Hcs 02

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

Rexroth IndraDrive C R911306138
Edition 03
Drive Controllers
Power Sections HCS02.1
Project Planning Manual
About this Documentation IndraDrive C
Title Rexroth IndraDrive C

Drive Controllers
Type of Documentation Project Planning Manual
Document Typecode DOK-INDRV*-HCS02.1****-PR02-EN
Internal File Reference Document number 120-2400-B314-02/EN
Record of Revisions Description Release Notes

Date
DOK-INDRV*-HCS02.1****-PR01-EN 04.2004 First Edition
DOK-INDRV*-HCS02.1****-PR02-EN 02.2005 Revision
DOK-INDRV*-HCS02.1****-PR03-EN 01.2006 Revision
Copyright  Bosch Rexroth AG 2006

Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
Validity The specified data only serve to describe the product. No statements
concerning a certain condition or suitability for a certain application can be
derived from our information. The given information does not release the
user from the obligation of own judgement and verification. It must be
remembered that our products are subject to a natural process of wear
and aging.
Published by Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telefon +49 (0)93 52 / 40-0 • Tx 68 94 21 • Fax +49 (0)93 52 / 40-48 85
http://www.boschrexroth.de/
Abt. BRC/EDY1 (RR/US)
Note This document has been printed on chlorine-free bleached paper.
DOK-INDRV*-HCS02.1****-PR03-EN-P
Rexroth IndraDrive C Contents I
Contents
1 Introduction 1-1
1.1 Documentation.............................................................................................................................. 1-1
About this Documentation ....................................................................................................... 1-1
Documentations - Overview .................................................................................................... 1-2
1.2 Basic Design of a Drive Controller................................................................................................ 1-3
Power Section.......................................................................................................................... 1-3
Control Section ........................................................................................................................ 1-4
1.3 Drive Controllers - Block Diagram ................................................................................................ 1-4
HCS02.1E-W0012-NNNN ....................................................................................................... 1-4
HCS02.1E-W0012-NNNV........................................................................................................ 1-5
HCS02.1E-W0028-NNNN ....................................................................................................... 1-5
HCS02.1E-W0028-NNNV........................................................................................................ 1-6
HCS02.1E-W0054/70-NNNN .................................................................................................. 1-6
HCS02.1E-W0054/70-NNNV................................................................................................... 1-7
1.4 General Information on How to Install the Drive Controller .......................................................... 1-8
2 Important Directions for Use 2-1

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

3.1 General Information ...................................................................................................................... 3-1
Using the Safety Instructions and Passing them on to Others................................................ 3-1
Instructions for Use.................................................................................................................. 3-1
Explanation of Warning Symbols and Degrees of Hazard Seriousness ................................. 3-3
Hazards by Improper Use........................................................................................................ 3-4
3.2 Instructions with Regard to Specific Dangers............................................................................... 3-5
Protection Against Contact with Electrical Parts ..................................................................... 3-5
Protection Against Electric Shock by Protective Low Voltage (PELV) .................................... 3-6
Protection Against Dangerous Movements ............................................................................. 3-7
Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting .................................................................................................................................. 3-9
Protection Against Contact with Hot Parts ............................................................................ 3-10
Protection During Handling and Mounting............................................................................. 3-11
Battery Safety ........................................................................................................................ 3-11
Protection Against Pressurized Systems .............................................................................. 3-12
II Contents Rexroth IndraDrive C
4 Identification 4-1
4.1 Device Types ................................................................................................................................ 4-1
Type Code ............................................................................................................................... 4-1
4.2 Type Plates ................................................................................................................................... 4-2
Type Plate Arrangement.......................................................................................................... 4-2
Type Plate Power Section (Example)...................................................................................... 4-2
Type Plate Control Section...................................................................................................... 4-2
4.3 Scope of Delivery.......................................................................................................................... 4-3
5 Mechanical Data 5-1

5.1 Dimensions ................................................................................................................................... 5-1
HCS02.1E-W0012 ................................................................................................................... 5-1
HCS02.1E-W0028 ................................................................................................................... 5-2
HCS02.1E-W0054 and HCS02.1E-W0070 ............................................................................. 5-3
5.2 Weight........................................................................................................................................... 5-4
5.3 Temperatures Above the Top of the Device................................................................................. 5-5
Outlet Temperatures in Normal Operation .............................................................................. 5-6
6 Electrical Data 6-1

6.1 Power Section – Mains Supply..................................................................................................... 6-1
6.2 Power Section – DC Bus .............................................................................................................. 6-2
6.3 Power Section – DC Bus Power ................................................................................................... 6-3
Allowed DC Bus Continuous Power with Three-Phase Mains Connection............................. 6-5
Allowed DC Bus Continuous Power with Single-Phase Mains Connection ............................ 6-6
Mains Connection Power and DC Bus Continuous Power ..................................................... 6-7
6.4 Power Section – Braking Resistor ................................................................................................ 6-9
6.5 Power Section – Inverter ............................................................................................................ 6-10
6.6 Power Section - Examples of Allowed Load Profiles.................................................................. 6-12
6.7 Power Section - Operating Standard Motors.............................................................................. 6-13
6.8 Power Section – Cooling, Power Dissipation, Insulation Resistance, Sound Pressure............. 6-15
6.9 Control Voltage ........................................................................................................................... 6-20
Devices without Internal Control Voltage Supply (HCS02.1E-W00xx-NNNN)...................... 6-20
Devices with Internal Control Voltage Supply Generation from DC bus
(HCS02.1E-W00xx-NNNV).................................................................................................... 6-21
6.10 Connections ................................................................................................................................ 6-23
Complete Connection Diagram ............................................................................................. 6-23
Connections at HCS02.1E-W0012........................................................................................ 6-24
Connections at HCS02.1E-W0028, -W0054, -W0070 .......................................................... 6-26
X1, Module Bus ..................................................................................................................... 6-29
X3, Mains Connection ........................................................................................................... 6-30
X5, Motor Connection............................................................................................................ 6-32
X6, Motor Temperature Monitoring and Motor Holding Brake .............................................. 6-34
X9, Connection of Braking Resistor....................................................................................... 6-37
X13, Control Voltage (+24 V, 0 V) ......................................................................................... 6-38
DC Bus (L+, L-)...................................................................................................................... 6-41
Connection Point of Equipment Grounding Conductor and Equipment Grounding
Connections........................................................................................................................... 6-42
Rexroth IndraDrive C Contents III
Ground Connection of Housing ............................................................................................. 6-42

XS1, Shield Connection (Control Wires) ............................................................................... 6-43
XS2, Shield Connection (Motor Cable) ................................................................................. 6-44
7 Touch Guard 7-1

7.1 Cutouts.......................................................................................................................................... 7-1
7.2 Mounting ....................................................................................................................................... 7-2
8 Disposal and Environmental Protection 8-1

8.1 Disposal ........................................................................................................................................ 8-1
Products................................................................................................................................... 8-1
Packaging Materials ................................................................................................................ 8-1
8.2 Environmental Protection.............................................................................................................. 8-1
No Release of Hazardous Substances ................................................................................... 8-1
Materials Contained in the Products ....................................................................................... 8-1
Recycling ................................................................................................................................. 8-2
9 Service & Support 9-1

9.1 Helpdesk ....................................................................................................................................... 9-1
9.2 Service-Hotline ............................................................................................................................. 9-1
9.3 Internet.......................................................................................................................................... 9-1
9.4 Vor der Kontaktaufnahme... - Before contacting us... .................................................................. 9-1
9.5 Kundenbetreuungsstellen - Sales & Service Facilities ................................................................. 9-2
10 Index 10-1
IV Contents Rexroth IndraDrive C
Rexroth IndraDrive C Introduction 1-1
1 Introduction
1.1 Documentation
About this Documentation

This documentation basically contains the technical data of the Rexroth
IndraDrive C HCS02.1 drive controllers.
Personal injury and property damage caused by

incorrect project planning for applications,
machines and installations!
WARNING ⇒ Take the content of the Project Planning Manual
"Rexroth IndraDrive Drive System" (DOK-INDRV*-
SYSTEM*****-PRxx-EN-P; part no. R911309636)
into account.
For complete project planning of a Rexroth IndraDrive drive system you

need, in any case, the Project Planning Manual "Rexroth IndraDrive Drive
System" (DOK-INDRV*-SYSTEM*****-PRxx-EN-P; part no. R911309636).
This Project Planning Manual, among other things, contains:
• specifications for the components of the drive system
• configuration of the drive system components
• arrangement of the components in the control cabinet
• electromagnetic compatibility (EMC)
• types of mains connection
• requirements to the mains connection
• control circuits for the mains connection
• connections of the components in the drive system
• fusing and selecting the mains contactor
• accessories in the drive system
• calculations (determining appropriate drive controller; mains
connection; leakage capacitance; operating data of mains filters;
selecting the 24V supply; braking behavior when using a DC bus
resistor unit)
• notes on how to replace devices
1-2 Introduction Rexroth IndraDrive C
Documentations - Overview
For project planning of the drive system the following documentations are
available:
1)
Title Kind of Documentation Document Typecode
Rexroth IndraDrive Project Planning Manual DOK-INDRV*-SYSTEM*****-PRxx-EN-P
Drive System
Rexroth IndraDrive Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P
Drive Controllers
Control Sections CSx
Rexroth IndraDrive M Project Planning Manual DOK-INDRV*-HMS+HMD****-PRxx-EN-P
Drive Controllers
Power Sections HMx
Rexroth IndraDrive C Project Planning Manual DOK-INDRV*-HCS02.1****-PRxx-EN-P
Drive Controllers
Rexroth IndraDrive C Project Planning Manual DOK-INDRV*-HCS03.1****-PRxx-EN-P
Drive Controllers
Rexroth IndraDrive Project Planning Manual DOK-INDRV*-HMV-*******-PRxx-EN-P
Supply Units
Electromagnetic Compatibility (EMC) in Project Planning Manual DOK-GENERAL-EMV********-PRxx-EN-P
Drive and Control Systems
Rexroth IndraDrive Functional and Application DOK-INDRV*-SI*-**VRS**-FKxx-EN-P
Integrated Safety Technology Description
Rexroth Connection Cables Selection Data DOK-CONNEC-CABLE*STAND-AUxx-EN-P
Safety Instructions for Electrical Drives Safety Guidelines DOK-GENERAL-DRIVE-******-SVSx-MS-P
Rexroth IndraDrive Project Planning Manual DOK-INDRV*-ADDCOMP****-PRxx-EN-P
Additional Components
Rexroth IndraDrive Functional Description DOK-INDRV*-MP*-02VRS**-FKxx-EN-P
Firmware for Drive Controllers
Rexroth IndraDrive Parameter Description DOK-INDRV*-GEN-**VRS**-PAxx-EN-P
Rexroth IndraDrive Troubleshooting Guide DOK-INDRV*-GEN-**VRS**-WAxx-EN-P
Rexroth IndraDyn S Project Planning Manual DOK-MOTOR*-MSK********-PRxx-EN-P
Synchronous Motors MSK
Rexroth IndraDyn A Project Planning Manual DOK-MOTOR*-MAD/MAF****-PRxx-EN-P
Asynchronous Motors MAD/MAF
Rexroth IndraDyn T Project Planning Manual DOK-MOTOR*-MBT********-PRxx-EN-P
Synchronous Torque Motors MBT
Rexroth IndraDyn H Project Planning Manual DOK-MOTOR*-MBS-H******-PRxx-EN-P
Synchronous Kit –Spindle Motors MBS-H
Rexroth IndraDyn L Project Planning Manual DOK-MOTOR*-MLF********-PRxx-EN-P
Synchronous Linear Motors MLF
Third Party Motors Project Planning Manual DOK-DRIVE*-3RDPART*MOT-AWxx-EN-P
and Commissioning
1) in the document typecodes "xx" is a wild card for the current edition of
the documentation (example: "PR01" is the first edition of a Project
Planning Manual)
Fig. 1-1: Documentations - overview
1.2 Basic Design of a Drive Controller
hcs_lt_rt.fh7
1: Power section
2: Control section
Fig. 1-2: Basic design
The drive controller consists of two essential parts:

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

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

documentation (see page 1-2).
1.3 Drive Controllers - Block Diagram
HCS02.1E-W0012-NNNN
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
line input with braking resistor DC bus converter

bridge circuit circuit capacitance bridge circuit
rectifier charging with output to
current limit the motor
hcs_block_12n.FH7
Fig. 1-3: HCS02.1E-W0012-NNNN - Block diagram
HCS02.1E-W0012-NNNV
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
line input with optional braking resistor DC bus converter

bridge circuit integrated circuit capacitance bridge circuit
rectifier control with output to
voltage charging the motor
supply current limit
hcs_block_12v.FH7
Fig. 1-4: HCS02.1E-W0012-NNNV - Block diagram
HCS02.1E-W0028-NNNN
L+
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
L-
line input with braking resistor DC bus converter DC bus
bridge circuit circuit capacitance bridge circuit connection
rectifier with output to
charging the motor
current limit
hcs_block_28n.FH7
Fig. 1-5: HCS02.1E-W0028-NNNN - Block diagram
HCS02.1E-W0028-NNNV
L+
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
L-
line input with optional braking resistor DC bus converter DC bus
bridge circuit integrated circuit capacitance bridge circuit connection
hcs_block_28v.FH7
Fig. 1-6: HCS02.1E-W0028-NNNV - Block diagram
HCS02.1E-W0054/70-NNNN
L+
optional
external
braking
resistor
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
L-
line input with braking resistor DC bus converter DC bus
bridge circuit circuit capacitance bridge circuit connection
rectifier with output to
charging the motor
current limit
hcs_block_54_70n.FH7
Fig. 1-7: HCS02.1E-W0054/70-NNNN - Block diagram
HCS02.1E-W0054/70-NNNV
L+
optional
external
braking
resistor
RSoftstart
L1 RB A1
L2 A2
CZW
L3 A3
L-
line input with optional braking resistor DC bus converter DC bus
bridge circuit integrated circuit capacitance bridge circuit connection
hcs_block_54_70v.FH7
Fig. 1-8: HCS02.1E-W0054/70-NNNV - Block diagram
1.4 General Information on How to Install the Drive Controller

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

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

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

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

connecting and disconnecting live connections!
⇒ Do not connect and disconnect live connections.
CAUTION
Rexroth IndraDrive C Important Directions for Use 2-1
2 Important Directions for Use
2.1 Appropriate Use
Introduction
Rexroth products represent state-of-the-art developments and
manufacturing. They are tested prior to delivery to ensure operating safety
and reliability.
The products may only be used in the manner that is defined as
appropriate. If they are used in an inappropriate manner, then situations
can develop that may lead to property damage or injury to personnel.
Note: Rexroth as manufacturer is not liable for any damages

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

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

making it possible for the motor to execute the specific functions of an
application.
The drive controllers have been developed for use in single- and multi-
axis drive and control tasks.
To ensure an application-specific use, the drive controllers are available
with different drive power and different interfaces.
Typical applications of the drive controllers include:
• handling and mounting systems,
• packaging and food machines,
• printing and paper processing machines and
• machine tools.
The drive controllers may only be operated under the assembly and
installation conditions described in this documentation, in the specified
position of normal use and under the ambient conditions as described
(temperature, degree of protection, humidity, EMC, etc.).
2.2 Inappropriate Use

Using the drive controllers outside of the operating conditions described in
this documentation and outside of the indicated technical data and
specifications is defined as "inappropriate use".
Drive controllers must not be used, if
• ... they are subject to operating conditions that do not meet the
specified ambient conditions. This includes, for example, operation
under water, under extreme temperature fluctuations or extremely high
maximum temperatures.
• Furthermore, the drive controllers must not be used in applications
which have not been expressly authorized by Rexroth.
• Please carefully follow the specifications outlined in the general Safety
Instructions!
Rexroth IndraDrive C Safety Instructions for Electric Drives and Controls 3-1
3 Safety Instructions for Electric Drives and Controls
3.1 General Information
Using the Safety Instructions and Passing them on to Others

Do not attempt to install or commission this device without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation prior to working with the
device. If you do not have the user documentation for the device, contact
your responsible Bosch Rexroth sales representative. Ask for these
documents to be sent immediately to the person or persons responsible
for the safe operation of the device.
If the device is resold, rented and/or passed on to others in any other
form, then these safety instructions must be delivered with the device.
Improper use of these devices, failure to follow

the safety instructions in this document or
tampering with the product, including disabling
WARNING of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
Instructions for Use

Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these
safety instructions at all times.
• Bosch Rexroth AG is not liable for damages resulting from failure to
observe the warnings provided in this documentation.
• Read the operating, maintenance and safety instructions in your
language before starting up the machine. If you find that you cannot
completely understand the documentation for your product, please ask
your supplier to clarify.
• Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this device.
• Only assign trained and qualified persons to work with electrical
installations:
• Only persons who are trained and qualified for the use and
operation of the device may work on this device or within its
proximity. The persons are qualified if they have sufficient
knowledge of the assembly, installation and operation of the
equipment as well as an understanding of all warnings and
precautionary measures noted in these instructions.
• Furthermore, they must be trained, instructed and qualified to
switch electrical circuits and devices on and off in accordance with
technical safety regulations, to ground them and to mark them
according to the requirements of safe work practices. They must
have adequate safety equipment and be trained in first aid.
• Only use spare parts and accessories approved by the manufacturer.
• Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
3-2 Safety Instructions for Electric Drives and Controls Rexroth IndraDrive C
• The devices have been designed for installation in industrial

machinery.
• The ambient conditions given in the product documentation must be
observed.
• Only use safety-relevant applications that are clearly and explicitly
approved in the Project Planning Manual. If this is not the case, they
are excluded.
Safety-relevant are all such applications which can cause danger to
persons and material damage.
• The information given in the documentation of the product with regard
to the use of the delivered components contains only examples of
applications and suggestions.
The machine and installation manufacturer must
• make sure that the delivered components are suited for his
individual application and check the information given in this
documentation with regard to the use of the components,
• make sure that his application complies with the applicable safety
regulations and standards and carry out the required measures,
modifications and complements.
• Startup of the delivered components is only permitted once it is sure
that the machine or installation in which they are installed complies
with the national regulations, safety specifications and standards of the
application.
• Operation is only permitted if the national EMC regulations for the
application are met.
• The instructions for installation in accordance with EMC requirements
can be found in the documentation "EMC in Drive and Control
Systems".
• The machine or installation manufacturer is responsible for
compliance with the limiting values as prescribed in the national
regulations.
• Technical data, connections and operational conditions are specified in
the product documentation and must be followed at all times.
Explanation of Warning Symbols and Degrees of Hazard Seriousness

The safety instructions describe the following degrees of hazard
seriousness. The degree of hazard seriousness informs about the
consequences resulting from non-compliance with the safety instructions:
Warning symbol with signal Degree of hazard seriousness according

word to ANSI Z 535
Death or severe bodily harm will occur.
DANGER
Death or severe bodily harm may occur.
WARNING
Bodily harm or material damage may occur.
CAUTION
Fig. 3-1: Hazard classification (according to ANSI Z 535)
Hazards by Improper Use
High electric voltage and high working current!

Risk of death or severe bodily injury by electric
shock!
DANGER
Dangerous movements! Danger to life, severe

bodily harm or material damage by
unintentional motor movements!
DANGER
High electric voltage because of incorrect

connection! Risk of death or bodily injury by
electric shock!
WARNING
Health hazard for persons with heart

pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING
Hot surfaces on device housing! Danger of

injury! Danger of burns!
CAUTION
Risk of injury by improper handling! Risk of

bodily injury by bruising, shearing, cutting,
hitting, or improper handling of pressurized
CAUTION lines!
Risk of injury by improper handling of batteries!
CAUTION
3.2 Instructions with Regard to Specific Dangers
Protection Against Contact with Electrical Parts
Note: This section only concerns devices and drive components with
voltages of more than 50 Volt.
Contact with parts conducting voltages above 50 Volts can cause

personal danger and electric shock. When operating electrical equipment,
it is unavoidable that some parts of the devices conduct dangerous
voltage.
High electrical voltage! Danger to life, electric

shock and severe bodily injury!
⇒ Only those trained and qualified to work with or on
DANGER electrical equipment are permitted to operate,
maintain and repair this equipment.
⇒ Follow general construction and safety regulations
when working on electrical power installations.
⇒ Before switching on the device, the equipment
grounding conductor must have been non-
detachably connected to all electrical equipment in
accordance with the connection diagram.
⇒ Do not operate electrical equipment at any time,
even for brief measurements or tests, if the
equipment grounding conductor is not permanently
connected to the mounting points of the components
provided for this purpose.
⇒ Before working with electrical parts with voltage
potentials higher than 50 V, the device must be
disconnected from the mains voltage or power
supply unit. Provide a safeguard to prevent
reconnection.
⇒ With electrical drive and filter components, observe
the following:
Wait 30 minutes after switching off power to allow
capacitors to discharge before beginning to work.
Measure the voltage on the capacitors before
beginning to work to make sure that the equipment is
safe to touch.
⇒ Never touch the electrical connection points of a
component while power is turned on.
⇒ Install the covers and guards provided with the
equipment properly before switching the device on.
Before switching the equipment on, cover and
safeguard live parts safely to prevent contact with
those parts.
⇒ A residual-current-operated circuit-breaker or r.c.d.
cannot be used for electric drives! Indirect contact
must be prevented by other means, for example, by
an overcurrent protective device according to the
relevant standards.
⇒ Secure built-in devices from direct touching of
electrical parts by providing an external housing, for
example a control cabinet.
European countries: according to EN 50178/ 1998,
section 5.3.2.3.
USA: See National Electrical Code (NEC), National
Electrical Manufacturers' Association (NEMA), as well as
local engineering regulations. The operator must observe
all the above regulations at any time.
With electrical drive and filter components, observe the following:
High housing voltage and large leakage current!

Risk of death or bodily injury by electric shock!
⇒ Before switching on, the housings of all electrical
DANGER equipment and motors must be connected or
grounded with the equipment grounding conductor to
the grounding points. This is also applicable before
short tests.
⇒ The equipment grounding conductor of the electrical
equipment and the units must be non-detachably
and permanently connected to the power supply unit
at all times. The leakage current is greater than
3.5 mA.
⇒ Over the total length, use copper wire of a cross
2
section of a minimum of 10 mm for this equipment
grounding connection!
⇒ Before start-up, also in trial runs, always attach the
equipment grounding conductor or connect with the
ground wire. Otherwise, high voltages may occur at
the housing causing electric shock.
Protection Against Electric Shock by Protective Low Voltage (PELV)

All connections and terminals with voltages between 5 and 50 Volt at
Rexroth products are protective extra-low voltage systems which are
provided with touch guard according to the product standards.
High electric voltage by incorrect connection!

Risk of death or bodily injury by electric shock!
⇒ To all connections and terminals with voltages
WARNING between 0 and 50 Volt, only devices, electrical
components, and conductors may be connected
which are equipped with a PELV (Protective Extra-
Low Voltage) system.
⇒ Connect only voltages and circuits which are safely
isolated from dangerous voltages. Safe isolation is
achieved for example by isolating transformers, safe
optocouplers or battery operation without mains
connection.
Protection Against Dangerous Movements

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

injury, severe bodily harm or material damage!
⇒ For the above reasons, ensure personal safety by
DANGER means of qualified and tested higher-level monitoring
devices or measures integrated in the installation.
They have to be provided for by the user according
to the specific conditions within the installation and a
hazard and fault analysis. The safety regulations
applicable for the installation have to be taken into
consideration. Unintended machine motion or other
malfunction is possible if safety devices are disabled,
bypassed or not activated.
To avoid accidents, bodily harm and/or material
damage:
⇒ Keep free and clear of the machine’s range of

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

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

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

pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
WARNING ⇒ Persons with heart pacemakers and metal implants
are not permitted to enter following areas:
- Areas in which electrical equipment and parts are
mounted, being operated or commissioned.
- Areas in which parts of motors with permanent
magnets are being stored, repaired or mounted.
⇒ If it is necessary for somebody with a pacemaker to
enter such an area, a doctor must be consulted prior
to doing so. The interference immunity of present or
future implanted heart pacemakers differs greatly, so
that no general rules can be given.
⇒ Those with metal implants or metal pieces, as well
as with hearing aids must consult a doctor before
they enter the areas described above. Otherwise
health hazards may occur.
Protection Against Contact with Hot Parts
Hot surfaces at motor housings, on drive

controllers or chokes! Danger of injury! Danger
of burns!
CAUTION ⇒ Do not touch surfaces of device housings and
chokes in the proximity of heat sources! Danger of
burns!
⇒ Do not touch housing surfaces of motors! Danger of
burns!
⇒ According to operating conditions, temperatures can
be higher than 60 °C, 140 °F during or after
operation.
⇒ Before accessing motors after having switched them
off, let them cool down for a sufficiently long time.
Cooling down can require up to 140 minutes!
Roughly estimated, the time required for cooling
down is five times the thermal time constant
specified in the Technical Data.
⇒ After switching drive controllers or chokes off, wait
15 minutes to allow them to cool down before
touching them.
⇒ Wear safety gloves or do not work at hot surfaces.
⇒ For certain applications, the manufacturer of the end
product, machine or installation, according to the
respective safety regulations, has to take measures
to avoid injuries caused by burns in the end
application. These measures can be, for example:
warnings, guards (shielding or barrier), technical
documentation.
Protection During Handling and Mounting

In unfavorable conditions, handling and assembling certain parts and
components in an improper way can cause injuries.
Risk of injury by improper handling! Bodily

injury by bruising, shearing, cutting, hitting!
⇒ Observe the general construction and safety
regulations on handling and assembly.
⇒
CAUTION
Use suitable devices for assembly and transport.
⇒ Avoid jamming and bruising by appropriate
measures.
⇒ Always use suitable tools. Use special tools if
specified.
⇒ Use lifting equipment and tools in the correct
manner.
⇒ If necessary, use suitable protective equipment (for
example safety goggles, safety shoes, safety
gloves).
⇒ Do not stand under hanging loads.
⇒ Immediately clean up any spilled liquids because of
the danger of skidding.
Battery Safety
Batteries consist of active chemicals enclosed in a solid housing.
Therefore, improper handling can cause injury or damages.
Risk of injury by improper handling!

⇒ Do not attempt to reactivate low batteries by heating
or other methods (risk of explosion and
cauterization).
CAUTION
⇒ Do not recharge the batteries as this may cause
leakage or explosion.
⇒ Do not throw batteries into open flames.
⇒ Do not dismantle batteries.
⇒ Do not damage electrical parts installed in the
devices.
Note: Environmental protection and disposal! The batteries installed

in the product are considered dangerous goods during land,
air, and sea transport (risk of explosion) in the sense of the
legal regulations. Dispose of used batteries separate from
other waste. Observe the local regulations in the country of
assembly.
Protection Against Pressurized Systems

According to the information given in the Project Planning Manuals,
motors cooled with liquid and compressed air, as well as drive controllers,
can be partially supplied with externally fed, pressurized media, such as
compressed air, hydraulics oil, cooling liquids, and cooling lubricating
agents. In these cases, improper handling of external supply systems,
supply lines, or connections can cause injuries or damages.
Risk of injury by improper handling of pressurized

lines!
⇒ Do not attempt to disconnect, open, or cut
pressurized lines (risk of explosion).
CAUTION
⇒ Observe the respective manufacturer's operating
instructions.
⇒ Before dismounting lines, relieve pressure and
empty medium.
⇒ Use suitable protective equipment (for example
safety goggles, safety shoes, safety gloves).
⇒ Immediately clean up any spilled liquids from the
floor.
Note: Environmental protection and disposal! The agents used to

operate the product might not be economically friendly.
Dispose of ecologically harmful agents separate from other
waste. Observe the local regulations in the country of
assembly.
Rexroth IndraDrive C Identification 4-1
4 Identification
4.1 Device Types
Type Code
Note: The following figure illustrates the basic structure of the type
code. Your sales representative will help with the current
status of available versions.
Abbrev. 1 2 3 4
Column 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
Example: H C S 0 2 . 1 E - W 0 0 1 2 - A - 0 3 - N N N N
1. Product
1.1 HCS. . . . . . . . = HCS
2. Line
2.1 1.5 to 11 kW. . . . . . . . = 02
3. Design
3.1 1......................=1
4. Power supply
4.1 feeded . . . . . . . . . . . . . . . . . . . = E
5. Cooling mode
5.1 Air, internal (through integrated blower) = W
6. Maximum current
6.1 12 A . . . . . . . . . . . . . . . . . . . . . . . . . = 0012
6.2 28 A . . . . . . . . . . . . . . . . . . . . . . . . . = 0028
6.3 54 A . . . . . . . . . . . . . . . . . . . . . . . . . = 0054
6.4 70 A . . . . . . . . . . . . . . . . . . . . . . . . . = 0070
7. Protection mode
7.1 IP 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = A
8. Mains connecting voltage

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

Standard Title Edition
DIN EN 60529 Degrees of protection provided 2000-09
by enclosures (IP-Code)
Fig. 4-1: Type code (power section)
4-2 Identification Rexroth IndraDrive C
4.2 Type Plates
Type Plate Arrangement
hcs_lt_rt_typenschildert.fh7
1: Power section type plate

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

See Project Planning Manual of the control sections.
Rexroth IndraDrive C Identification 4-3
4.3 Scope of Delivery
as standard optional
Power section Control section
Touch guard Accessories HAS02.1
Connectors X3, X5, X6, X13 Further accessories
Connector X9 (HCS02.1E-W0054 and
HCS02.1E-W0070 only)
Accessories HAS01.1
Fig. 4-4: Scope of delivery
4-4 Identification Rexroth IndraDrive C
Notes
Rexroth IndraDrive C Mechanical Data 5-1
5 Mechanical Data
5.1 Dimensions
HCS02.1E-W0012
A: minimum mounting clearance (when using accessories HAS02.1);

plus space for cables
B: minimum mounting clearance; plus space for cables
Fig. 5-1: Dimensional drawing HCS02.1E-W0012
5-2 Mechanical Data Rexroth IndraDrive C
HCS02.1E-W0028

Fig. 5-2: Dimensional drawing HCS02.1E-W0028
HCS02.1E-W0054 and HCS02.1E-W0070

Fig. 5-3: Dimensional drawing HCS02.1E-W0054 and HCS02.1E-W0070
5.2 Weight
Device Weight in kg
HCS02.1E-W0012 2.9
HCS02.1E-W0028 3.8
HCS02.1E-W0054 6.7
HCS02.1E-W0070 6.8
Fig. 5-4: Weight of the devices (without control section and accessories)
The weight of devices with integrated 24V power supply (-NNNV) is 0.2 kg
higher.
Note: Weight of control section: 0.42 kg.
5.3 Temperatures Above the Top of the Device

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

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

Designation Symbol Unit HCS02.1E- HCS02.1E- HCS02.1E- HCS02.1E-
W0012 W0028 W0054 W0070
temperature rise
with distance of 40 mm from ∆T K 110 150 250 280
top of device
temperature rise
with distance of 80 mm from ∆T K 80 90 100 110
top of device
Fig. 5-5: Outlet temperatures when cooling air current fails
Outlet Temperatures in Normal Operation

The diagrams below (see next page) show the temperature rise of the air
from air intake at the bottom of the device to air outlet at the top of the
device, depending on the average continuous power at the breaking
resistor. The values "d" are representing different distances from the top
of the device (see following figure):
d
B
kuehlluft.FH7
A: air inlet
B: air outlet
C: control cabinet mounting plate
d: distance from the top of the device (see also following diagrams)
Fig. 5-6: Air inlet and outlet of drive controller
HCS02.1E-W0012
40
35
30
25
20
∆T [K]
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50
PBD [W]
∆T @ d~0mm
∆T @ d~40mm
∆T @ d~80mm
∆T @ d~120mm
PBD: average continuous power of braking resistor

d: distance from the top of the device
Fig. 5-7: HCS02.1E-W0012
HCS02.1E-W0028
100
90
80
70
60
50
∆T [K]40
30
20
10
0
0 15 30 45 60 75 90 105 120 135 150
PBD [W]
∆T @ d~0mm
∆T @ d~40mm
∆T @ d~80mm
∆T @ d~120mm

Fig. 5-8: HCS02.1E-W0028
HCS02.1E-W0054
90
80
70
60
∆T [K]50
40
30
20
10
0
0 35 70 105 140 175 210 245 280 315 350
PBD [W]
∆T @ d~0mm
∆T @ d~40mm
∆T @ d~80mm
∆T @ d~120mm
Fig. 5-9: HCS02.1E-W0054
HCS02.1E-W0070
120
100
80
60
∆T [K]
40
20
0
0 50 100 150 200 250 300 350 400 450 500
PBD [W]
∆T @ d~0mm
∆T @ d~40mm
∆T @ d~80mm
∆T @ d~120mm

Fig. 5-10: HCS02.1E-W0070
Rexroth IndraDrive C Electrical Data 6-1
6 Electrical Data
Note: The current and power data below apply when the allowed
motor cable length is complied with.
6.1 Power Section – Mains Supply

W0012 W0028 W0054 W0070
operating mode on the
allowed
three-phase mains
operating mode on the allowed
single-phase mains
rotary field no rotary field condition
total power factor TPF at TPF 0.4 0.4 0.4 0.4
PDC (single-phase)
total power factor TPF at TPF 0.6 / -- 0.6 / 0.7 0.64 / 0.75 0.56 / 0.76
PDC without / with mains
choke
h1
power factor of fundamental cosϕ 0.97 / -- 0.97 / -- -- / -- -- / --
component DPF PDC
without / with mains choke
mains input voltage ULN V 1 * AC (200…250) +-10%
3 * AC (200…500) +-10%
mains frequency fLN Hz (50…60) +-2
mains input continuous IL,cont Aeff 6 13 19 30
current at PDC cont
nominal inrush current IL trans max (on) A 1.4…4.3 3.5…10.7 6.3…19.3 9.9…27.5
(depending on mains input
voltage)
connected load SLN kVA 3.5 8.5 11 16
at PDC_cont ; ULN = AC400V;
without HNL01.1E
connected load SLN kVA -- 7.3 13.3 18.5
at PDC_cont ; ULN = AC400V;
with HNL01.1E
assigned mains choke HNL01.1E- HNL01.1E- HNL01.1E- HNL01.1E-
1000-N0012 1000-N0012 1000-N0020 0600-N0032
Fig. 6-1: Data power section – mains supply
6-2 Electrical Data Rexroth IndraDrive C
6.2 Power Section – DC Bus

W0012 W0028 W0054 W0070
DC bus voltage (range) (unloaded) UDC V uncontrolled
ULN * 1.41
internal DC bus capacitance CDC mF 0.135 0.270 0.405 0.675
max. allowed external DC bus CDCext mF - 5 7 13
1)
capacitance
limitation of inrush current charging via resistor; N/O contact:
min. 250.000 switching actions
continuous power soft-start resistor PDC(Start) kW 0.05 0.15 0.35 0.5
max. DC bus charging energy W MAX kWs 1 5 9 13
storable energy of the internal W DC Ws 19 38 57 95
DC bus capacitors at 3AC400V
lower DC bus voltage limit UDC limit (min) V 200
see also Functional Description of firmware
upper DC bus voltage limit (switch- UDC limit (max) V 900
off threshold)
capacitance in DC bus against CY nF 100 100 100 100
ground; between L+ and L-
balancing factor for PDC cont - -
(for parallel operation with common
DC bus)
with / without mains choke: 0.8 / 0.5 0.8 / 0.5 0.8 / 0.5
rated power at ULN = AC400V PDC_cont kW 2.1 5.1 7.0 9

without mains choke
minimum inductance of mains
supply
Lmin uH 40 40 40 40
rated power at ULN = AC400V, PDC_cont kW 2.1 5.1 10 14
with mains choke
1) using additional capacitances at the DC bus requires mains choke
Fig. 6-2: Data power section – DC bus
6.3 Power Section – DC Bus Power

W0012 W0028 W0054 W0070
P
Profile DC bus power

PDC_peak
overload operation
overload capacity:
PDC_base
PDC_peak
K= t t
PDC_ base
T
DC bus peak power PDC_peak_1 kW

ULN = 3AC400 V, at Ta<40 °C;
t=0.4 s; T=4 s
without mains choke 5 8 12 14
with mains choke 5 10 16 19
DC bus power PDC_base_1 kW
ULN = 3AC400 V, at Ta<40 °C;
t=0.4 s; T=4 s
without mains choke 1.5 4.7 6.2 8.3
with mains choke 1.5 4.2 9.1 13.3
ULN = 3AC400 V, at Ta<40 °C;
t=2 s; T=20 s
ULN = 3AC400 V, at Ta<40 °C;
t=2 s; T=20 s
ULN = 3AC400 V, at Ta<40 °C;
t=60 s; T=5 min
ULN = 3AC400 V, at Ta<40 °C;
t=60 s; T=5 min
ULN = 3AC400 V, at Ta<40 °C;
t=60 s; T=10 min

W0012 W0028 W0054 W0070
ULN = 3AC400 V, at Ta<40 °C;
t=60 s; T=10 min
Fig. 6-3: Data power section – DC bus power
Damage due to drive controller overload!

⇒ Make sure the specified performance data - peak
power and continuous power - are complied with by
correct drive dimensioning and selective fusing in the
WARNING
mains connection.
Allowed DC Bus Continuous Power with Three-Phase Mains Connection

The diagram below illustrates the characteristic of the allowed DC bus
continuous power over the mains connection voltage range.
Using HNL mains chokes increases the allowed DC bus continuous
power for W0054 and W0070 devices, because this reduces the load of
the DC bus capacitors in the drive controllers.
18,0
W0070 @
16,0 HNL01.1
14,0 W0054 @
HNL01.1
12,0
W0070
PDC cont [kW]
10,0
8,0 W0054
6,0
W0028
4,0
W0012
2,0
0,0
200 250 300 350 400 450 500
ULN [V]
Fig. 6-4: PDC_cont HCS02.1E 3-phase
Allowed DC Bus Continuous Power with Single-Phase Mains

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

is only allowed for single-source supply!
Apart from the specified continuous power, there is no peak
power available in the DC bus in the case of single-phase
operation.
1,8
1,6 W0070
1,4
1,2 W0054
PDC cont [kW]
1,0
0,8
W0028
0,6
0,4
W0012
0,2
0,0
200 250 300 350 400 450 500
U LN [V]
Fig. 6-5: PDC_cont HCS02.1E single-phase
Mains Connection Power and DC Bus Continuous Power

The diagrams below illustrate the interrelation between mains connection
power (SLN) and DC bus continuous power (PDCcont) with and without the
use of mains chokes.
HCS02.1-E-W0012 @3AC400V
4,5
4
3,5
3
SLN [kVA]
2,5
2
1,5
1
0,5
0
0 0,5 1 1,5 2 2,5
PDC cont [kW]
Fig. 6-6: HCS02.1E-W0012
HCS02.1-E-W0028 @3AC400V
9
S LN 5
[kVA]
4
2
without choke
1
with choke
0
0 1 2 3 4 5
P DC cont [kW]
Fig. 6-7: HCS02.1E-W0028
HCS02.1-E-W0054 @3AC400V
16
14
12
10
S LN
8
[kVA]
6
4
without choke
2 with choke
0
0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,
PDC cont [kW]
Fig. 6-8: HCS02.1E-W0054
HCS02.1-E-W0070 @3AC400V
20
18
16
14
12
10
S LN 8
[kVA] 6 without choke
4 with choke
2
0
0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10, 11, 12, 13, 14,
PDC cont [kW]
Fig. 6-9: HCS02.1E-W0070
6.4 Power Section – Braking Resistor

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

braking resistor threshold RDC (R_DC On) V see Functional Description of firmware
cooling of braking resistor forced forced forced forced
braking resistor peak power PBS kW 4 10 18 25
at UDC = 850 V
(allowed load cycle) (0.25s ON; (0.5s ON; 33s (0.5s ON; 26s (0.5s ON; 25s
20s OFF) OFF) OFF) OFF)
braking resistor continuous PBD KW 0.05 0.15 0.35 0.5
power, at Ta<40 °C
under max. temperature ∆T K 12 40 40 50
range with distance from d mm 80 80 80 80
1)
top side of housing
balancing factor for PBD - 0.8 0.8 0.8
(for parallel operation with
common DC bus)
operation external braking -- -- allowed allowed
resistor (optional)
min. resistance of external RDC(Bleeder) Ohm -- -- 40 28
braking resistor
allowed continuous power kW -- -- 3.8 5.5
of external braking resistor
ext. braking resistor peak PBS kW -- -- 18 25
power
at UDC = 850 V (0,5s ON; (0,5s ON;
2)
(allowed load cycle) 1,9s OFF) 1,9s OFF)
1) see also section Temperatures Above the Top of the Device on page
5-5
2) take energy absorption capacity of external braking resistor into
account
Fig. 6-10: Data power section – braking resistor
6.5 Power Section – Inverter

W0012 W0028 W0054 W0070
output voltage Uout
fundamental component with open-loop U/f ctrl Veff UDC * 0,85 / 1,41
of voltage with closed-loop oper. Veff UDC * 0,85 / 1,41
output frequency range fout Hz 400 400 400 400
- at fs = 4 kHz
- at fs = 8 kHz 800 800 800 800
- at fs = 10 kHz 1000 1000 1000 1000
- at fs = 12 kHz
- at fs = 16 kHz 1200 1200 1200 1200
1600 1600 1600 1600
rise of voltage at output at dv/dt kV/µs 5 5 5 5
ULN=400V and 15 m
motor cable length
1) 10% - 90%
rise of voltage at output at dv/dt kV/µs

400V and 15m motor
cable length 10% - 90%
phase-phase: 6 5 5 4
phase-ground: 6 6 5 4
maximum output current Iout_max (4 kHz) Aeff 11.5 28.3 54 70.8

Iout_max (8 kHz) 11.5 28.3 54 70.8
Iout_max(12 kHz) 11.5 28.3 54 70.8
Iout_max(16 kHz) 11.5 28.3 54 70.8
continuous output current Iout_cont (4 kHz) Aeff 4.5 12.0 20.6 28.0
(effective value)
or rated current Iout_cont (8 kHz) 4.5 9.2 20.6 21.4
Iout_cont (12 kHz) 4.0 5.1 13.8 14.1
Iout_cont (16 kHz) 2.8 4.4 11.1 10.5
continuous output current Iout_cont (4 kHz) A 4.5 9.7 20.2 20.2
or rated current
Iout_cont (8 kHz) 3.3 5.6 13.1 11.9
at electric rotational Iout_cont (12 kHz) 1.2 2.3 7.5 6.7
frequency 0 Hz
Iout_cont (16 kHz) 0.7 2.1 6.1 4.2
1) recommended value; see following note
Fig. 6-11: Data – inverter
Note: Observe that the load at the motor terminal is almost

independent of the power section used.
Especially when using standard motors, make sure that they
can withstand the voltage load.
Observe section "Using Third-Party Motors in Drive System
Rexroth IndraDrive" of the Project Planning Manual "Rexroth
IndraDrive Drive System".
Note: Depending on the electric rotational frequency, the output

current is reduced for thermal protection of the power section.
The output current is reduced when the value of the electric
rotational frequency falls below 4 Hz.
6.6 Power Section - Examples of Allowed Load Profiles

The capacity of the drive controllers is described below with examples of
load profiles.

W0012 W0028 W0054 W0070
Iout_peak
output current profile for
overload operation
overload capacity: Iout_base
K = Iout_peak
Iout_base t t
T
maximum output current Iout_peak_1 (4 kHz) Aeff 11.5 28.3 54.0 69.0
t=400ms; T=4s Iout_peak_1 (8 kHz) 10.7 18.4 39.6 42.3
Iout_peak_1 (12 kHz) 6.9 10.4 26.3 28.3
Iout_peak_1 (16 kHz) 4.9 9.0 21.4 21.1
base load current Iout_base_1 (4 kHz) Aeff 2.6 6.3 12.0 15.3
available at maximum
current Iout_base_1 (8 kHz) 2.4 4.1 8.8 9.4
T=4s; t=400ms Iout_base_1 (12 kHz) 1.5 2.3 5.8 6.3

Iout_base_1 (16 kHz) 1.1 2.0 4.8 4.7
t=2s; T=20s; K=2.5 Iout_peak_3 (8 kHz) 8.9 14.9 33.2 34.5
Iout_peak_3 (12 kHz) 6.0 8.4 21.7 22.9
Iout_peak_3 (16 kHz) 4.2 7.2 17.6 17.0
t=2s; T=20s; K=2.5 Iout_base_3 (12 kHz) 2.4 3.3 8.7 9.2
Iout_base_3 (16 kHz) 1.7 2.9 7.0 6.8
t=60s; T=5min; K=1.7 Iout_peak_4 (8 kHz) 5.4 10.5 23.4 25.1
Iout_peak_4 (12 kHz) 4.4 5.9 15.2 16.6
Iout_peak_4 (16 kHz) 3.1 5.1 12.2 12.3
t=60s; T=5min; K=1.7 Iout_base_4 (12 kHz) 2.6 3.5 8.9 9.8
Iout_base_4 (16 kHz) 1.8 3.0 7.2 7.3

W0012 W0028 W0054 W0070
t=60s; T=10min; K=1.2 Iout_peak_5 (8 kHz) 4.9 9.7 22.2 22.9
Iout_peak_5 (12 kHz) 4.2 5.4 14.3 15.1
Iout_peak_5 (16 kHz) 2.9 4.7 11.6 11.2
t=60s; T=10min; K=1.2 Iout_base_5 (12 kHz) 3.5 4.5 12.0 12.6
Iout_base_5 (16 kHz) 2.4 3.9 9.6 9.3
Fig. 6-12: Data load profiles – inverter
Note: The load profiles are characterized by their time flow and the
corresponding currents and represent the output current
capacity. These profiles are limited by the drive controller via
the thermal effect of the output current. When the current
limitation is triggered, it is therefore necessary to compare the
actual load with the above data and, if necessary,
• reduce the load with Iout_ max or
• reduce the pulse time or
• increase the cycle time or
• reduce the switching frequency fs or
• use a device with higher type current
(See also Functional Description and Troubleshooting Guide
of the firmware.)
Note: The load profiles are available if particularly the maximum

current at switching frequencies of 8, 12 and 16 kHz is
externally (e.g. by the NC) limited to the indicated values.
6.7 Power Section - Operating Standard Motors

The tables below contain the nominal power PNenn of 4-pole standard
motors which can be operated at the respective drive controller. The
following conditions apply:
• the dedicated mains choke is used
• switching frequency: 4 kHz
• output frequency: > 4 Hz
• ambient temperature: Ta < Tamax °C
• control factor: a0 > 0,8
• relation of overload: K = Ppeak Pbase
ULN = 3AC400 V, 48…62 Hz:

W0012 W0028 W0054 W0070
standard motor nominal power for
overload operation: PNenn kW 1,1 3,0 5,5 7,5
t=2 s; T=20 s; K=2,0
t=60 s; T=5 min; K=1,5
overload operation: PNenn kW 1,5 4,0 7,5 11
t=60 s; T=10 min; K=1,1
continuous operation: PNenn kW 1,5 4,0 7,5 11
t>10 min; K=1,0
Fig. 6-13: Standard motors 3AC400V, 50 Hz
ULN = 3AC460…480 V, 48…62 Hz:

1) 1) 1) 1)
W0012 W0028 W0054 W0070
t=2 s; T=20 s; K=2,0
t=60 s; T=5 min; K=1,5
t=60 s; T=10 min; K=1,1
continuous operation: PNenn kW 1,5 4,8 9,0 13,2
t>10 min; K=1,0
1) preliminary data
Fig. 6-14: Standard motors 3AC460…480V, 50/60 Hz
6.8 Power Section – Cooling, Power Dissipation, Insulation

Resistance, Sound Pressure
W0012 W0028 W0054 W0070
cooling of power section forced forced forced forced
volumetric capacity of m³/h approx. 24 approx. 24 approx. 40 approx. 40
forced cooling
cooling air flow together for braking resistor and power section
max. device power PDiss,Drive W 80 120 270 300
dissipation (with inverter,
chopper and rectifier losses;
without internal continuous
braking resistor power)
min. insulation resistance at Ris MOhm 1 8 8 8
DC500V
coupling capacitance power CKop nF 210 210 210 210
section against housing
sound pressure level dB (A) 67 67 71 71
(accuracy class 2)
Fig. 6-15: Data power section - cooling, power dissipation, insulation
resistance, sound pressure
The current-depending power dissipation of the power sections illustrated

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

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

HCS02.1E-W0054

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

HCS02.1E-W0070

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

6.9 Control Voltage
Devices without Internal Control Voltage Supply (HCS02.1E-W00xx-

NNNN)
Note: The data below apply to the control sections.

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

control voltage UN3 V • 24 ±20%
(if no motor holding brake has to be supplied)
• If motor holding brakes are to be supplied, observe the
data of the motor documentation. The following values are
normally sufficient:
24 ±5% with motor cable length <50 m
26 ±5% with motor cable length >50 m
max. ripple content w - mustn't exceed the control voltage range
max. allowed overvoltage UN3max V 33 (max. 1 ms)
max. inrush current IEIN3 A 2.8
plus inrush current of control section (see Project Panning
Manual IndraDrive Control Sections)
max. pulse width of IEIN3 tEIN3Lade ms 15
max. input capacitance CN3 mF 1.2 * 0.47
1)
power consumption :
HCS02.1E-W0012 PN3 W 12
HCS02.1E-W0028 PN3 W 14
HCS02.1E-W0054 PN3 W 23
HCS02.1E-W0070 PN3 W 23
1): data without motor holding brake and control section taken into
account
Fig. 6-20: Control voltage
Note: Overvoltage of more 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 overvoltages
to the allowed value.
• Overvoltage limiters at the control cabinet input that limit
existing 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 overvoltages by
inductive or capacitive coupling.
Devices with Internal Control Voltage Supply Generation from DC bus

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

control voltage UN3 V • 24 ±20%
(when no motor holding brake is used)
• If motor holding brakes are to be supplied, observe
the data of the motor documentation. The following
values are normally sufficient:
24 ±5% with motor cable length <50 m
26 ±5% with motor cable length >50 m
max. ripple content w - mustn't exceed the control voltage range
max. allowed overvoltage UN3max V 33 (max. 1 ms)
max. charging current IEIN3 A 2.8
plus charging current of control section (see Project
Planning Manual IndraDrive Control Sections)
max. pulse duration of IEIN3 tEIN3Lade ms 15
max. input capacity CN3 mF 1.2 * 0.47
power consumption:
HCS02.1E-W0012 PN3 W 12
HCS02.1E-W0028 PN3 W 14
HCS02.1E-W0054 PN3 W 23
HCS02.1E-W0070 PN3 W 23
internally generated control UN3 V 24 ±10%
voltage
(not used for supplying the motor holding brake)
output power W 70
for required power of control
section CS* and power section
power dissipation W 25
short-circuit strength present
overload withstand capability present
overtemperature protection present
Fig. 6-21: Control voltage -***V
Note: Overvoltages of more than 33 V have to be derived by

measures in the electrical equipment of the machine or
installation. This includes:
• 24-Volt mains sections that reduce incoming overvoltages
to the allowed value.
• Overvoltage limiters at the control cabinet input that limit
existing overvoltages to the allowed value. This also
applies to long 24-Volt lines that have been laid in parallel
with power and mains cables and can absorb overvoltages
caused by inductive or capacitive coupling.
Block diagram of control voltage generation from the DC bus:
int.
24 V Br LT ST SMPS ZK
(optional)
hcs_block_steuerspg.fh7
Br: brake circuit

LT: power section
ST: control section
int. SMPS: internal switching-mode power supply
ZK: DC bus
Fig. 6-22: Block diagram of internal control voltage generation
Note: The external 24V supply takes place via connection X13.
6.10 Connections
Complete Connection Diagram
XS1 shield connection
X1out
X1:Out bus connection OUT
1-8
X1in
X1:In bus connection IN

1-8
X13:1 0V control voltage

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

1
MotTemp-
2
+24VBr motor holding brake

3
0VBr
4
X9
1 external braking resistor

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

X9: not available for HCS02.1E-W0012 and –W0028
Fig. 6-23: Complete connection diagram
Note: Apart from the connections listed below, it is necessary to wire

the Bb contact at the control section for signaling the
readiness for operation of the drive controller (see Project
Planning Manual for Control Section).
Connections at HCS02.1E-W0012
Front
XS1
1 2 3 4
X13
hcs0012_front.fh7
X13: control voltage

XS1: shield connection (control wires)
Fig. 6-24: HCS02.1E-W0012 power section connections (front)
Bottom
1 2 3 4
X6
XS2
X5
X3
hcs0028_x3_x5_x6.fh7
X3: mains connection

X5: motor connection
X6: motor temperature monitoring, motor holding brake
XS2: shield connection (motor cable)
Fig. 6-25: HCS02.1E-W0012 power section connections (bottom)
Connections at HCS02.1E-W0028, -W0054, -W0070

Front
XS1
X1 out X1 in
1 2 3 4
X13
L+
L-
hcs0028_front.fh7
X1: module bus

X13: control voltage
XS1: shield connection (control wires)
L+, L-: DC bus
Fig. 6-26: HCS02.1E-W0028, -W0054, -W0070 power section connections
(front)
Bottom (HCS02.1E-W0028)
1 2 3 4
X6
XS2
X5
X3
hcs0028_x3_x5_x6.fh7

Fig. 6-27: HC02.1E-W0028 power section connections (bottom)
Bottom (HCS02.1E-W0054, -W0070)
1 2 3 4
X9
X6
XS2
X3 X5
hcs0054_x3_x5_x6_x9.fh7

X9: external braking resistor
Fig. 6-28: HC02.1E-W0054, -W0070 power section connections (bottom)
X1, Module Bus

The module bus permits data exchange between the drive controllers.
Graphic Representation
X1 out X1 in
X1f2.FH7
Fig. 6-29: X1
Design Type No. of poles Type of design

Ribbon cable male 8 Male (device)
connector
Ribbon cable female 8 Female (ribbon cable)
connector
Fig. 6-30: Design
X3, Mains Connection
High electrical voltage! Danger to life, severe

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

poles
W0012 Screw terminal 4 Pins on device
block
block
block
block
Fig. 6-31: Design
Identification of the individual connections:

Identification Significance
L1 phase 1
L2 phase 2
L3 phase 3
equipment grounding conductor
Fig. 6-32: Identification of the individual connections
Note: Only with single-phase operation: connect the connecting lines

of the mains voltage supply L1 and N with the connections L1
and L2.
Connection Cross Section HCS02.1E- Cross section Cross section Cross section
single-wire multi-wire in AWG
[mm²] [mm²]
W0012 0.2-4 0.2-4 24-10
W0028 0.2-4 0.2-4 24-10
W0054 0.5-10 0.5-10 20-8
W0070 0.5-10 0.5-10 20-8
Fig. 6-33: Connection cross section
Tightening Torque HCS02.1E- Tightening torque [Nm]

W0012 0.5 – 0.6
W0028 0.5 – 0.6
W0054 1.2 – 1.5
W0070 1.2 – 1.5
Fig. 6-34: Tightening torque
Damage to the drive controller

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

DANGER connector!
Design HCS02.1E- Type No. of poles Type of design

block
block
block
block
Fig. 6-35: Design

A1 phase 1
A2 phase 2
A3 phase 3
equipment grounding conductor
Short Circuit Protection The outputs A1, A2, A3 are short-circuit proof at the device output against
each other and against ground.
Connection Cross Section HCS02.1N- Cross section Cross section Cross section
[mm²] [mm²]
W0012 0.2-4 0.2-4 24-10
W0028 0.2-4 0.2-4 24-10
W0054 0.5-10 0.5-10 20-8
W0070 0.5-10 0.5-10 20-8
Tightening Torque HCS02.1N- Tightening torque [Nm]

W0012 0.5 – 0.6
W0028 0.5 – 0.6
W0054 1.2 – 1.5
W0070 1.2 – 1.5
Connection of the Motor Power For the connection between drive controller and motor, use Rexroth motor
Cable power cables (see documentation "Rexroth Connection Cables; Selection
Data", DOK-CONNEC-CABLE*STAND-AUxx-EN-P).
Damage to the drive controller!

⇒ Strain relief for the motor power cables cannot be
provided at the drive controller. Therefore, make
sure strain relief of the motor power cables is
CAUTION
provided in the control cabinet.
Note: For optimum shield contact of the motor power cable use our
special accessories HAS02.1, where possible (See project
planning manual "Rexroth IndraDrive Drive System", DOK-
INDRV*-SYSTEM*****-PRxx-EN-P.)
X6, Motor Temperature Monitoring and Motor Holding Brake

The drive controller is supplied with 24V for the motor holding brake via
connection X13.

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

Spring tension 4 Pins on device
Fig. 6-39: Design

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

Cross section Cross section Cross section
[mm²] [mm²]
0.14-1.5 0.14-1.5 28-16
Note: Make sure the voltage supply for the motor holding brake is
sufficient. In this respect observe the lengths and cross
sections of the cables used.
MotTemp+
MotTemp-
+24VBr
0VBr
1
4
X6
A1 A2 A3
X5
shield for
motor cable
G
H
C
E
A
F
U AC motor
M
3
holding
brake
PTC /
NTC /
KTY84
(depends on motor type)
x6_kabel_anschluss.FH7
Fig. 6-42: Motor cable, temperature monitor and holding brake connection
Maximum allowed braking current:

• HCS02.1N-W0012: 2.0 Aeff
• HCS02.1N-W0028: 2.0 Aeff
CAUTION
• HCS02.1N-W0054: 2.0 Aeff
• HCS02.1N-W0070: 2.0 Aeff
Where braking currents are higher, the motor holding
brake must be activated by means of an external contact
element.
The contact elements used in the drive controller are
subject to wear. Guaranteed number of switching
actions at max. time constant of load < 50 ms
(LBrake/(24V/IBrake)): 250.000.
Note: The output to the motor holding brake (+24 V, 0 V) is

protected against overload and short-circuit by means of a
PTC thermistor.
Dangerous movements! Danger to personnel

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

more than 50 V!
⇒ Exclusively operate the drive controller with plugged
DANGER on connector!
Design HCS02.1E- Type No. of poles Type of design

block
block
Fig. 6-43: Design

1 phase 1
2 phase 2
Connection Cross Section HCS02.1E- Cross section Cross section Cross section
[mm²] [mm²]
W0054 0.5-10 0.5-10 20-8
W0070 0.5-10 0.5-10 20-8
Fig. 6-45: Connection cross sections
Tightening Torque HCS02.1E- Tightening torque [Nm]

W0054 1.2 – 1.5
W0070 1.2 – 1.5
Damage to the drive controller!

⇒ You have to provide strain relief for the connection
cable in the control cabinet or use the optionally
available connection accessory (shielding plate;
CAUTION
HAS02.1).
Load Capacity
Maximum allowed current load Imax = 30 A
Ieff = 15 A
short circuit protection via fusing of devices
Fig. 6-47: Load capacity
X13, Control Voltage (+24 V, 0 V)

The external 24V supply is applied via connection X13 for
• the power section of the drive controller
• brake control via X6 and
• the control section of the drive controller
With regard to control voltage supply, the HCS02.1 drive controllers are
available in two different designs.
• Standard design HCS02.1E-W****-***N:
The control voltage is supplied by an external 24V power supply unit.
• Optional design HCS02.1E-W****-***V:
The control voltage is supplied by an integrated 24V power supply unit.
A power supply unit that makes available the control voltage supply for the
power section and the control section from the DC bus is integrated in the
drive controller.
Note: • Technical data: see page 6-21

• Falling short of the permissible control voltage leads to a
corresponding error message (=> refer also to firmware
function description).
• Interruption to the control voltage when the motor is
running leads to torque-free (brakeless) runout in the motor.
Note on design -***V (see also page 6-21):

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

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

Spring tension 4 Pins on connector
Fig. 6-48: Design
Connection Cross Section Cross section Cross section Cross section

[mm²] [mm²]
0.14-1.5 0.14-1.5 28-16
Connection 4 +24 V
3 +24 V
2 0V
1 0V
Load Capacity looping through the power supply up to max. 6 Aeff allowed
polarity reversal protection over the allowed voltage range by
internal protective diode of +24V
circuit
Fig. 6-51: Load capacity
Note: The input 0 V connected in conductive form with the housing

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

line routing preferably in parallel
max. allowed inductance between 24V 100 µH
supply source and X13
(corresponds to approx. 2*75 m)
Fig. 6-52: Supply line 24 V
The control voltage supply is routed to the connection X13 from above
(see following figure).
1: lines to control voltage supply

Fig. 6-53: Control voltage supply at X13
DC Bus (L+, L-)

By means of the DC bus connection, the following components are linked:
• several drive controllers to one another, and
• drive controllers to additional components in order to
• increase the stored power by means of DC bus capacitor unit
• increase the permissible braking resistor continuous output by
means of DC bus resistor unit
Design The DC bus is connected via contact bars and screws (M6) at the front of
the drive controller. Depending on the width of the drive controllers, there
are contact bars of different lengths.
Tightening Torque 6 Nm
DC Bus Wiring If in special cases it is not possible to use the DC bus rails for connection,
connection must be established using the shortest possible twisted wires.
Length of twisted wire max. 2 m

Wire cross section min. 10 mm²,
but not less than supply feeder
cross section
Wire protection by means of fuses in the mains
supply
Dielectric strength of single strand against > 750 V
ground (e.g.: strand type - H07)
Damage caused by voltage arcing!

⇒ If drive controllers are stacked in the control cabinet,
the connections for the DC buses between the drive
controllers have to be correctly made. There is
CAUTION
otherwise a risk of voltage arcing (See project
planning manual "Rexroth IndraDrive Drive System",
DOK-INDRV*-SYSTEM*****-PRxx-EN-P.)
Connection Point of Equipment Grounding Conductor and Equipment

Grounding Connections
Dangerous contact voltage at device housing!

Lethal electric shock!
⇒ Connect the drive controller to the equipment
DANGER grounding system via connection X3 (mains).
Ground Connection of Housing

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.
XS1, Shield Connection (Control Wires)
XS1
hcs_xs1.fh7
Fig. 6-54: Shield connection XS1
Connection for shields of lines connected to the control section (only for
lines with connectors, which do not have their own shield connection).
Note: Always connect shields of control lines with a large metal-to-

metal contact surface.
Risk of damage caused by high temperature of

outlet air!
⇒ Observe outlet temperatures at the top of the drive
CAUTION controllers.
XS2, Shield Connection (Motor Cable)
XS2 XS2
hcs0028_XS2.fh7 hcs0054_XS2.fh7
Fig. 6-55: XS2
XS2 is used for mounting the accessory HAS02.1 for shield connection of
the motor cable (See Project Planning Manual "Rexroth IndraDrive Drive
System", DOK-INDRV*-SYSTEM*****-PRxx-EN-P.)
Rexroth IndraDrive C Touch Guard 7-1
7 Touch Guard

more than 50 V!
⇒ The appropriate touch guard must be mounted for
each drive controller following connection work.
⇒
WARNING
Never mount a damaged touch guard.
⇒ Immediately replace a damaged touch guard by an
undamaged touch guard.
7.1 Cutouts
A B
hcs_beruehrschutz_seite.fh7
Fig. 7-1: Cutouts at the touch guard

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

contact rails, only the cutout B (see picture) may be broken off the
touch guard.
• If the DC bus and the control voltage are connected by means of
cables (e.g. in the case of multiple-line arrangement of the drive
controllers), the cutouts A, and B (see picture) may be broken off the
touch guard.
• At the first and last drive controller in a line of drive controllers
connected to each other there mustn't any cutout be broken off at the
outer side of the touch guard.
7-2 Touch Guard Rexroth IndraDrive C
7.2 Mounting
hcs_beruehrschutz.fh7
Fig. 7-2: Touch guard
The touch guard must always be mounted following connection work.
Note: Risk of damage to the touch guard!

The maximum tightening torque for the fixing screw for the
touch guard is 2.8 Nm.
Tightening Torque 2,8 Nm
Rexroth IndraDrive C Disposal and Environmental Protection 8-1
8 Disposal and Environmental Protection
8.1 Disposal
Products
Our products can be returned to us free of charge for disposal. However,
the products must be free of oil, grease or other dirt.
Furthermore, the products returned for disposal must not contain any
undue foreign matter or foreign component.
Please send the products free domicile to the following address:

Bosch Rexroth AG
Electric Drives and Controls
Bürgermeister-Dr.-Nebel-Straße 2
D-97816 Lohr am Main
Packaging Materials
The packaging materials consist of cardboard, wood and polystyrene.
These materials can be easily recycled in any municipal recycling system.
For ecological reasons, please refrain from returning the empty packages
to us.
8.2 Environmental Protection
No Release of Hazardous Substances

Our products do not contain any hazardous substances which may be
released in the case of appropriate use. Accordingly, our products will
normally not have any negative effect on the environment.
Materials Contained in the Products

Electronic Devices
Electronic devices mainly contain:
• steel
• aluminum
• copper
• synthetic materials
• electronic components and modules
Motors
Motors mainly contain:
• steel
• aluminum
• copper
• brass
• magnetic materials
• electronic components and modules
8-2 Disposal and Environmental Protection Rexroth IndraDrive C
Recycling
Due to their high content of metal, most of the product components can
be recycled. In order to recycle the metal in the best possible way, the
products must be disassembled into individual modules.
Metals contained in electric and electronic modules can also be recycled
by means of special separation processes. The synthetic materials
remaining after these processes can be thermally recycled.
Rexroth IndraDrive C Service & Support 9-1
9 Service & Support
9.1 Helpdesk
Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am
am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries.
Sie erreichen uns Contact us
- telefonisch - by phone: +49 (0) 9352 40 50 60

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

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

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

Wir können Ihnen schnell und effizient helfen wenn For quick and efficient help, please have the
Sie folgende Informationen bereithalten: following information ready:
1. detaillierte Beschreibung der Störung und der 1. Detailed description of the failure and
Umstände. circumstances.
2. Angaben auf dem Typenschild der 2. Information on the type plate of the affected
betreffenden Produkte, insbesondere products, especially type codes and serial
Typenschlüssel und Seriennummern. numbers.
3. Tel.-/Faxnummern und e-Mail-Adresse, unter 3. Your phone/fax numbers and e-mail address,
denen Sie für Rückfragen zu erreichen sind. so we can contact you in case of questions.
9-2 Service & Support Rexroth IndraDrive C
9.5 Kundenbetreuungsstellen - Sales & Service Facilities
Deutschland – Germany vom Ausland: (0) nach Landeskennziffer weglassen!

from abroad: don’t dial (0) after country code!
Vertriebsgebiet Mitte
Germany Centre SERVICE AUTOMATION SERVICE AUTOMATION SERVICE AUTOMATION
Rexroth Indramat GmbH CALL ENTRY CENTER ERSATZTEILE / SPARES
Bgm.-Dr.-Nebel-Str. 2 / Postf. 1357 Helpdesk HOTLINE 24 / 7 / 365 verlängerte Ansprechzeit
97816 Lohr am Main / 97803 Lohr MO – FR - extended office time -
von 07:00 - 18:00 Uhr außerhalb der Helpdesk-Zeit ♦ nur an Werktagen
Kompetenz-Zentrum Europa from 7 am – 6 pm out of helpdesk hours - only on working days -
Tel.: +49 (0)9352 40-0 ♦ von 07:00 - 18:00 Uhr
Tel. +49 (0) 9352 40 50 60 Tel.: +49 (0)172 660 04 06
Fax: +49 (0)9352 40-4885 - from 7 am - 6 pm -
Fax +49 (0) 9352 40 49 41 oder / or
Tel.: +49 (0)171 333 88 26 Tel. +49 (0) 9352 40 42 22
service.svc@boschrexroth.de
Vertriebsgebiet Süd Vertriebsgebiet West Gebiet Südwest
Germany South Germany West Germany South-West
Bosch Rexroth AG Bosch Rexroth AG Bosch Rexroth AG
Landshuter Allee 8-10 Regionalzentrum West Service-Regionalzentrum Süd-West
80637 München Borsigstrasse 15 Siemensstr. 1
40880 Ratingen 70736 Fellbach
Tel.: +49 (0)89 127 14-0 Tel.: +49 (0)2102 409-0 Tel.: +49 (0)711 51046–0
Fax: +49 (0)89 127 14-490 Fax: +49 (0)2102 409-406 Fax: +49 (0)711 51046–248
+49 (0)2102 409-430
Vertriebsgebiet Nord Vertriebsgebiet Mitte Vertriebsgebiet Ost Vertriebsgebiet Ost

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

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

Bosch Rexroth GmbH Bosch Rexroth GmbH Bosch Rexroth NV/SA BEC A/S
Electric Drives & Controls Electric Drives & Controls Henri Genessestraat 1 Zinkvej 6
Stachegasse 13 Industriepark 18 1070 Bruxelles 8900 Randers
1120 Wien 4061 Pasching
Tel.: +43 (0)1 985 25 40 Tel.: +43 (0)7221 605-0 Tel: +32 (0) 2 451 26 08 Tel.: +45 (0)87 11 90 60
Fax: +43 (0)1 985 25 40-93 Fax: +43 (0)7221 605-21 Fax: +32 (0) 2 451 27 90 Fax: +45 (0)87 11 90 61
info@boschrexroth.be
service@boschrexroth.be
Great Britain – Großbritannien Finland - Finnland France - Frankreich France - Frankreich

Bosch Rexroth Ltd. Bosch Rexroth Oy Bosch Rexroth SAS Bosch Rexroth SAS
Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls
Broadway Lane, South Cerney Ansatie 6 Avenue de la Trentaine ZI de Thibaud, 20 bd. Thibaud
Cirencester, Glos GL7 5UH 017 40 Vantaa (BP. 74) (BP. 1751)
77503 Chelles Cedex 31084 Toulouse
Tel.: +44 (0)1285 863000 Tel.: +358 (0)9 84 91-11 Tel.: +33 (0)164 72-63 22 Tel.: +33 (0)5 61 43 61 87
Fax: +44 (0)1285 863030 Fax: +358 (0)9 84 91-13 60 Fax: +33 (0)164 72-63 20 Fax: +33 (0)5 61 43 94 12
sales@boschrexroth.co.uk Hotline: +33 (0)608 33 43 28
service@boschrexroth.co.uk
France – Frankreich Italy - Italien Italy - Italien Italy - Italien

Bosch Rexroth SAS Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth S.p.A.
Electric Drives & Controls Via G. Di Vittorio, 1 Via Paolo Veronesi, 250 Via Mascia, 1
91, Bd. Irène Joliot-Curie 20063 Cernusco S/N.MI 10148 Torino 80053 Castellamare di Stabia NA
69634 Vénissieux – Cedex Hotline: +39 02 92 365 563
Tel.: +33 (0)4 78 78 53 65 Tel.: +39 02 92 365 1 Tel.: +39 011 224 88 11 Tel.: +39 081 8 71 57 00
Fax: +33 (0)4 78 78 53 62 Service: +39 02 92 365 300 Fax: +39 011 224 88 30 Fax: +39 081 8 71 68 85
Fax: +39 02 92 365 500
Service: +39 02 92 365 516
Italy - Italien Italy - Italien Netherlands - Niederlande/Holland Netherlands – Niederlande/Holland

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

Bosch Rexroth AS Goimendi Automation Bosch Rexroth S.A. Bosch Rexroth S.A.
Electric Drives & Controls Parque Empresarial Zuatzu Electric Drives & Controls Electric Drives & Controls
Berghagan 1 or: Box 3007 C/ Francisco Grandmontagne no.2 Centro Industrial Santiga c/ Almazara, 9
1405 Ski-Langhus 1402 Ski 20018 San Sebastian Obradors s/n 28760 Tres Cantos (Madrid)
Tel.: +47 (0) 64 86 41 00 08130 Santa Perpetua de Mogoda
Tel.: +34 9 43 31 84 21 Barcelona Tel.: +34 91 806 24 79
Fax: +47 (0) 64 86 90 62 - service: +34 9 43 31 84 56 Tel.: +34 9 37 47 94 00 Fax: +34 91 806 24 72
Fax: +34 9 43 31 84 27 Fax: +34 9 37 47 94 01 fernando.bariego@boschrexroth.es
Hotline: +47 (0)64 86 94 82 - service: +34 9 43 31 84 60
jul.ruud@rexroth.no sat.indramat@goimendi.es
Sweden - Schweden Sweden - Schweden Switzerland East - Schweiz Ost Switzerland West - Schweiz West
Bosch Rexroth AB Bosch Rexroth AB Bosch Rexroth Schweiz AG Bosch Rexroth Suisse SA
Electric Drives & Controls Electric Drives & Controls Electric Drives & Controls Av. Général Guisan 26
- Varuvägen 7 Ekvändan 7 Hemrietstrasse 2 1800 Vevey 1
(Service: Konsumentvägen 4, Älfsjö) 254 67 Helsingborg 8863 Buttikon
125 81 Stockholm Tel.: +46 (0) 42 38 88 -50 Tel. +41 (0) 55 46 46 111 Tel.: +41 (0)21 632 84 20
Fax: +46 (0) 42 38 88 -74 Fax +41 (0) 55 46 46 222 Fax: +41 (0)21 632 84 21
Tel.: +46 (0)8 727 92 00
Fax: +46 (0)8 647 32 77
Europa (Ost) - Europe (East)

vom Ausland: (0) nach Landeskennziffer weglassen
from abroad: don’t dial (0) after country code
Czech Republic - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland – Polen
Bosch -Rexroth, spol.s.r.o. DEL a.s. Bosch Rexroth Kft. Bosch Rexroth Sp.zo.o.
Hviezdoslavova 5 Strojírenská 38 Angol utca 34 ul. Staszica 1
627 00 Brno 591 01 Zdar nad Sázavou 1149 Budapest 05-800 Pruszków
Tel.: +420 (0)5 48 126 358 Tel.: +420 566 64 3144 Tel.: +36 (1) 422 3200 Tel.: +48 22 738 18 00
Fax: +420 (0)5 48 126 112 Fax: +420 566 62 1657 Fax: +36 (1) 422 3201 – service: +48 22 738 18 46
Fax: +48 22 758 87 35
– service: +48 22 738 18 42
Poland – Polen Romania - Rumänien Romania - Rumänien Russia - Russland

Bosch Rexroth Sp.zo.o. East Electric S.R.L. Bosch Rexroth Sp.zo.o. Bosch Rexroth OOO
Biuro Poznan Bdul Basarabia no.250, sector 3 Str. Drobety nr. 4-10, app. 14 Wjatskaja ul. 27/15
ul. Dabrowskiego 81/85 73429 Bucuresti 70258 Bucuresti, Sector 2 127015 Moskau
60-529 Poznan Tel./Fax:: +40 (0)21 255 35 07 Tel.: +40 (0)1 210 48 25 Tel.: +7-095-785 74 78
Tel.: +48 061 847 64 62 /-63 +40 (0)21 255 77 13 +40 (0)1 210 29 50 +7-095 785 74 79
Fax: +48 061 847 64 02 Fax: +40 (0)21 725 61 21 Fax: +40 (0)1 210 29 52 Fax: +7 095 785 74 77
eastel@rdsnet.ro laura.kanina@boschrexroth.ru
Russia Belarus - Weissrussland Turkey - Türkei Turkey - Türkei Slowenia - Slowenien

ELMIS Bosch Rexroth Otomasyon Servo Kontrol Ltd. Sti. DOMEL
10, Internationalnaya San & Tic. A..S. Perpa Ticaret Merkezi B Blok Otoki 21
246640 Gomel, Belarus Fevzi Cakmak Cad No. 3 Kat: 11 No: 1609 64 228 Zelezniki
Tel.: +375/ 232 53 42 70 34630 Sefaköy Istanbul 80270 Okmeydani-Istanbul
+375/ 232 53 21 69 Tel.: +90 212 413 34 00 Tel: +90 212 320 30 80 Tel.: +386 5 5117 152
Fax: +375/ 232 53 37 69 Fax: +90 212 413 34 17 Fax: +90 212 320 30 81 Fax: +386 5 5117 225
elmis_ltd@yahoo.com www.boschrexroth.com.tr remzi.sali@servokontrol.com brane.ozebek@domel.si
www.servokontrol.com
Africa, Asia, Australia – incl. Pacific Rim
Australia - Australien Australia - Australien China China

AIMS - Australian Industrial Bosch Rexroth Pty. Ltd. Shanghai Bosch Rexroth Shanghai Bosch Rexroth
Machinery Services Pty. Ltd. No. 7, Endeavour Way Hydraulics & Automation Ltd. Hydraulics & Automation Ltd.
28 Westside Drive Braeside Victoria, 31 95 Waigaoqiao, Free Trade Zone 4/f, Marine Tower
Laverton North Vic 3026 Melbourne No.122, Fu Te Dong Yi Road No.1, Pudong Avenue
Melbourne Shanghai 200131 - P.R.China Shanghai 200120 - P.R.China
Tel.: +61 3 93 14 3321 Tel.: +61 3 95 80 39 33 Tel.: +86 21 58 66 30 30 Tel: +86 21 68 86 15 88
Fax: +61 3 93 14 3329 Fax: +61 3 95 80 17 33 Fax: +86 21 58 66 55 23 Fax: +86 21 58 40 65 77
Hotlines: +61 3 93 14 3321 mel@rexroth.com.au richard.yang_sh@boschrexroth.com.cn
+61 4 19 369 195 gf.zhu_sh@boschrexroth.com.cn
enquires@aimservices.com.au
China China China China

Bosch Rexroth China Ltd. Bosch Rexroth China Ltd. Bosch Rexroth (China) Ltd. Melchers GmbH
15/F China World Trade Center Guangzhou Repres. Office A-5F., 123 Lian Shan Street BRC-SE, Tightening & Press-fit
1, Jianguomenwai Avenue Room 1014-1016, Metro Plaza, Sha He Kou District 13 Floor Est Ocean Centre
Beijing 100004, P.R.China Tian He District, 183 Tian He Bei Rd Dalian 116 023, P.R.China No.588 Yanan Rd. East
Guangzhou 510075, P.R.China 65 Yanan Rd. West
Shanghai 200001
Tel.: +86 10 65 05 03 80 Tel.: +86 20 8755-0030 Tel.: +86 411 46 78 930 Tel.: +86 21 6352 8848
Fax: +86 10 65 05 03 79 +86 20 8755-0011 Fax: +86 411 46 78 932 Fax: +86 21 6351 3138
Fax: +86 20 8755-2387
Hongkong India - Indien India - Indien India - Indien

Bosch Rexroth (China) Ltd. Bosch Rexroth (India) Ltd. Bosch Rexroth (India) Ltd. Bosch Rexroth (India) Ltd.
6th Floor, Electric Drives & Controls Electric Drives & Controls S-10, Green Park Extension
Yeung Yiu Chung No.6 Ind Bldg. Plot. No.96, Phase III Advance House, II Floor New Delhi – 110016
19 Cheung Shun Street Peenya Industrial Area Ark Industrial Compound
Cheung Sha Wan, Bangalore – 560058 Narol Naka, Makwana Road
Kowloon, Hongkong Andheri (East), Mumbai - 400 059
Tel.: +852 22 62 51 00 Tel.: +91 80 51 17 0-211...-218 Tel.: +91 22 28 56 32 90 Tel.: +91 11 26 56 65 25
Fax: +852 27 41 33 44 Fax: +91 80 83 94 345 +91 22 28 56 33 18 +91 11 26 56 65 27
alexis.siu@boschrexroth.com.hk +91 80 83 97 374 Fax: +91 22 28 56 32 93 Fax: +91 11 26 56 68 87
mohanvelu.t@boschrexroth.co.in singh.op@boschrexroth.co.in koul.rp@boschrexroth.co.in
Indonesia - Indonesien Japan Japan Korea

PT. Bosch Rexroth Bosch Rexroth Automation Corp. Bosch Rexroth Automation Corp. Bosch Rexroth-Korea Ltd.
Building # 202, Cilandak Service Center Japan Electric Drives & Controls Electric Drives and Controls
Commercial Estate Yutakagaoka 1810, Meito-ku, 2F, I.R. Building Bongwoo Bldg. 7FL, 31-7, 1Ga
Jl. Cilandak KKO, Jakarta 12560 NAGOYA 465-0035, Japan Nakamachidai 4-26-44, Tsuzuki-ku Jangchoong-dong, Jung-gu
YOKOHAMA 224-0041, Japan Seoul, 100-391
Tel.: +62 21 7891169 (5 lines) Tel.: +81 52 777 88 41 Tel.: +81 45 942 72 10 Tel.: +82 234 061 813
Fax: +62 21 7891170 - 71 +81 52 777 88 53 Fax: +81 45 942 03 41 Fax: +82 222 641 295
rudy.karimun@boschrexroth.co.id +81 52 777 88 79
Fax: +81 52 777 89 01
Korea Malaysia Singapore - Singapur South Africa - Südafrika

Bosch Rexroth-Korea Ltd. Bosch Rexroth Sdn.Bhd. Bosch Rexroth Pte Ltd TECTRA Automation (Pty) Ltd.
1515-14 Dadae-Dong, Saha-gu 11, Jalan U8/82, Seksyen U8 15D Tuas Road 71 Watt Street, Meadowdale
Electric Drives & Controls 40150 Shah Alam Singapore 638520 Edenvale 1609
Pusan Metropolitan City, 604-050 Selangor, Malaysia
Tel.: +82 51 26 00 741 Tel.: +60 3 78 44 80 00 Tel.: +65 68 61 87 33 Tel.: +27 11 971 94 00
Fax: +82 51 26 00 747 Fax: +60 3 78 45 48 00 Fax: +65 68 61 18 25 Fax: +27 11 971 94 40
eunkyong.kim@boschrexroth.co.kr hockhwa@hotmail.com sanjay.nemade Hotline: +27 82 903 29 23
rexroth1@tm.net.my @boschrexroth.com.sg georgv@tectra.co.za
Taiwan Taiwan Thailand

Bosch Rexroth Co., Ltd. Bosch Rexroth Co., Ltd. NC Advance Technology Co. Ltd.
Taichung Industrial Area Tainan Branch 59/76 Moo 9
No.19, 38 Road No. 17, Alley 24, Lane 737 Ramintra road 34
Taichung, Taiwan 407, R.O.C. Chung Cheng N.Rd. Yungkang Tharang, Bangkhen,
Tel : +886 - 4 -235 08 383 Tainan Hsien, Taiwan, R.O.C. Bangkok 10230
Fax: +886 - 4 -235 08 586 Tel : +886 - 6 –253 6565 Tel.: +66 2 943 70 62
jim.lin@boschrexroth.com.tw Fax: +886 - 6 –253 4754 +66 2 943 71 21
david.lai@boschrexroth.com.tw charlie.chen@boschrexroth.com.tw Fax: +66 2 509 23 62
Hotline +66 1 984 61 52
sonkawin@hotmail.com
Nordamerika – North America

USA USA Central Region - Mitte USA Southeast Region - Südwest USA SERVICE-HOTLINE
Headquarters - Hauptniederlassung
Bosch Rexroth Corporation Bosch Rexroth Corporation
Bosch Rexroth Corporation Electric Drives & Controls Electric Drives & Controls
- 7 days x 24hrs -
Electric Drives & Controls Central Region Technical Center Southeastern Technical Center
5150 Prairie Stone Parkway 1701 Harmon Road 3625 Swiftwater Park Drive
Hoffman Estates, IL 60192-3707 Auburn Hills, MI 48326 Suwanee, Georgia 30124
+1-800-REXROTH
Tel.: +1 847 645-3600 Tel.: +1 248 393-3330 Tel.: +1 770 932-3200 +1 800 739-7684
Fax: +1 847 645-6201 Fax: +1 248 393-2906 Fax: +1 770 932-1903
servicebrc@boschrexroth-us.com
repairbrc@boschrexroth-us.com
USA East Region – Ost USA Northeast Region – Nordost USA West Region – West
Bosch Rexroth Corporation Bosch Rexroth Corporation Bosch Rexroth Corporation

Electric Drives & Controls Electric Drives & Controls 7901 Stoneridge Drive, Suite 220
Charlotte Regional Sales Office Northeastern Technical Center Pleasant Hill, California 94588
14001 South Lakes Drive 99 Rainbow Road
Charlotte, North Carolina 28273 East Granby, Connecticut 06026
Tel.: +1 704 583-9762 Tel.: +1 860 844-8377 Tel.: +1 925 227-1084
+1 704 583-1486 Fax: +1 860 844-8595 Fax: +1 925 227-1081
Canada East - Kanada Ost Canada West - Kanada West Mexico Mexico
Bosch Rexroth Canada Corporation Bosch Rexroth Canada Corporation Bosch Rexroth Mexico S.A. de C.V. Bosch Rexroth S.A. de C.V.
Burlington Division 5345 Goring St. Calle Neptuno 72 Calle Argentina No 3913
3426 Mainway Drive Burnaby, British Columbia Unidad Ind. Vallejo Fracc. las Torres
Burlington, Ontario Canada V7J 1R1 07700 Mexico, D.F. 64930 Monterrey, N.L.
Canada L7M 1A8
Tel.: +1 905 335 5511 Tel. +1 604 205 5777 Tel.: +52 55 57 54 17 11 Tel.: +52 81 83 65 22 53
Fax: +1 905 335 4184 Fax +1 604 205 6944 Fax: +52 55 57 54 50 73 +52 81 83 65 89 11
Hotline: +1 905 335 5511 Hotline: +1 604 205 5777 mariofelipe.hernandez@boschrexroth.com.m +52 81 83 49 80 91
x
michael.moro@boschrexroth.ca david.gunby@boschrexroth.ca Fax: +52 81 83 65 52 80
Südamerika – South America

Argentina - Argentinien Argentina - Argentinien Brazil - Brasilien Brazil - Brasilien
Bosch Rexroth S.A.I.C. NAKASE Bosch Rexroth Ltda. Bosch Rexroth Ltda.
"The Drive & Control Company" Servicio Tecnico CNC Av. Tégula, 888 R. Dr.Humberto Pinheiro Vieira, 100
Rosario 2302 Calle 49, No. 5764/66 Ponte Alta, Atibaia SP Distrito Industrial [Caixa Postal 1273]
B1606DLD Carapachay B1653AOX Villa Balester CEP 12942-440 89220-390 Joinville - SC
Provincia de Buenos Aires Provincia de Buenos Aires
Tel.: +54 11 4756 01 40 Tel.: +54 11 4768 36 43 Tel.: +55 11 4414 56 92 Tel./Fax: +55 47 473 58 33
+54 11 4756 02 40 Fax: +54 11 4768 24 13 +55 11 4414 56 84 Mobil: +55 47 9974 6645
+54 11 4756 03 40 Hotline: +54 11 155 307 6781 Fax sales: +55 11 4414 57 07 prochnow@zaz.com.br
+54 11 4756 04 40 nakase@usa.net Fax serv.: +55 11 4414 56 86
Fax: +54 11 4756 01 36 nakase@nakase.com alexandre.wittwer@rexroth.com.br
+54 11 4721 91 53 gerencia@nakase.com (Service)
victor.jabif@boschrexroth.com.ar
Columbia - Kolumbien
Reflutec de Colombia Ltda.
Calle 37 No. 22-31
Santafé de Bogotá, D.C.
Colombia
Tel.: +57 1 368 82 67
+57 1 368 02 59
Fax: +57 1 268 97 37
reflutec@etb.net.co
Rexroth IndraDrive C Index 10-1
10 Index
A
appropriate use 2-1
B
Bb contact 1-4
Block diagrams 1-4
Brake supply 6-38
Braking resistor
connection 6-37
C
Cables
motor 6-33
Connection
braking resistor 6-37
control voltage 6-38
DC bus 6-41
diagram 6-23
HCS02.1E-W0012 6-24
HCS02.1E-W0028 6-26
HCS02.1E-W0054 6-26
HCS02.1E-W0070 6-26
mains (X3) 6-30
motor 6-32
motor holding brake 6-34
motor temperature monitoring 6-34
Connection point of equipment grounding conductor 6-42
Control section 1-4
type plate 4-2
Control voltage
connection 6-38
data 6-20
Control wires
shield connection 6-43
D
Data
electrical 6-1
mechanical 5-1
DC bus 6-41
DC bus continuous power
allowed power with single-phase mains connection 6-6
DC bus continuous power and mains connection power 6-7
Device types 4-1
Dimensional drawings 5-1
Documentation
overview 1-2
Drive controller
basic design 1-3
block diagrams 1-4
control section 1-4
HCS02.1 4-1
power section 1-3
type codes 4-1
E
Electrical data 6-1
Electrical installation 1-8
Equipment grounding connections 6-42
10-2 Index Rexroth IndraDrive C
G
Ground connection
of housing 6-42
H
HAS02.1
XS2 6-44
HCS02.1 4-1
Holding brake 6-38
Housing
ground connection 6-42
I
inappropriate use 2-2
IndraDrive
documentation 1-2
Installation
connection diagram 6-23
electrical 1-8
L
L+, L- 6-41
M
Mains
connection (X3) 6-30
Mains connection power and DC bus continuous power 6-7
Mechanical data 5-1
Module bus 6-29
Motor
cables 6-33
connection 6-32
holding brake 6-34
temperature monitoring 6-34
Motor cable
shield connection 6-44
Motor holding brake 6-34
Motor temperature monitoring 6-34
P
Power section 1-3
type plate 4-2
S
safety instructions for electric drives and controls 3-1
Shield connection
control wires 6-43
motor cable 6-44
T
Technical data
electrical 6-1
mechanical 5-1
Temperatures
above top of device 5-5
Touch guard 7-1
Type code
HCS02.1 4-1
Type plates 4-2
Rexroth IndraDrive C Index 10-3
U
use
appropriate 2-1
inappropriate 2-2
W
Weight 5-4
X
X1 6-29
X13 6-38
X3 6-30
X5 6-32
X6 6-34
X9 6-37
XS1 6-43
XS2 6-44
10-4 Index Rexroth IndraDrive C
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 (0)93 52-40-50 60
Fax +49 (0)93 52-40-49 41
service.svc@boschrexroth.de
www.boschrexroth.com
Printed in Germany
R911306138 DOK-INDRV*-HCS02.1****-PR03-EN-P

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Industrial Electric Drives Linear Motion and Service Mobile

Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

Rexroth IndraControl VCP 20

Title Rexroth IndraDrive C

Type of Documentation Project Planning Manual

Document Typecode DOK-INDRV*-HCS02.1****-PR02-EN

Internal File Reference Document number 120-2400-B314-02/EN

Record of Revisions Description Release Notes

Copyright  Bosch Rexroth AG 2006

Published by Bosch Rexroth AG

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

2 Important Directions for Use 2-1

3 Safety Instructions for Electric Drives and Controls 3-1

5 Mechanical Data 5-1

6 Electrical Data 6-1

Ground Connection of Housing ............................................................................................. 6-42

7 Touch Guard 7-1

8 Disposal and Environmental Protection 8-1

9 Service & Support 9-1

About this Documentation

Personal injury and property damage caused by

For complete project planning of a Rexroth IndraDrive drive system you

1.2 Basic Design of a Drive Controller

The drive controller consists of two essential parts:

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

Note: The control sections are described in a separate

1.3 Drive Controllers - Block Diagram

line input with braking resistor DC bus converter

Fig. 1-3: HCS02.1E-W0012-NNNN - Block diagram

line input with optional braking resistor DC bus converter

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

Fig. 1-5: HCS02.1E-W0028-NNNN - Block diagram

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

Fig. 1-7: HCS02.1E-W0054/70-NNNN - Block diagram

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

1.4 General Information on How to Install the Drive Controller

Electrostatic charges can cause damage to

Such exposed conductive parts include:

Note: Rexroth connection diagrams are only to be used for

Risk of damage to the drive controller by

2 Important Directions for Use

2.1 Appropriate Use

Note: Rexroth as manufacturer is not liable for any damages

Areas of Use and Application

Every drive controller has to be programmed before commissioning,

2.2 Inappropriate Use

3 Safety Instructions for Electric Drives and Controls

3.1 General Information

Using the Safety Instructions and Passing them on to Others

Improper use of these devices, failure to follow

Instructions for Use

• The devices have been designed for installation in industrial

Explanation of Warning Symbols and Degrees of Hazard Seriousness

Warning symbol with signal Degree of hazard seriousness according

Death or severe bodily harm will occur.

Death or severe bodily harm may occur.

Bodily harm or material damage may occur.

Hazards by Improper Use

High electric voltage and high working current!