth IndraDrive, Drive Sys‐ tem" → "Connections of the

Components in the Drive Sys‐ tem" → "Connection of the DC

Bus Connections"

2

1/0

35

50

2

1/0

6,6

5,4

Tab. 20-16: Connection cross section HAS05.1-004

When mounted, the accessory requires the following mounting clearance to the left or to the right.

Fig. 20-89: Mounting dimensions HAS05.1-004-NNR, -NNL

362/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

Observe the minimum bending radiuses of the lines used. This re‐ quires additional mounting clearance, particularly on the left side.

Dimension

Mounting dimension B

Mounting dimension H

Mounting dimension T

Unit mm mm mm

HAS05.1-004-NNL HAS05.1-004-NNR

41 50

50

35

51

56

Tab. 20-17: Mounting dimensions HAS05.1-004

How to Mount HAS05.1-004

Cases to be Distinguished

Outgoing Direction of the Lines to the Right (HAS05.1-004-NNR)

● Outgoing direction of the lines to the right (HAS05.1-004-NNR)

● Outgoing direction of the lines to the left (HAS05.1-004-NNL)

● Outgoing direction of the lines to both sides (HAS05.1-004-NNR and

HAS05.1-004-NNL)

1.

Mount bar

Without DC bus contact bars (see

picture 1

):

Screw bar (5) and end piece (12) to terminal block (tightening torque:

6 Nm)

With DC bus contact bars (see

picture 2

):

Screw bar (5), DC bus contact bar (11) and connection piece (13) to ter‐ minal block (tightening torque: 6 Nm)

2.

Mount line:

(See

picture 1 and picture 2

)

Screw ring cable lug (10) to bar (5) (tightening torque: 6 Nm; with 2 ring cable lugs, observe inverse arrangement)

3.

Mount touch guard:

(See

picture 3 )

Mount touch guard of drive controller (tightening torque: max. 2.8 Nm)

Insert touch guard of bars (2) and touch guard cover (1) and screw them together (tightening torque: 1.6 Nm)

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Rexroth IndraDrive Additional Components and Accessories

Picture 1

Bosch Rexroth AG 363/431

Accessories

Fig. 20-90:

Picture 2

HAS05.1-004-NNR; outgoing direction of the lines to the right; with‐ out DC bus contact bars

Fig. 20-91:

364/431 Bosch Rexroth AG

Accessories

Picture 3

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Rexroth IndraDrive Additional Components and Accessories

Outgoing Direction of the Lines to the Left (HAS05.1-004-NNL)

Fig. 20-92: HAS05.1-004-NNR; mounting the touch guard

Make sure there is strain relief for the lines outgoing backward.

1.

Mount bar

Without DC bus contact bars (see

picture 4

):

Screw bar (05) and end piece (12) to terminal block (tightening torque:

6 Nm)

With DC bus contact bars (see

picture 5

):

Screw bar (05), DC bus contact bar (11) and connection piece (13) to terminal block (tightening torque: 6 Nm)

2.

Put fixing device (01) on bar (05)

3.

Screw cable holder (02) to left equipment grounding connection

4.

Mount line:

(See

picture 4 and picture 5

)

Screw ring cable lug (10) to bar (05) (tightening torque: 6 Nm; with 2 ring cable lugs, observe inverse arrangement)

Fix lines with cable tie to cable holder (02)

5.

Mount touch guard of drive controller (tightening torque: max. 2.8 Nm)

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Rexroth IndraDrive Additional Components and Accessories

Picture 4

Bosch Rexroth AG 365/431

Accessories

Fig. 20-93:

Picture 5

HAS05.1-004-NNL; outgoing direction of the lines to the left; without

DC bus contact bars

Fig. 20-94:

366/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

Outgoing Direction of the Lines to

Both Sides (HAS05.1-004-NNR and HAS05.1-004-NNL)

Beneath the touch guard, run the non-twisted lines in parallel.

Outside of the touch guard (after the strain relief), twist the line pairs.

In the case of four lines at the connections L+ and L-, twist L+ and

L- to form one pair.

Keep the surface between the individual lines of a pair as small as possible.

Run the line pairs with the smallest possible distance to each oth‐ er.

For mounting with outgoing direction to both sides, observe the descriptions

on " Outgoing Direction of the Lines to the Left (HAS05.1-004-NNL)

" and

" Outgoing Direction of the Lines to the Right (HAS05.1-004-NNR)

".

Fig. 20-95: Mounting HAS05.1-004-NNL and -NNR

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 367/431

Accessories

20.5.7 HAS05.1-005, Signal Level Converter RS232/RS485

Use

Accessories Use

HAS05.1-005-NNN-NN Converts serial interface of Rexroth IndraDrive control sections from RS232 standard to RS485 standard

Tab. 20-18: Use

Scope of Supply

Scope of Supply Order this accessory as a separate item. It is not part of the scope of supply of the device.

Parts of the accessory: See product insert

Fig. 20-96: Product Insert

368/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

Technical Data

Dimensions

Scope of Supply

● Converter

● Connector at X2 and X3

● Cable tie

● Product Insert

Electrical Data

Fig. 20-97: Dimensions

HAS05.1-005 can be mounted on a top-hat rail. For mounting it at a wall, remove the top-hat rail clip at the back of the housing.

You can also mount HAS05.1-005 on electrically insulating surfa‐ ces.

Feature

Number of nodes

Allowed cable length 1)

Unit m

Transmission rates 2)

Operation mode

Connection between X1 and X2, X3

Allowed voltage difference between the reference potentials of the drive controllers (housing) kBaud

V mA Current consumption at X1.1

Termination (TERM)

Short-circuit protection

Cable length at X1 m

Min.

9,6

Typ.

Semi-duplex 2-wire line

Galvanically connected

20

Max.

31

500

115

Switchable ON, OFF

50

Data+ against Data-

Data+, Data- against GND

5

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 369/431

Accessories

Position of Connections, Termina‐ tion

Feature

Cable length at X2, X3

Unit m

Min.

Typ.

Max.

Comply with bus length; see allowed cable length

Connections X2, X3

Connection cross section stranded wire

1)

2)

Tab. 20-19: mm 2

/AWG

Spring terminal

0.14-1.5 / 28-16; ferrule without insu‐ lating sleeve

Bus length RS485, corresponds to total length of all connected cables

Is set via firmware used

Technical Characteristics

Pin Assignment X1

Fig. 20-98:

Connec‐ tion

1

8

9

6

7

4

5

2

3

Tab. 20-20:

HAS05.1-005 with Connection Cables

Signal Function

V cc

RxD

TxD n. c.

GND n. c.

n. c.

RTS n. c.

Pin Assignment X1

Supply voltage (+5V)

Receive Data

Transmit Data n. c.

Reference potential n. c.

n. c.

Request to send n. c.

370/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

Installation

Pin Assignment X2

Pin Assignment X3

Connec‐ tion

1

2

3

Tab. 20-21:

Connec‐ tion

1

2

3

4

Tab. 20-22:

Signal Function

Data+

Data-

Data transmission +

Data transmission -

Shield Connection overall shield

Pin Assignment X2

Signal Function

Data+ Data transmission +

DataData transmission -

Shield Connection overall shield

GND Connection inner shield (signal shield)

Pin Assignment X3

General Information

Three connections connect the accessory HAS05.1-005 to form an RS485 bus:

● Connection X1 to serial interface X2 at control section

● Connection X2 to connection X3 at next HAS05

● Connection X2 to bus master (e.g. RS232/485 converter controlled by a

PC)

Terminate the RS485 bus line at the most remote bus ends.

To do this, switch on the termination at the bus master (converter at PC). At the last node, set the "TERM" switch to "ON".

See also Functional Description of firmware "Communication via RS485

Interface" and Parameter Description, e.g. "P-0-4050, Answer delay

RS-232/485"

Example of Connection

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 371/431

Accessories

Connection From X1 to Control

Section (X2)

Fig. 20-99: Example of Connection

Connect PC and RS485 bus to a so-called bus master converter; this RS232/485 converter automatically generates the RTS con‐ trol signal.

The accessory HAS05.1-005 does not accomplish this function!

Connection at X1

Fig. 20-100: Connection Cable RKB0010

For direct connection from X1 to the control section, use our cable

RKB0010 and observe its maximum allowed length (see

"Electri‐ cal Data" on page 368

).

Connection at X2 and X3

Connect X2 and X3 with a cable according to the interconnection diagram be‐ low.

372/431 Bosch Rexroth AG

Accessories

Connection Between X2 and X3

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Rexroth IndraDrive Additional Components and Accessories

Strain Relief at Connection X2 and

X3

Fig. 20-101: Connection Cable at X2 and X3

To assemble connection cables at X2 and X3, use our bulk cable

INK0572.

Fig. 20-102: Strain Relief at Connection X2 and X3

Provide sufficient strain relief for the connections at X2 and X3!

Use the supplied cable ties.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 373/431

Accessories

20.5.8 HAS05.1-006, Adapter for Controlling Motor Holding Brake

Use

Assignment

Function

Scope of Supply

Identification, Parts

The accessory HAS05.1-006 can be used at the following drive controllers:

● HMS02.1N-W0028

● HMS02.1N-W0054

The accessory HAS05.1-006 switches the power supply of the motor holding brake (connection point X6, motor temperature monitoring and motor holding brake) and has a feedback contact to the switching action.

Connector at X44

(Connector at X6 is not part of the scope of supply. Use the connector of the power section.)

The accessory has a type plate for identification.

Technical Data

1

2

3

Fig. 20-103:

Type plate

Connector at connection point X44

HAS05.1-006

HAS05.1-006 at Connection Point X6 at Drive Controller

Mounting Dimensions

The accessory requires the following mounting clearance at the drive control‐ ler.

374/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

Fig. 20-104:

Data in mm

Mounting Dimensions

Observe the minimum bending radiuses of the lines used. This re‐ quires additional mounting clearance at the drive controller, par‐ ticularly downward.

View

Spring terminal (connector)

Connection cross section solid wire

Connection cross section stranded wire

Connection Points

X6

The connection point is described in the Project Planning Manual

"Rexroth IndraDrive Supply Units and Power Sections" → "Functions and

Electrical Connection Points" → "X6, Motor Temperature Monitoring and Mo‐ tor Holding Brake".

X44

Connec‐ tion

X44.6

X44.5

X44.4

X44.3

X44.2

X44.1

Signal name nc_Rel nc_Rel

0V

+24V

Function

Relay contact "N/C"

Relay control

Unit mm 2 mm 2

Min.

0,14

0,14

Max.

1,5

1,5

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 375/431

Accessories

Connection cross section

Electrical data

Supply d1 (X44.1/2, X44.3/4)

Switching capacity K1 (X44.5, X44.6)

Switching capacity K2 (X6.3, X6.4)

Minimum load of the contacts

Contact resistance at minimum current

Pick up delay

Drop out delay

Time constant of load

Number of switching actions at maximum time constant of load

Number of mechanical switching cycles

Short circuit protection

Overload protection

Tab. 20-23:

AWG 28 16 mA

Ω ms ms

V mA

A

V ms

10

19,2

ohmic

30

30

1

28,8

50

2

28,8

1 × 10 6

1 × 10 6

See description of the connection point "X6, Motor Tempera‐ ture Monitoring and Motor Holding Brake" in the Project

Planning Manual "Rexroth IndraDrive Supply Units and Pow‐ er Sections"

Function, Pin Assignment

Application

Block Diagram

D1

D2 d1

K1

K2

Fig. 20-105:

Free-wheeling diode

Polarity reversal protection diode

Relay

N/C contact

N/O contact

Block Diagram

376/431 Bosch Rexroth AG

Accessories

Example of Use

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Rexroth IndraDrive Additional Components and Accessories

Mounting

1)

2)

Fig. 20-106:

Safety door monitor

Safety door contacts

Example of Connection

Mount HAS05.1-006

1. Plug HAS05.1-006 in connection point X6 at drive controller

Make sure that HAS05.1-006 snaps in at X6 at the drive control‐ ler.

2. Plug connectors X6 and X44 in HAS05.1-006

Make sure there is sufficient strain relief for the connectors.

Dismount HAS05.1-006

1. Remove connection cable from HAS05.1-006

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 377/431

Accessories

2. Loosen snap-in connection with screwdriver and remove HAS05.1-006 from drive controller

378/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.9 HAS05.1-007, Adapter From D-Sub to Terminal Connector

Use

The adapter HAS05.1-007 exists in the following types of design:

● NNL: Mounting direction left (outgoing direction spring terminal left)

● NNR: Mounting direction right (outgoing direction spring terminal right)

HAS05.1-007-

NNL NNR

Assignment

Tab. 20-24: Types of Design

The accessory HAS05.1-007 can be used at the following control sections:

HAS05.1-007-NNL

CSH01.1C at X41

(Condition: Option 3 not equipped)

HAS05.1-007-NNR

CSH01.1C at X41

CDB01.1C at X41.1 (option ST1)

CSH01.2C at X41

CSH01.3C at X41

CDB01.1C at X41.2 (option ST2)

Tab. 20-25: Assignment HAS05.1-007

At CDB01 control sections, you can use both types of design together. How‐ ever, there is the following restriction:

When using the type of design NNL at HMD01.1N-W0012 or HMD01.1N-

W0020 drive controllers of a width of 50 mm, you cannot use the adapter of type of design NNR at the neighboring control section on the left-hand side.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 379/431

Accessories

Function

Identification, Parts

Fig. 20-107:

Universal adapter for safety technology

Usage:

1.

Converter of D-Sub connection to terminal connection for an axis

2.

Connection of additional component

HAT01

to the optional module S1 or S2

3.

Converter of D-Sub connection to terminal connection for bus connec‐ tion of optional modules S1 or S2 of the axes of one zone (see figure

"Wiring Example With HAS05.1-007-NNR" on page 383

)

The accessory has a type plate for identification.

380/431 Bosch Rexroth AG

Accessories

HAS05.1-007-NNL

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Rexroth IndraDrive Additional Components and Accessories

1

2

3

Fig. 20-108:

Adapter

Connector (spring terminal)

Type plate

HAS05.1-007-NNL

HAS05.1-007-NNR

Technical Data

1

2

3

Fig. 20-109:

Adapter

Connector (spring terminal)

Type plate

HAS05.1-007-NNR

The adapter is plugged in the connection point X41 (resp. X41.1 or X41.2 for double-axis devices) of the control section and secured with screws (screw tightening torque: 0.5 Nm).

Mounting Dimensions

The accessory requires the following mounting clearance at the drive control‐ ler.

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Rexroth IndraDrive Additional Components and Accessories

HAS05.1-007-NNL

Bosch Rexroth AG 381/431

Accessories

Fig. 20-110:

Data in mm

Mounting Dimensions HAS05.1-007-NNL

HAS05.1-007-NNR

Fig. 20-111:

Data in mm

Mounting Dimensions HAS05.1-007-NNR

Observe the minimum bending radiuses of the lines used. This re‐ quires additional mounting clearance at the front of the drive con‐ troller.

382/431 Bosch Rexroth AG

Accessories

View

Connection Point X41

HAS05.1-007-NNL

Spring terminal / D-Sub female connector

Connec‐ tion (termi‐ nal)

1

4

5

2

3

8

9

6

7

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Rexroth IndraDrive Additional Components and Accessories

Signal name

X41.1

X41.2

X41.3

X41.4

X41.5

X41.6

X41.7

X41.8

X41.9

Function

The adapter brings the con‐ nections of X41 to the con‐ nections 1-9 of a spring ter‐ minal and a D-Sub female connector.

Description of connection point X41: See Project Plan‐ ning Manual "Rexroth

IndraDrive Control Sections", section "Optional Modules for

Control Sections, Safety

Technology".

HAS05.1-007-NNR

D-Sub female connector / spring terminal

Spring terminal (connector)

Cable cross section stranded wire

Cable cross section

Coding

Unit mm 2

Min.

0,5

Max.

1,5

AWG 20 16

At both types of design, the connection point 5 has been coded, i.e. pro‐ vided with a coding section. The spring terminal was already assembled accordingly at the factory.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 383/431

Accessories

●

●

Electrical Data

Mating connector for D-Sub female con‐ nector

Ribbon cable

Tab. 20-26:

Description of connection point X41: See Project Planning Manual

"Rexroth IndraDrive Control Sections", section "Optional Modules for

Control Sections, Safety Technology".

●

●

●

RBS0017/S05 → D-Sub connector, 9-pin

(Screw tightening torque: 0.5 Nm)

● REB0401 → Ribbon cable, 9-pin, can be ordered in steps of 0.1 m

For professional assembly of the ribbon cable in the D-Sub connector, use the following Tyco tools:

Pistol-Grip tool (part number 734155-1)

Matrix for D-Sub connector (part number 734148-1)

Function, Pin Assignment

Wiring Example With

HAS05.1-007-NNR

Fig. 20-112: HAS05.1-007-NNL and HAS05.1-007-NNR at CDB Control Section

HAS05.1-007-NNR is the preferred adapter for the bus connection of several optional modules S1 or S2.

384/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

RBS0017/S05 D-Sub connector with connection for ribbon cable

REB0401

Fig. 20-113:

Ribbon cable

HAS05.1-007-NNR

At CSH01.1C control sections, the adapter HAS05.1-007-NNL can only be used at the left end of the bus connection, when option 3 has not been equip‐ ped.

Fig. 20-114: HAS05.1-007-NNR, RBS0017/S05 and REB0401 for Bus Connec‐ tion of Optional Modules S1 or S2 of the Axes of One Zone

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 385/431

Accessories

20.5.10 HAS05.1-008, Adapter for Connecting two Cables

Usage

Assignment

Function

Scope of Supply

The accessory HAS05.1-008 can be used at the following drive controllers:

● HCS03.1E-W0100…0210

● HMS01.1N-W0150…0210

With the accessory HAS05.1-008, you can connect two 16 mm tion), each at A1, A2 and A3.

2 cables with ring cable lugs at the mentioned devices at terminal block X5 (motor connec‐

The accessory contains:

● 3 × adapter

● 3 × screw M6 × 25

386/431 Bosch Rexroth AG

Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Fig. 20-115: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Mounting

Bosch Rexroth AG 387/431

Accessories

B - B

Fig. 20-116:

Transverse profile of connection

HAS05.1-008 at an X5 connection point

1. Screw adapter to connection point with supplied screw.

2. Connect cable as shown and screw it on.

3. Repeat steps 1 and 2 for each connection point.

388/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.11 HAS05.1-009, Coding Pin for Terminal Connector RHS

Terminal connectors RHS are used at distributed servo drives KSM and dis‐ tributed drive controllers KMS at the conection point X3.1 or X3.2. Coding pins prevent a terminal connector, which has not been coded accordingly, from being accidentally plugged on.

A

Fig. 20-117:

Coding pins

Coding Pins at X3.1 and X3.2

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 389/431

Accessories

20.5.12 HAS05.1-010, Brake Current Monitoring

Use

Assignment The accessory HAS05.1-010 can be used at the following drive controllers:

Tab. 20-27:

HCS02.1E-…

W0012

W0028

W0054

W0070

Assignment Accessories ↔ Drive Controller

HMS01.1N-…

W0020

W0036

W0054

W0070

Function

Scope of Supply

Fig. 20-118: HAS05.1-010 at an HCS02 Drive Controller

The accessory HAS05.1-010 monitors motor holding brakes.

These values are monitored:

● Maximum value of brake current (2.5 A; short circuit monitoring)

● Minimum value of brake current (0.15 A; wire break monitoring)

● Minimum value of brake voltage (20 V; output HAS05.1-010)

Order this accessory as a separate item. It is not part of the scope of supply of the device.

Parts of the accessory: See product insert

390/431 Bosch Rexroth AG

Accessories

Product Insert HAS05.1-010-NNN-NN

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Rexroth IndraDrive Additional Components and Accessories

Fig. 20-119: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Product Insert HAS05.1-010-NHN-NN

Bosch Rexroth AG 391/431

Accessories

Fig. 20-120: Product Insert

392/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

Identification, Parts The accessory has a type plate for identification.

Technical Data

1

2

3

4

Fig. 20-121:

Type plate

Connector at connection point X46 (part of the accessories)

Connector at connection point X6_Controller (part of the en‐ closed adapter cable)

Connector at connection point X6_Motor (part of the motor ca‐ ble)

HAS05.1-010 with Connectors

Mounting Dimensions

When HAS05.1-010 is mounted, it is not possible to mount

HAS02 (strain relief and shield connection for motor cable) at the drive controller.

Observe the minimum bending radiuses of the lines used. This re‐ quires additional mounting clearance at the drive controller, par‐ ticularly downward.

The accessory requires the following mounting clearance at the drive control‐ ler.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 393/431

Accessories

View

Spring terminal (connector)

Connection cable solid wire

Connection cable stranded wire

Short circuit protection

Overload protection

Fig. 20-122:

Data in mm

Mounting Dimensions

Connection Points

X6_Controller, X6_Motor

Signal name Connec‐ tion

1

2

3

4

MotTemp+

MotTemp-

+24V

0V

Function

Input motor temperature evaluation

Output for controlling the mo‐ tor holding brake

Tab. 20-28:

Unit mm 2 mm 2

AWG

Function, Pin Assignment

Min.

0,5

Max.

1,5

0,5

20

X6_Motor: Available

X6_Controller: Not available

1,5

16

394/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

View

X46, Brake Check

Connec‐ tion

X46.1

X46.2

Signal name

+24V

High ↔ Low

Function

Power supply

Diagnostic output:

●

●

Signal level "high":

Brake current and brake voltage are okay

Signal level "low":

Brake current and brake voltage are not okay

Spring terminal (connector)

Connection cross section solid wire

Connection cross section stranded wire

Connection cross section

Electrical data

Signal level "high"

Signal level "low"

Short circuit protection

Overload protection

Tab. 20-29:

Mounting and Installation

Unit mm 2 mm 2

AWG

Min.

0,5

0,5

20

Max.

1,5

1,5

16

Function, Pin Assignment

≥ 15 V

Max. 10 mA

Output gets highly resistive

Available

Mounting

When HAS05.1-010 is mounted, it is not possible to mount

HAS02 (strain relief and shield connection for motor cable) at the drive controller.

HAS05.1-010 is mounted to the the bottom of the drive controller.

NOTICE Risk of damage to the drive controller by too long screws!

Exclusively use screws of a maximum length of 12 mm for the thread of shield connection XS2.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 395/431

Accessories

1

2

Fig. 20-123:

Mounting screw of drive controller

Mounting screw of accessories

Mounting HAS05.1-010

Mount HAS05.1-010

1. Unscrew bottom or bottom left mounting screw (1) of drive controller.

2. Put HAS05.1-010 to bottom of drive controller and screw down mount‐ ing screw (1) at drive controller again.

3. Screw mounting screw (2) of accessories (M6 × 12) in thread XS2 at bottom of drive controller.

396/431 Bosch Rexroth AG

Accessories

Installation

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Rexroth IndraDrive Additional Components and Accessories

X*

X*.*

+24V

Fig. 20-124:

Interface with digital inputs at CSB or CSH control section

Unassigned digital input of interface X*

24 V power supply for diagnostic output X46.2 of brake current monitoring and for digital I/Os of interface X*

Example of Connection

Wire HAS05.1-010

1. Connect control voltage supply (+24V) to X46.1. When doing this, run control voltage supply in parallel to power supply of digital I/Os of control section.

2. Connect motor cable to connection point X6_Motor.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 397/431

Accessories

3. With enclosed adapter cable, connect connection point X6_Controller to

X6 (drive controller).

4. Connect X46.2 to an unassigned digital input at control section. (Via pa‐ rameters "P-0-0300" and "P-0-0301", drive signal is assigned to digital input.)

Signal Evaluation

Motor holding brake

Release

Apply

Signal Evaluation at Diagnostic Output X46.2

Diagnostic output X46.2

When the releasing of the motor holding brake starts, incorrect diagnostic messages are sometimes output at the diagnostic output X46.2.

Before evaluating the diagnostic output X46.2, wait until the delay of the motor hold‐ ing brake (S-0-0206) has passed.

After the delay has passed: X46.2 → "high" (provided that no short circuit and no cur‐ rent interruption are present).

When drive enable (AF = Antriebsfreigabe) is set by the control unit, the releasing of the motor holding brake is triggered. The motor holding brake is released with a de‐ lay, due to the inductance of the winding and the motor line. The drive controller is informed on this delay via the parameter "S-0-0206, Drive on delay time". The content of this parameter is automatically set für Rexroth motors with feedback data memory.

For other motors, you must parameterize this parameter in accordance with the spec‐ ification of the motor holding brake used.

See also Functional Description of firmware → Operating Behavior of the Motor Hold‐ ing Brake

When the applying of the motor holding brake ends, incorrect diagnostic messages are sometimes output at the diagnostic output X46.2.

Before evaluating the diagnostic output X46.2, wait until the delay of the motor hold‐ ing brake (S-0-0207) has passed.

When the current has fallen below 0.15 A: X46.2 → "low"

When drive enable (AF) is reset, the applying of the motor holding brake is triggered.

The motor holding brake is applied with a delay, due to the inductance of the winding and the motor line. The drive controller is informed on this delay via "S-0-0207, Drive off delay time". The content of this parameter is automatically set für Rexroth motors with feedback data memory. For other motors, you must parameterize this parameter in accordance with the specification of the motor holding brake used.

See also Functional Description of firmware → Operating Behavior of the Motor Hold‐ ing Brake

398/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

Motor holding brake Diagnostic output X46.2

Short circuit at output "X6_Motor" The short circuit (I ≥ 2.5 A) is detected: X46.2 → "low"

The drive controller or HAS05.1-010 (thermal overcurrent protection) interrupts the power supply of the motor holding brake (+24VBr).

Current interruption at output

"X6_Motor"

The current interruption (I ≤ 0.15 A; e.g. in the case of wire break) is detected:

X46.2 → "low"

Tab. 20-30: Signal Evaluation at Diagnostic Output X46.2

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 399/431

Accessories

20.5.13 HAS05.1-014, Mounting Plate for Safety Zone Module

Use

Mounting

As a standard, the safety zone module HSZ01 is equipped to be mounted on a top-hat rail.

The accessories HAS05.1-014-NNN-NN (material number: R911340518) al‐ low mounting the safety zone module HSZ01 without a top-hat rail.

1.

Remove top-hat rail terminal connectors at the back of safety zone mod‐ ule HSZ01.

2.

With supplied screws (M4), screw plate from accessories to back of safety zone module HSZ01 (tightening torque: 1.4 Nm).

3.

With supplied screws (M6), mount safety zone module HSZ01 vertically in control cabinet (tightening torque: 6 Nm).

When mounting the safety zone module HSZ01, observe the minimum distances to be complied with.

400/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

Fig. 20-125: Product Insert

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 401/431

Accessories

20.5.14 Snap-on ferrite (HAS05.1-015)

Use The accessory HAS05.1-015-NNN-NN (snap-on ferrite) ensures that

Class C3 of the EMC Directive EN 61800-3 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

Product insert

Fig. 20-126: Product insert

402/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

Mounting ● Before mounting the snap-on ferrite, store it for at least 1 hour at a tem‐ perature of 15 … 25 °C.

● When mounting the snap-on ferrite, avoid putting it under mechanical stress. The housing or the ferrite core might brake.

● Do not mount the snap-on ferrite in the immediate vicinity of strong 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. 20-127: Snap-on ferrite at connection line of external braking resistor

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Rexroth IndraDrive Additional Components and Accessories

To open the snap-on ferrite, use the proper tool:

Bosch Rexroth AG 403/431

Accessories

Fig. 20-128: Opening the snap-on ferrite

404/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.15 HAS05.1-016, brake module with connectors

The brake module of the HAS05.1-016 accessories corresponds to the brake module of the HAS05.1-006 accessories.

1

2

3

Fig. 20-129:

Connector

Connector

Connector

HAS05.1-016, brake module with connectors

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 405/431

Accessories

20.5.16 HAS05.1-017, X6 adapter

See

chapter 17.8 "X6 adapter (RKL0091, RKL0092)" on page 239 .

406/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.17 HAS05.1-018, dummy plate for KMS03 encoder connection

Fig. 20-130: HAS05.1-018, dummy plate for KMS03 encoder connection

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Rexroth IndraDrive Additional Components and Accessories

20.5.18 HAS05.1-019, KNK03 mains voltage

Bosch Rexroth AG 407/431

Accessories

Fig. 20-131: HAS05.1-019, KNK03 mains voltage

The accessory contains the following parts:

● Cable gland (plastic, M20, range: 6 … 12 mm)

● Plate incl. screws

● Connector (screw terminal)

● Coding pin

408/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

20.5.19 HAS05.1-020, KMV03 control voltage

Fig. 20-132: HAS05.1-020, KMV03 control voltage

The accessory contains the following parts:

● Cable gland (plastic, M20, range: 6 … 12 mm)

● Plate incl. screws

● Connector (screw terminal)

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 409/431

Accessories

20.6 HAS10, mechanical mounting parts

20.6.1 Type code

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: H A S 1 0 . 1 - 0 0 1 - 0 0 2 - N N

① ② ③ ④ ⑤ ⑥

①

②

③

④

Product:

HAS = IndraDrive accessories

Series:

10 = Mechanical mounting parts

Design:

1 = 1

Device assignment 1) :

001 = KSM01.2, KSM02.1 KMS01.2 and KMS02.1

002 = HMU05.1 and HCS05.1

⑤

⑥

Other properties 2) :

001 = Fixing clip of connectors for increased vibration resistance

002 = Fixing clip of connectors and master communication for increased vibration resistance

003 = Dummy cover for slide-in ducts: 1 × parallel module / 1 × motor mains module / 1 × control section

004 = Motor monitor grounding

005 = Mounting plate for device width 200 mm

006 = Mounting plate for device width 220 mm

Other design:

NN = None

Tab. 20-31: HAS10, type code

20.6.2 Use

Use

HAS10

HAS10.1-001-001-NN

HAS10.1-001-002-NN

HAS10.1-001-003 … 006-NN

Use

Fixing clip for hybrid cables at devices without op‐ tion TO, ES …

Fixing clip for hybrid cables at devices with op‐ tion TO, ES …

Mechanical mounting parts for HMU05 universal inverters.

Further information: See HMU05 Project Planning

Manual.

Tab. 20-32: HAS10

410/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

Restricted Usage of the Accessory:

The accessory cannot be used at hybrid cables with a vertical outgoing direction of the cable from the connec‐ tor.

HAS10.1-001-001-NN The accessory HAS10.1-001-001-NN consists of a fixing clip with a screw.

The fixing clip is screwed to a KSM or KMS and increases the vibration re‐ sistance of the connected hybrid cable connectors.

HAS10.1-001-002-NN

Fig. 20-133: HAS10.1-001-001-NN

The HAS10.1-001-002-NN accessory consists of the following parts:

● Fixing clip with screw (tightening torque: 1.5 … 1.7 Nm)

● RKB0043 cable

● Cable tie

The fixing clip increases the vibration resistance of the connected hybrid ca‐ ble connectors. The RKB0043 cable is fixed to the fixing clip with 2 cable ties.

Fig. 20-134:

20.6.3 Scope of supply

Scope of supply

HAS10.1-001-002-NN

Components of the accessory: see product insert

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Rexroth IndraDrive Additional Components and Accessories

Product insert HAS10.1-001-001-NN

Bosch Rexroth AG 411/431

Accessories

Fig. 20-135: Product insert HAS10.1-001-001-NN

412/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

Product insert HAS10.1-001-002-NN

Fig. 20-136: Product insert HAS10.1-001-002-NN

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Rexroth IndraDrive Additional Components and Accessories

20.7 Fiber Optic Cable Connections

20.7.1 Overview of Types

Bosch Rexroth AG 413/431

Accessories

1

2

3

Fig. 20-137:

Fiber optic cable connections outside of control cabinet

Control cabinet duct

Fiber optic cable connections inside of control cabinet

Fiber Optic Cable Connections

Point of installation Description Type designation

Outside of control cabinet

At control cabinet

Inside of control cabi‐ net

Robust fiber optic cable connections from peripherals to control cabinet

Control cabinet duct with plug-in con‐ nectors

Fiber optic cable connections to and between drive controllers

RKO0101

INS0610

RKO0100

Tab. 20-33: Fiber Optic Cable Connection Elements

For ordering the fiber optic cable connection, you have to gener‐ ate the complete order code containing details on type and length.

For the type designation see the above table and add the re‐ quired length to it.

Determine the length by means of the list of different device ar‐ rangements.

Example of order code for arrangement HCS02 (left 105 mm) next to HCS02

(right 65 mm):

● Required length: 0.25 m

414/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

● Type designation: RKO0100

● Order code: RKO0100 / 0,25

20.7.2 Interconnection of Drive Controllers

General Information

For selecting the fiber optic cable connection of drive controllers, take differ‐ ent possible combinations and different device widths into account.

Combination of HCS02 and HCS02

Fig. 20-138: HCS02 with HCS02

For fiber optic cables from CSB01.1N-SE control sections to other control section types, take fiber optic cables which are 0.05 m lon‐ ger (at the devices, SERCOS connections are at different heights and sides).

Observe the routing guidelines and technical data (e.g. allowed bending radiuses) contained in documentation "Rexroth Connec‐ tion Cables", DOK-CONNEC-CABLE*LWL**-AW**-**-*.

Width left HCS02 [mm]

Required fiber optic cable length [m]

Width right HCS02 [mm]

65

105

65

0,15

0,25

Tab. 20-34: Fiber Optic Cable Lengths

105

0,15

0,25

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Rexroth IndraDrive Additional Components and Accessories

Combination of HCS02 to the Right of HMS or HMD

Bosch Rexroth AG 415/431

Accessories

Fig. 20-139: HCS02 to the Right of HMS or HMD

Independent of the width of the devices, cable length is 0.15 m.

Combination of HCS02 to the Left of HMS or HMD

Fig. 20-140: HCS02 to the Left of HMS or HMD

For fiber optic cables from CSB01.1N-SE control sections to other control section types, take fiber optic cables which are 0.05 m lon‐ ger (at the devices, SERCOS connections are at different heights and sides).

Observe the routing guidelines and technical data (e.g. allowed bending radiuses) contained in documentation "Rexroth Connec‐ tion Cables", DOK-CONNEC-CABLE*LWL**-AW**-**-*.

Cable length = width HCS02 + width HMS/HMD + 10 cm

Width HCS02 [mm]

Required fiber optic cable length [m]

Width HMS / HMD [mm]

50 75 100 125

416/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Accessories

65

105

Required fiber optic cable length [m]

0,25

0,25

0,25

0,30

--

0,30

Tab. 20-35: Fiber Optic Cable Lengths

Combination of HCS03 to the Right of HMS or HMD

--

0,30

Fig. 20-141: HCS03 to the Right of HMS or HMD

Combination of HCS03 to the Left of HMS or HMD

Fig. 20-142: HCS03 to the Left of HMS or HMD

For fiber optic cables from CSB01.1N-SE control sections to other control section types, take fiber optic cables which are 0.05 m lon‐ ger (at the devices, SERCOS connections are at different heights and sides).

Observe the routing guidelines and technical data (e.g. allowed bending radiuses) contained in documentation "Rexroth Connec‐ tion Cables", DOK-CONNEC-CABLE*LWL**-AW**-**-*.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 417/431

Accessories

Required fiber optic cable length [m]

Width left de‐ vice [mm]

50

75

100

125

150

200

225

350

Tab. 20-36:

Width right device [mm]

50

0,15

0,15

0,15

0,15

0,15

0,15

0,15

0,15

75

0,25

0,25

0,25

0,25

0,25

0,25

0,25

0,25

Fiber Optic Cable Lengths

100

0,25

0,25

0,25

0,25

0,25

0,25

0,25

0,25

125

0,25

0,25

0,25

0,25

0,25

0,25

0,25

0,25

150

0,30

0,30

0,30

0,30

0,30

0,30

0,30

0,30

200

0,50

0,50

0,50

0,50

0,50

0,50

0,50

0,50

225 350

0,50 0,50

0,50 0,50

0,50 0,50

0,50 0,50

0,50 0,50

0,50 0,50

0,50 0,50

0,50 0,50

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Rexroth IndraDrive Additional Components and Accessories

Accessories

20.8 RKB0001, Extension for Module Bus Connections

20.8.1 Use

Assignment The extension RKB0001 can be used at:

● HMV01.1E

● HMV01.1R

● HMS01.1N

● HMD01.1N

● HMV02.1R

● HMS02.1N

● HCS03.1E-W0070, -W0100, -W0150, -W0210

Function

Lengths That Can Be Ordered, Or‐ der Code

The extension RKB0001 cannot be mounted at HCS02 drive con‐ trollers.

With the accessory RKB0001 you can extend the module bus connection be‐ tween devices, when the distance between the drive controllers is greater than 5 mm, e.g. for multiple-line arrangement.

Lengths: 0.5 m to 40 m (in steps of 0.5 m)

Parts:

● Housing with hinged cover

● Cable with strain relief mounted at both ends

Indicate the complete order code for your order.

Example:

● Required length: 2.5 m

● Type designation: RKB0001

● Order code: RKB0001 / 02,5

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Rexroth IndraDrive Additional Components and Accessories

20.8.2 Mounting

Bosch Rexroth AG 419/431

Accessories

Fig. 20-143: Dimensions RKB0001

420/431 Bosch Rexroth AG

Accessories

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Rexroth IndraDrive Additional Components and Accessories

Fig. 20-144: Extension of Module Bus

Mounting the RKB0001 Bus Cable

1. Mount housing to point of connection for equipment grounding conduc‐ tor.

2. Open cover and plug ribbon cable of right device into circuit board.

3. Close cover.

4. Screw strain relief down to point of connection for equipment grounding conductor.

5. Plug ribbon cable into X1.

Make sure the connection between strain relief and point of con‐ nection for equipment grounding conductor is well conductive.

By means of appropriate wiring, establish equipment grounding connections of devices that are not directly adjoining.

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Rexroth IndraDrive Additional Components and Accessories

Bosch Rexroth AG 421/431

Environmental protection and disposal

21 Environmental protection and disposal

21.1 Environmental protection

Production processes

No release of hazardous substan‐ ces

Significant components

The products are made with energy- and resource-optimized production pro‐ cesses which allow re-using and recycling the resulting waste. We regularly try to replace pollutant-loaded raw materials and supplies by more environ‐ ment-friendly alternatives.

Our products do not contain any hazardous substances which may be re‐ leased in the case of appropriate use. Normally, our products will not have any negativ influences on the environment.

Basically, our products contain the following components:

Electronic devices

∙ steel

∙ aluminum

∙ copper

∙ synthetic materials

∙ electronic components and modules

Motors

∙ steel

∙ aluminum

∙ copper

∙ brass

∙ magnetic materials

∙ electronic components and modules

21.2 Disposal

Return of products

Packaging

Batteries and accumulators

Our products can be returned to our premises free of charge for disposal. It is a precondition, however, that the products are free of oil, grease or other dirt.

Furthermore, the products returned for disposal must not contain any undue foreign material or foreign components.

Send the products ”free domicile” to the following address:

Bosch Rexroth AG

Electric Drives and Controls

Buergermeister-Dr.-Nebel-Strasse 2

97816 Lohr am Main, Germany

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 can be labeled with this symbol.

Recycling

The symbol indicating "separate collection" for all batteries and accu‐ mulators is the crossed-out wheeled bin.

The end user within the EU is legally obligated to return used batteries. Out‐ side the validity of the EU Directive 2006/66/EC keep the stipulated direc‐ tives.

Used batteries can contain hazardous substances, which can harm the envi‐ ronment or the people´s health when they are improper stored or disposed of.

After use, the batteries or accumulators contained in Rexroth products have to be properly disposed of according to the country-specific collection.

Most of the products can be recycled due to their high content of metal. In order to recycle the metal in the best possible way, the products must be dis‐ assembled into individual modules.

422/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Environmental protection and disposal

Metals contained in electric and electronic modules can also be recycled by means of special separation processes.

Products made 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.

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Rexroth IndraDrive Additional Components and Accessories

22

Bosch Rexroth AG 423/431

Service and support

Service and support

Service Germany

Our worldwide service network provides an optimized and efficient support.

Our experts offer you advice and assistance should you have any queries.

You can contact us 24/7.

Our technology-oriented Competence Center in Lohr, Germany, is responsi‐ ble for all your service-related queries for electric drive and controls.

Contact the Service Hotline and Service Helpdesk under:

Phone: +49 9352 40 5060

Fax: +49 9352 18 4941

E-mail: [email protected]

Internet: http://www.boschrexroth.com

Service worldwide

Preparing information

Additional information on service, repair (e.g. delivery addresses) and training can be found on our internet sites.

Outside Germany, please contact your local service office first. For hotline numbers, refer to the sales office addresses on the internet.

To be able to help you more quickly and efficiently, please have the following information ready:

● Detailed description of malfunction and circumstances

● Type plate specifications of the affected products, in particular type co‐ des and serial numbers

● Your contact data (phone and fax number as well as your e-mail ad‐ dress)

424/431 Bosch Rexroth AG DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Index

0 … 9

24V supply

Specification................................................... 47

A

Acceptance tests................................................. 39

Accessories

Brake current monitoring.............................. 389

Brake module with connectors,

HAS05.1-016-NNN-NN................................ 404

Coding pin for terminal connector RHS....... 388

Connection of two cables, adapter............... 385

Control of motor holding brake, adapter...... 373

D-Sub to terminal connector, adapter.......... 378

Dummy plate for KMS03 encoder con‐

nection, HAS05.1-018-NNN-NN.................. 406

For drive systems Rexroth IndraDrive......... 263

HAS01, basic accessories........................... 263

HAS03, control cabinet adapter................... 331

HAS04, capacitor......................................... 335

HAS05, accessories for connection

points........................................................... 344

HAS05.1-001, adapter for mains and mo‐

tor connection.............................................. 348

HAS05.1-002, extension (connection

HNK01 to HCS03+HMF01).......................... 352

HAS05.1-003, signal level converter en‐

coder emulation........................................... 354

HAS05.1-004, adapter DC bus connec‐

tion............................................................... 358

HAS05.1-005, signal level converter

RS232/RS485.............................................. 367

HAS05.1-006, Adapter for controlling mo‐

tor holding brake.......................................... 373

HAS05.1-007, adapter from D-Sub to ter‐

minal connector............................................ 378

HAS05.1-008, adapter for connecting two

cables........................................................... 385

HAS05.1-009............................................... 388

HAS05.1-010............................................... 389

HAS05.1-014-NNN-NN................................ 399

HAS10.......................................................... 409

KMV03 control voltage, HAS05.1-020-

NNN-NN....................................................... 408

KNK03 mains voltage, HAS05.1-019-NNN-

NN................................................................ 407

Mechanical mounting parts (HAS10)........... 409

Snap-on ferrite, HAS05.1-015-NNN-NN...... 401

Accessory

HAS02, shield connection............................ 297

Accumulators.................................................... 421

Adapter

DC bus connection....................................... 358

Mains and motor connection........................ 348

Additional documentations.................................. 12

Bosch Rexroth AG 425/431

Index

Ambient conditions.............................................. 42

Applications

Drive system Rexroth IndraDrive................... 29

Appropriate use................................................... 17

Applications.................................................... 17

Approvals............................................................ 39

Autotransformers................................................ 50

B

Bar

HAS01, use.................................................. 264

Batteries............................................................ 421

Brake chopper

HLT01.......................................................... 177

Brake current monitoring

Accessories HAS05.1-010........................... 389

Brake module with connectors

HAS05.1-016-NNN-NN................................ 404

Braking function................................................ 179

Braking resistor................................................. 179

Braking resistor HLR01

Brief description..................................... 34, 151

See "HLR01"................................................ 151

Braking unit....................................................... 179

HLT01.......................................................... 177

Braking unit HLT01.1A...................................... 179

Braking unit HLT01.1A -200.............................. 180

Braking unit HLT01.1A -400K........................... 186

Bus cable

Extension (RKB0001).................................. 418

Bus master........................................................ 370

C

C-UL-US listing................................................... 39

C-UR-US listing................................................... 40

Cable

IKB0041....................................................... 144

Cables

Documentation............................................... 13

INK0572....................................................... 372

RKB0010...................................................... 371

RKB0051...................................................... 255

RKB0052...................................................... 255

CCC, China Compulsory Certification................. 41

CE label.............................................................. 39

Certifications....................................................... 39

China Compulsory Certification (CCC)............... 41

Coding pin

For terminal connector RHS (accessories

HAS05.1-009).............................................. 388

Coding pin for terminal connector RHS

Accessories HAS05.1-009........................... 388

Commissioning interface................................... 143

Compatibility

With foreign matters....................................... 46

426/431 Bosch Rexroth AG

Index

Components

Documentations............................................. 12

Mounting positions......................................... 45

Conditions

Ambient and operating conditions.................. 42

Connection

DC bus................................................. 119, 134

Equipment grounding conductor.......... 121, 136

Ground................................................. 123, 138

Connection diagram

RS232.......................................................... 144

Serial interface............................................. 144

Connection points

X44............................................................... 374

X46............................................................... 394

Contained substances

see "Significant components"...................... 421

Control cabinet

Cooling........................................................... 44

Design............................................................ 44

Control cabinet adapter

HAS03.......................................................... 331

Control module for holding brake HAT01.......... 213

Control module for inductive loads HAT02....... 221

Control voltage

Specification................................................... 47

D

Data

Ambient conditions......................................... 42

Operating conditions...................................... 42

DC bus

Connection........................................... 119, 134

DC bus capacitor unit

HLC01.......................................................... 111

DC bus capacitor unit HLC01

Brief description............................................. 35

DC bus choke

HLL01.......................................................... 103

DC bus connection

Adapter........................................................ 358

DC bus resistor unit

HLB01.......................................................... 127

HLB01, brief description................................. 33

Declaration of conformity.................................... 39

Devices

Mounting positions......................................... 45

Digital inputs

Technical data, safety technology S op‐

tions............................................................. 256

Digital outputs

Technical data, safety technology S op‐

tions............................................................. 257

Technical data; safety technology S op‐

tions; SDL.................................................... 259

Disposal............................................................ 421

DLT

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Brief description............................................. 30

Documentation

Cables............................................................ 13

Changes......................................................... 10

Drive systems................................................ 12

Editions.......................................................... 10

Firmware........................................................ 13

Motors............................................................ 12

Overview........................................................ 12

Reference documentations............................ 12

System components...................................... 12

Drive system....................................................... 19

Drive system Rexroth IndraDrive

Applications.................................................... 29

DST

Autotransformers........................................... 50

Brief description............................................. 30

Dummy plate for KMS03 encoder connection

HAS05.1-018-NNN-NN................................ 406

E

Editions

Documentation............................................... 10

Electric drive system........................................... 19

Encoder emulation

Voltage signal level converter...................... 354

End piece

HAS01, use.................................................. 264

Environmental protection.................................. 421

Equipment grounding conductor

Connection........................................... 121, 136

Extension

For mains filter HNK01 and mains input

HCS03......................................................... 352

F

Fiber optic cables

Accessories.................................................. 413

Fields of application

Drive system Rexroth IndraDrive................... 29

File numbers

UL.................................................................. 39

Firmware

Documentation............................................... 13

Fixing clip

for hybrid cable connectors (HAS10)........... 409

Foreign matters

Compatibility.................................................. 46

G

G1, G2, G3, G4, G5

Mounting positions......................................... 45

Ground

Connection........................................... 123, 138

Ground connection.................................... 123, 138

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

H

H1

LED, HAT02................................................. 240

H2

HLB01, LED................................................. 149

HSZ01, LED................................................. 260

H3

HLB01, LED................................................. 149

HAB01

Data............................................................. 261

Mounting...................................................... 262

Type code.................................................... 261

HAB01 fan unit

Data............................................................. 261

Mounting...................................................... 262

Type code.................................................... 261

HAC01

Brief description............................................. 37

Housing for control sections......................... 207

HAS01

Assignment.................................................. 264

Basic accessories........................................ 263

Mounting "bar" and "end piece"................... 296

HAS02

Shield connection......................................... 297

HAS03

Control cabinet adapter................................ 331

HAS04

Capacitor...................................................... 335

HAS05

Accessories for connection points............... 344

HAS05.1-

001, adapter for mains and motor con‐

nection......................................................... 348

002, extension (connection HNK01 to

HCS03+HMF01).......................................... 352

003, signal level converter encoder emu‐

lation............................................................ 354

004, adapter DC bus connection................. 358

005, signal level converter RS232/RS485... 367

006, adapter for controlling motor holding

brake............................................................ 373

007, adapter from D-Sub to terminal con‐

nector........................................................... 378

008, adapter for connecting two cables....... 385

009............................................................... 388

010............................................................... 389

014, mounting accessories for safety

zone module HSZ01.................................... 399

015, snap-on ferrite...................................... 401

016, brake module with connectors............. 404

018, dummy plate for KMS03 encoder

connection.................................................... 406

019, KNK03 mains voltage.......................... 407

020, KMV03 control voltage......................... 408

HAS05.1-017-NNN-NN

X6 adapter................................................... 239

Bosch Rexroth AG 427/431

Index

HAS10

Fixing clip for hybrid cable connectors......... 409

Mechanical mounting parts.......................... 409

HAT01

Connection points........................................ 217

Control module for holding brake................. 213

Dimensions.................................................. 215

Technical data.............................................. 215

Type code.................................................... 213

Type plate.................................................... 214

HAT02

Connection points........................................ 228

Control module for inductive loads............... 221

Dimensions.................................................. 225

Display elements.......................................... 240

LED.............................................................. 240

S1, S2, S3, S4, rotary coding switches........ 234

Technical data.............................................. 227

Type code.................................................... 222

Type plate.................................................... 223

Hazardous substances..................................... 421

Helpdesk........................................................... 423

HLB01

Brief description............................................. 33

Commissioning, operation, diagnostics....... 147

Connection points........................................ 132

Data, electrical............................................. 130

Data, mechanical......................................... 128

DC bus resistor unit..................................... 127

H2, LED....................................................... 149

H3, LED....................................................... 149

S1, reset button............................................ 148

Type code.................................................... 127

HLC01

Brief description............................................. 35

Connection points........................................ 116

Data, electrical............................................. 116

Data, mechanical......................................... 114

DC bus capacitor unit................................... 111

Type code.................................................... 112

HLL01

DC bus choke.............................................. 103

HLR

Snap-on ferrite, HAS05.1-015-NNN-NN...... 401

HLR01

Braking resistor............................................ 151

Brief description..................................... 34, 151

Dimension table type A................................ 173

Dimension table type B................................ 174

Dimension table type C................................ 175

For HCS02................................................... 154

For HCS03................................................... 156

Installation and mounting............................. 163

Scope of supply........................................... 153

Technical data.............................................. 154

Type code.................................................... 151

Type of construction A (version for device

mounting)..................................................... 164

428/431 Bosch Rexroth AG

Index

Type of construction N (version for free

assembly)..................................................... 173

Type plate.................................................... 153

HLT01

Braking unit.................................................. 177

Type code.................................................... 178

HMF01

Motor filter.................................................... 191

Motor filter, brief description........................... 36

HNF

Brief description............................................. 31

HNF01

Data, electrical............................................... 66

Data, mechanical........................................... 61

Mains filter...................................................... 59

Type code...................................................... 59

HNK

Brief description............................................. 31

Data, electrical............................................... 78

Data, mechanical........................................... 74

Mains filterr.................................................... 72

Type code...................................................... 72

Type plate...................................................... 72

With HCS03................................................... 79

HNL

Brief description............................................. 32

Mains choke................................................... 87

Type code...................................................... 87

Type plate...................................................... 88

HNL01.1E........................................................... 88

Technical data................................................ 88

HNL01.1E-****-S................................................. 95

HNL01.1R........................................................... 93

Technical data................................................ 93

HNL02................................................................. 98

Technical data................................................ 99

Type code...................................................... 98

HNS02

Brief description............................................. 31

Connection points.......................................... 85

Data, electrical............................................... 85

Data, mechanical........................................... 84

Fuses............................................................. 85

Mains filter...................................................... 83

Type code...................................................... 83

Holding brake

Control module HAT01................................ 213

Hotline............................................................... 423

Housing for control sections HAC01................. 207

Brief description............................................. 37

HSZ01

Connection points........................................ 250

Dimensions.................................................. 246

LED H2........................................................ 260

Mounting accessories HAS05.1-014-NNN-

NN................................................................ 399

Safety zone module..................................... 243

Technical data.............................................. 248

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Type code.................................................... 244

Type plate.................................................... 245

I

Inappropriate use................................................ 18

Consequences, exclusion of liability.............. 17

Inductive load

Control module HAT02................................ 221

Industrial sectors................................................. 29

INS0610............................................................ 413

Installation conditions.......................................... 42

Insulation monitoring........................................... 48

Insulation resistance testing................................ 46

K

KMV03 control voltage

HAS05.1-020-NNN-NN................................ 408

KNK03 mains voltage

HAS05.1-019-NNN-NN................................ 407

L

L+, L-

DC bus................................................. 119, 134

LED

H2, HSZ01................................................... 260

Listing

C-UL-US........................................................ 39

C-UR-US........................................................ 40

M

Mains and motor connection

Adapter HAS05.1-001.................................. 348

Mains choke

Brief description............................................. 32

Current-compensated.................................... 95

Feeding.......................................................... 88

HNL................................................................ 87

HNL02............................................................ 98

Regenerative.................................................. 93

Mains filter

Brief description............................................. 31

HNF01............................................................ 59

HNS02........................................................... 83

NFD, NFE...................................................... 53

Mains filterr

HNK............................................................... 72

Mains transformers

Brief description............................................. 30

Module bus............................................... 118, 139

Extension (RKB0001).................................. 418

Motor

Documentation............................................... 12

Motor filter

HMF01......................................................... 191

Motor filter HMF01

Brief description............................................. 36

Mounting position

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Definition (G1, G2, G3, G4, G5)..................... 45

N

NFD

Brief description............................................. 31

Data, electrical............................................... 57

Data, mechanical........................................... 54

Mains filter...................................................... 53

NFE

Brief description............................................. 31

Data, electrical............................................... 57

Data, mechanical........................................... 54

Mains filter...................................................... 53

O

Operating conditions........................................... 42

P

Packaging......................................................... 421

PELV................................................................... 23

Production processes....................................... 421

Project Planning Manuals................................... 12

Protective extra-low voltage................................ 23

R

Recycling.......................................................... 421

Reference documentations................................. 12

Return of products............................................ 421

RHS

Coding pin for terminal connector................ 388

RKB0001

Extension for module bus connections........ 418

RKB0051........................................................... 255

RKB0052........................................................... 255

RKL0091

X6 adapter................................................... 239

RKL0092

X6 adapter................................................... 239

RKO0100.......................................................... 413

RKO0101.......................................................... 413

RS232............................................................... 143

RS232/485

Signal level converter................................... 367

S

S1

HAT02, rotary coding switch, withstand

voltage......................................................... 235

HLB01, reset button..................................... 148

S2

S3

HAT02, rotary coding switch, overexcita‐

tion duration................................................. 236

HAT02, rotary coding switch, switching

state signal evaluation................................. 237

S4

Bosch Rexroth AG 429/431

Index

HAT02, rotary coding switch, waiting

time.............................................................. 238

Safety instructions for electric drives and

controls............................................................... 19

Safety zone module

HSZ01.......................................................... 243

Serial interface (RS232)

X2................................................................. 143

Service hotline.................................................. 423

Service interface............................................... 143

Shield

Connection accessory HAS02..................... 297

Signal level converter

Voltage signal level converter (for encod‐

er emulation)................................................ 354

Signal level converter RS232/485..................... 367

Significant components..................................... 421

Snap-on ferrite

HAS05.1-015-NNN-NN................................ 401

Specifications

Of the components......................................... 39

Standard motors

Voltage load................................................. 194

State-of-the-art.................................................... 17

Storing

Components................................................... 42

Support............................................................. 423

T

Technical data

Digital inputs, safety technology S op‐

tions............................................................. 256

Digital outputs safety technology S op‐

tions; SDL.................................................... 259

Digital outputs, safety technology S op‐

tions............................................................. 257

TERM

HAS05.1-005............................................... 368

Termination

HAS05.1-005............................................... 368

Testing

Factory-side................................................... 46

Insulation resistance...................................... 46

Voltage testing............................................... 46

Touch guard.............................................. 123, 145

Transformers....................................................... 49

Transporting

Components................................................... 41

Type code

HNL................................................................ 87

Type plate

Device.......................................................... 245

HNL................................................................ 88

U

UL

File numbers.................................................. 39

430/431 Bosch Rexroth AG

Index

Use

Listing....................................................... 39, 40

Appropriate use.............................................. 17

Inappropriate use........................................... 18

V

Voltage testing.................................................... 46

X

X1

Module bus.......................................... 118, 139

X2

Serial interface (RS232)............................... 143

X6 adapter

HAS05.1-017-NNN-NN................................ 239

RKL0091, RKL0092..................................... 239

X42, X43

Optional safety technology Safe Motion

(communication).......................................... 255

X44.................................................................... 374

X46.................................................................... 394

XG3

HAT02, 24 V power supply, brake con‐

nection......................................................... 229

XG48

HAT02, signal exchange with control sec‐

tion, brake control input................................ 231

XG49

HAT02, switching state signal input............. 233

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

DOK-INDRV*-ADDCOMP****-PR05-EN

Rexroth IndraDrive Additional Components and Accessories

Notes

Bosch Rexroth AG 431/431

Bosch Rexroth AG

Electric Drives and Controls

P.O. Box 13 57

97803 Lohr, Germany

Bgm.-Dr.-Nebel-Str. 2

97816 Lohr, Germany

Phone +49 9352 18 0

Fax +49 9352 18 8400 www.boschrexroth.com/electrics

*R911306140*

R911306140

DOK-INDRV*-ADDCOMP****-PR05-EN