CSH01.1C SE EN2 NNN NNN NN S NN FW REXROTH IndraDrive Manual

Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Rexroth IndraDrive R911309636

Edition 03
Drive System
Project Planning Manual

About this Documentation Rexroth IndraDrive
Title Rexroth IndraDrive

Drive System
Type of Documentation Project Planning Manual
Document Typecode DOK-INDRV*-SYSTEM*****-PR03-EN-P
Internal File Reference 120-2400-B321-03/EN
Purpose of Documentation This documentation describes the project planning of the drive system.
Record of Revisions Description Release Date Notes

DOK-INDRV*-SYSTEM*****-PR01-EN-P 11.2004 First edition
DOK-INDRV*-SYSTEM*****-PR02-EN-P 03.2005 Corrected edition for
online help MPx03
DOK-INDRV*-SYSTEM*****-PR03-EN-P 01.2006 3rd edition:
chapter on EMC revised;
HMV02, HMS02 included,
combinations
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 data specified above 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
Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85
http://www.boschrexroth.com/
Dept. BRC/EDY (RR/NN/BB)
Note This document has been printed on chlorine-free bleached paper.
DOK-INDRV*-SYSTEM*****-PR03-EN-P
Rexroth IndraDrive Contents I
Contents
1 Introduction 1-1
1.1 About this Documentation............................................................................................................. 1-1
Reference Documentations - Overview................................................................................... 1-3
Box with Project Planning Manuals on Rexroth IndraDrive..................................................... 1-4
Standards ................................................................................................................................ 1-4
Your Feedback ........................................................................................................................ 1-4
1.2 Overview and Contents of the Documentations on the Drive System Rexroth IndraDrive .......... 1-5
1.3 Introducing the System ................................................................................................................. 1-7
Drive System Rexroth IndraDrive C ........................................................................................ 1-7
Drive System Rexroth IndraDrive M ........................................................................................ 1-8
System Elements - Components of the System...................................................................... 1-8
Differences between Rexroth IndraDrive C and Rexroth IndraDrive M ................................ 1-10
Combination of Rexroth IndraDrive C and Rexroth IndraDrive M ......................................... 1-11
1.4 Basic Design of the Devices ....................................................................................................... 1-12
Basic Design of Drive Controllers.......................................................................................... 1-12
1.5 Available Type Currents and Performances............................................................................... 1-14
Selecting the Drive Controllers .............................................................................................. 1-14
Selecting the Component for Mains Supply .......................................................................... 1-15
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
II Contents Rexroth IndraDrive
Battery Safety ........................................................................................................................ 3-11

Protection Against Pressurized Systems .............................................................................. 3-12
4 Brief Description, Applications 4-1

4.1 Applications of the Drive System Rexroth IndraDrive .................................................................. 4-1
4.2 Mains Transformers DST and DLT............................................................................................... 4-1
Applications ............................................................................................................................. 4-1
4.3 Mains Filters HNF, HNK, NFE, HNS02, and NFD ........................................................................ 4-2
Applications ............................................................................................................................. 4-2
4.4 Mains Chokes HNL01 and HNL02 ............................................................................................... 4-3
Applications HNL01.1E, HNL01.1R and HNL02.1R................................................................ 4-3
4.5 Supply Units HMV01 / HMV02...................................................................................................... 4-3
Applications ............................................................................................................................. 4-3
4.6 Drive Controllers HMD01, HMS01................................................................................................ 4-4
Applications ............................................................................................................................. 4-4
4.7 Control Sections CSH01, CSB01, CDB01.................................................................................... 4-4
Applications ............................................................................................................................. 4-4
4.8 Drive Controllers HCS02 .............................................................................................................. 4-5
Applications ............................................................................................................................. 4-5
4.9 Drive Controllers HCS03 .............................................................................................................. 4-5
Applications ............................................................................................................................. 4-5
4.10 DC Bus Resistor Unit HLB01........................................................................................................ 4-6
Applications ............................................................................................................................. 4-6
4.11 Braking Resistor HLR01 ............................................................................................................... 4-6
Applications ............................................................................................................................. 4-6
4.12 DC Bus Capacitor Units HLC01 ................................................................................................... 4-7
Applications ............................................................................................................................. 4-7
4.13 Motor Filters HMF01 ..................................................................................................................... 4-7
Applications ............................................................................................................................. 4-7
4.14 Accessories HAS .......................................................................................................................... 4-7
Applications ............................................................................................................................. 4-7
4.15 Housing HAC01 for Control Sections ........................................................................................... 4-8
Applications ............................................................................................................................. 4-8
5 Specifications for the Components of the Drive System 5-1

5.1 Tests and Certifications ................................................................................................................ 5-1
Certifications ............................................................................................................................ 5-1
Tests ........................................................................................................................................ 5-3
5.2 Transport and Storage.................................................................................................................. 5-4
Transport of the Devices ......................................................................................................... 5-4
Storage of the Devices ............................................................................................................ 5-4
5.3 Installation Conditions................................................................................................................... 5-5
Ambient and Operating Conditions.......................................................................................... 5-5
Capacity Utilization .................................................................................................................. 5-6
5.4 Supply Voltages............................................................................................................................ 5-8
Control Voltage 24V Supply .................................................................................................... 5-8
Rexroth IndraDrive Contents III
Power Voltage Supply ........................................................................................................... 5-10
6 Configuration of the Drive System Rexroth IndraDrive 6-1

6.1 Allowed Combination of Individual Components in Drive System Rexroth IndraDrive ................ 6-1
Allowed Combination of Range Components from IndraDrive M and IndraDrive C ............... 6-1
Allowed Combinations with Additional Components ............................................................... 6-1
Allowed Components in Mains Connection Phase.................................................................. 6-2
Combination HMV01, HMV02 with HMS/HMD (Rexroth IndraDrive M).................................. 6-4
Combination HCS02 with HCS02 (Rexroth IndraDrive C) ...................................................... 6-6
Combination HCS03 with HCS03 (Rexroth IndraDrive C) ...................................................... 6-9
Combination HCS02 with HMS / HMD (Rexroth IndraDrive C with
Rexroth IndraDrive M) ........................................................................................................... 6-10
Combination HCS03 with HMS / HMD .................................................................................. 6-12
Combinations at Common DC Bus that are Not Allowed ...................................................... 6-13
6.2 Allowed Combinations in Mains Connection Phase with Mains Chokes HNL, Mains
Filters HNF and Mains Chokes HNK .......................................................................................... 6-14
Mains Connection Phase for HMV with Mains Chokes HNL and Mains Filters HNF............ 6-14
Mains Connection Phase for HCS with Mains Chokes HNL and Mains Filters HNF
resp. NFD .............................................................................................................................. 6-16
6.3 Allowed Combinations with Motor Filters HMF01....................................................................... 6-20
Drive Controllers HCS03 with HMF01 ................................................................................... 6-20
6.4 Combinations of Firmware, Control Section and Drive Controller.............................................. 6-21
6.5 Combination with Other Rexroth Components ........................................................................... 6-23
Combination with Components of the Control Range Rexroth IndraControl V ..................... 6-23
Combinations with Components of the Drive Range ANAX.................................................. 6-23
6.6 Selecting Connection Cables to Motor ....................................................................................... 6-24
6.7 Third-Party Motors at IndraDrive Controllers.............................................................................. 6-25
General Information on Third-Party Motors........................................................................... 6-25
Requirements on Third-Party Motors .................................................................................... 6-26
Requirements on the Encoder of the Third-Party Motor ....................................................... 6-29
Notes on Selection and Commissioning................................................................................ 6-29
7 Arranging the Components in the Control Cabinet 7-1

7.1 Arranging Components in Control Cabinet from Mainly Mechanical Point of View...................... 7-1
Position of Normal Use and Mounting Position ....................................................................... 7-1
Main Dimensions of the System Components ........................................................................ 7-3
Distances for Drive Controllers................................................................................................ 7-5
Boring Dimensions for the Mounting Plate .............................................................................. 7-9
7.2 Arranging Components in Control Cabinet from Mainly Thermal Point of View......................... 7-17
Multiple-Line Arrangement of Drive Controllers .................................................................... 7-17
Arrangement of Cooling Units ............................................................................................... 7-18
7.3 Arranging Components in Control Cabinet from Mainly Electrical Point of View ....................... 7-20
Performance-Dependent Arrangement ................................................................................. 7-20
EMC Measures for Design and Installation ........................................................................... 7-21
EMC-Optimal Installation in Facility and Control Cabinet...................................................... 7-22
Connection of Motor Cable to Drive Controller...................................................................... 7-28
Ground Connections.............................................................................................................. 7-32
IV Contents Rexroth IndraDrive
Installing Signal Lines and Cables......................................................................................... 7-33

Installing the 24V Supply ....................................................................................................... 7-34
General Measures of Radio Interference Suppression for Relays, Contactors,
Switches, Chokes, Inductive Loads....................................................................................... 7-35
8 Electromagnetic Compatibility (EMC) 8-1

8.1 EMC Requirements ...................................................................................................................... 8-1
Noise Immunity in Drive System.............................................................................................. 8-1
Noise Emission of Drive System ............................................................................................. 8-2
8.2 Ensuring the EMC Requirements ................................................................................................. 8-6
8.3 Measures to Reduce Noise Emission........................................................................................... 8-7
Shielding .................................................................................................................................. 8-7
Grounding ................................................................................................................................ 8-7
Filtering .................................................................................................................................... 8-7
8.4 Limit Value Classes to be Achieved with Mains Filters .............................................................. 8-10
Mains Filters for Supply Modules HMV01.1E and HMV01.1R with HMS01/ HMD01 ........... 8-10
Mains Filters for Drive Controllers HCS02 ............................................................................ 8-12
Mains Filters for Drive Controllers HCS03 ............................................................................ 8-14
9 Types of Mains Connection 9-1

9.1 Allowed Types of Mains Connection ............................................................................................ 9-1
9.2 Individual Supply........................................................................................................................... 9-2
Individual Supply with HMV ..................................................................................................... 9-2
Individual Supply with HCS ..................................................................................................... 9-2
9.3 Group Supply................................................................................................................................ 9-3
Group Supply without DC Bus Connection of the Groups ...................................................... 9-3
Group Supply with DC Bus Connection of the Groups............................................................ 9-5
9.4 Central Supply .............................................................................................................................. 9-7
10 Requirements to the Mains Connection 10-1

10.1 General Information .................................................................................................................... 10-1
10.2 Mains Types ............................................................................................................................... 10-1
TN-S System ......................................................................................................................... 10-1
TN-C System ......................................................................................................................... 10-2
IT System............................................................................................................................... 10-3
TT System ............................................................................................................................. 10-3
Mains with Grounded Outer Conductor (Corner Grounded Delta Mains) ............................. 10-4
10.3 Mains Short-Circuit Power and System Impedance – Minimum Values at Connection
Point............................................................................................................................................ 10-5
Maximum Connected Load to a Mains .................................................................................. 10-7
10.4 Limit Values for Interference-Free Operation at Mains .............................................................. 10-9
Mains Frequency Tolerance .................................................................................................. 10-9
Voltage Tolerances and Voltage Changes............................................................................ 10-9
Mains Voltage Unbalance...................................................................................................... 10-9
Commutation Drops............................................................................................................. 10-10
Short-Time Interruptions...................................................................................................... 10-10
Harmonics of the Mains....................................................................................................... 10-11
Rexroth IndraDrive Contents V
Maximum Allowed Mains Overvoltages .............................................................................. 10-11

10.5 Power Factors and Emitted Mains Harmonics of the Device ................................................... 10-14
Power Factors cosϕ1 (DPF) and cosϕ (TPF) ...................................................................... 10-14
Harmonics Factors THD and Distortion Factor k................................................................. 10-15
Mains Current Harmonics.................................................................................................... 10-16
Mains Voltage Harmonics.................................................................................................... 10-17
10.6 Protection Systems for the Mains Connection.......................................................................... 10-18
General Information............................................................................................................. 10-18
Fusing by Protective Grounding .......................................................................................... 10-18
Connecting Equipment Grounding Conductor..................................................................... 10-22
Use of Residual-Current-Operated Circuit-Breakers (RCCB, RCD) as Additional
Fusing .................................................................................................................................. 10-22
Insulation Monitoring Devices.............................................................................................. 10-25
11 Control Circuits for the Mains Connection 11-1

11.1 Control Circuits for the Mains Connection – General Information .............................................. 11-1
Conditions of Control ............................................................................................................. 11-1
11.2 Control Circuits for Mains Connection of Drive Controllers Rexroth IndraDrive C ..................... 11-5
Control via External Mains Contactor - HCS02 and HCS03 ................................................. 11-6
Control Circuits HCS02 with DC Bus Resistor Unit HLB01.1C ............................................. 11-8
11.3 Control Circuits for Mains Connection of Supply Units Rexroth IndraDrive M ........................... 11-9
Deceleration in the Case of Disturbed Electronic System of Drive ....................................... 11-9
Deceleration in the Case of E-Stop or Mains Failure ............................................................ 11-9
Control by E-Stop Relay ........................................................................................................ 11-9
Control by the Control Unit .................................................................................................. 11-14
Combination of Supply Unit HMV01.1 and DC Bus Resistor Unit HLB01.1D ..................... 11-16
12 Connections of the Components in the Drive System 12-1

12.1 System Connections of the Components ................................................................................... 12-1
Position of System Connections............................................................................................ 12-2
Ground Connection of Housing ............................................................................................. 12-2
Connection Point of Equipment Grounding Conductor and Equipment Grounding
Connections........................................................................................................................... 12-3
Connection of Mains Choke .................................................................................................. 12-5
DC Bus Connection (L+, L-) .................................................................................................. 12-5
Control Voltage Connection (0 V, + 24 V) ........................................................................... 12-10
Module Bus Connection X1 ................................................................................................. 12-12
Motor Connection ................................................................................................................ 12-13
12.2 Overall Connection Diagrams of the System ........................................................................... 12-13
13 Fusing and Selecting the Mains Contactor 13-1

13.1 Fusing and Selecting the Mains Contactor for Mains Connection.............................................. 13-1
Fusing and Selecting the Mains Contactor............................................................................ 13-2
Fusing Branches within the Control Cabinet ......................................................................... 13-7
14 Accessories in the Drive System Rexroth IndraDrive 14-1

14.1 Overview of HAS Accessories .................................................................................................... 14-1
VI Contents Rexroth IndraDrive
Allocation HAS01 Accessories .............................................................................................. 14-1

Allocation HAS02, HAS03, HAS04, HAS05 Accessories...................................................... 14-2
14.2 Basic Accessories HAS01 .......................................................................................................... 14-3
Type Code ............................................................................................................................. 14-3
Applications ........................................................................................................................... 14-4
Scope of Supply..................................................................................................................... 14-5
14.3 Shield Connection HAS02 ........................................................................................................ 14-29
Type Code ........................................................................................................................... 14-29
Applications ......................................................................................................................... 14-30
Scope of Supply................................................................................................................... 14-30
Mounting the HAS02 Accessories ....................................................................................... 14-41
Shield Connection of Motor Cable via Mains Filter ............................................................. 14-45
14.4 Control Cabinet Adapter HAS03............................................................................................... 14-48
Type Code ........................................................................................................................... 14-48
Applications ......................................................................................................................... 14-49
Scope of Supply................................................................................................................... 14-49
14.5 Capacitor HAS04 ...................................................................................................................... 14-52
Type Code ........................................................................................................................... 14-52
Applications ......................................................................................................................... 14-52
Scope of Supply................................................................................................................... 14-53
Capacitor ............................................................................................................................. 14-55
Dimensions .......................................................................................................................... 14-55
Mounting the HAS04.1-001 Accessories............................................................................. 14-56
Mounting the HAS04.1-002 Accessories............................................................................. 14-57
14.6 Accessories HAS05.1 ............................................................................................................... 14-59
Type Code HAS05.1............................................................................................................ 14-59
Applications ......................................................................................................................... 14-60
Scope of Supply................................................................................................................... 14-60
Accessories HAS05.1-001-NNN-NN ................................................................................... 14-60
Accessories HAS05.1-002-NNN-NN ................................................................................... 14-61
Accessories HAS05.1-003-NNN-NN and HAS05.1-005-NNN-NN...................................... 14-61
14.7 Accessories for Connection Technique .................................................................................... 14-62
Fiber Optic Cable Connections............................................................................................ 14-62
Interconnection of Drive Controllers .................................................................................... 14-63
Extension for Module Bus Connections .............................................................................. 14-66
15 Calculations 15-1
15.1 Determining the Appropriate Drive Controller............................................................................. 15-1
Introduction ............................................................................................................................ 15-1
DC Bus Continuous Power.................................................................................................... 15-1
DC Bus Peak Power .............................................................................................................. 15-4
Regenerative Power .............................................................................................................. 15-5
Calculation to Reduce Generated Power Dissipation - Additional External
Capacitances at DC Bus ....................................................................................................... 15-6
Continuous Regenerative Power........................................................................................... 15-8
Peak Regenerative Power..................................................................................................... 15-9
Calculating Control Factor ................................................................................................... 15-10
Rexroth IndraDrive Contents VII
15.2 Calculations for Mains Connection ........................................................................................... 15-11

Calculating Mains-Side Phase Current ............................................................................... 15-11
Calculating the Inrush Current............................................................................................. 15-11
Mains Contactor and Fusing................................................................................................ 15-12
Calculating the Mains Harmonics ........................................................................................ 15-12
Calculating Allowed Continuous Powers in Common DC Bus............................................ 15-14
15.3 Determining Appropriate Mains Connection Components ....................................................... 15-15
Mains Choke HNL................................................................................................................ 15-15
15.4 Using the Loop-Through Contacts for Control Voltage Supply ................................................ 15-16
15.5 Determining the Leakage Capacitance .................................................................................... 15-17
15.6 Calculations for Determining the Allowed Operating Data of Mains Filters.............................. 15-18
Reducing Allowed Operating Voltage Depending on Actual Temperature Rise due to
Harmonics............................................................................................................................ 15-18
Current Reduction in the Case of Overtemperature............................................................ 15-19
15.7 Determining the Data for Selecting the 24V Supply ................................................................. 15-19
Nominal Voltage of 24V Supply........................................................................................... 15-20
Continuous Current Capacity of 24V Supply....................................................................... 15-20
Peak Current Capacity of 24V supply.................................................................................. 15-20
15.8 Determining the Braking Behavior when Using DC Bus Resistor Unit HLB01 (DC Bus
Short Circuit) ............................................................................................................................. 15-20
15.9 Other Calculations .................................................................................................................... 15-21
Loading the DC Bus ............................................................................................................ 15-21
16 Replacing Devices 16-1

16.1 General Information .................................................................................................................... 16-1
16.2 How to Proceed When Replacing Devices................................................................................. 16-1
Replacing the Drive Controller............................................................................................... 16-1
Replacing the Motor .............................................................................................................. 16-2
Replacing Cables .................................................................................................................. 16-3
16.3 Fault Report ................................................................................................................................ 16-4
17 Disposal and Environmental Protection 17-1

17.1 Disposal ...................................................................................................................................... 17-1
Products................................................................................................................................. 17-1
Packaging Materials .............................................................................................................. 17-1
17.2 Environmental Protection............................................................................................................ 17-2
No Release of Hazardous Substances ................................................................................. 17-2
Materials Contained in the Products ..................................................................................... 17-2
Recycling ............................................................................................................................... 17-2
18 Service & Support 18-1

18.1 Helpdesk ..................................................................................................................................... 18-1
18.2 Service-Hotline ........................................................................................................................... 18-1
18.3 Internet........................................................................................................................................ 18-1
18.4 Vor der Kontaktaufnahme... - Before contacting us... ................................................................ 18-1
18.5 Kundenbetreuungsstellen - Sales & Service Facilities ............................................................... 18-2
VIII Contents Rexroth IndraDrive
19 Appendix 19-1
19.1 Technical Data "Capacitances Against Ground" ........................................................................ 19-1
Capacitance Data for Motors................................................................................................. 19-1
Capacitance Data for Power Cables ..................................................................................... 19-2
19.2 Short Designations of Products .................................................................................................. 19-3
19.3 Discharging of Capacitors........................................................................................................... 19-4
Discharging of DC Bus Capacitors ........................................................................................ 19-4
Discharging Device................................................................................................................ 19-5
20 Index 20-1
Rexroth IndraDrive Introduction 1-1
1 Introduction
1.1 About this Documentation
Personal injury and property damage caused by

incorrect project planning for applications,
machines and installations!
WARNING ⇒ Take contents of the listed reference
documentations into account.
Purpose of Documentation This documentation provides…

• overview information on the drive system Rexroth IndraDrive
• a presentation of the documentations on the drive system
Rexroth IndraDrive
• help for selecting the system components of the drive system
Rexroth IndraDrive
Contents of Project Planning Contents of the Project Planning Manual for the system are information
Manual for System on the interaction of the components, such as
• description of allowed combinations
• specifications for all components (ambient and operating conditions)
• application descriptions of system characteristics
Note: For detailed technical data of the individual components see

the respective Project Planning Manual (see reference
documents).
1-2 Introduction Rexroth IndraDrive
This documentation contains safety regulations, technical data and

operating instructions for the drive system Rexroth IndraDrive. The
individual chapters have the following main focuses:
Main Focuses of the Chapters
Chapter Title Content
1 Introduction general information
2 Important directions for use
3 Safety Instructions for Electric Drives and safety
Controls
4 Brief Description, Applications
5 Specifications for the Components of the
Drive System
6 Configuration of the Drive System
Rexroth IndraDrive
7 Arranging the Components in the Control
Cabinet
8 Electromagnetic Compatibility (EMC)
9 Types of Mains Connection product description
(for those doing project
10 Requirements to the Mains Connection
planning)
11 Control Circuits for the Mains Connection
12 Connections of the Components in the
Drive System
13 Fusing and Selecting the Mains Contactor
14 Accessories in the Drive System
Rexroth IndraDrive
15 Calculations
19 Appendix
16 Replacing Devices practical application (for
operators and
maintenance staff)
17 Disposal and Environmental Protection
18 Service & Support general information

20 Index
Fig. 1-1: Main focuses of the chapters
Reference Documentations - Overview

1)
Title Kind of documentation Document typecode
Rexroth IndraDrive Project Planning Manual DOK-INDRV*-CSH********-PRxx-EN-P
Drive Controllers
Control Sections Cxx
Rexroth IndraDrive Project Planning Manual DOK-INDRV*-HMV-*******-PRxx-EN-P
Supply Units HMV01
Rexroth IndraDrive M Project Planning Manual DOK-INDRV*-HMS+HMD****-PRxx-EN-P
Drive Controllers
Power Sections HMx01
Rexroth IndraDrive C Project Planning Manual DOK-INDRV*-HCS02.1****-PRxx-EN-P
Drive Controllers
Power Sections HCS02.1
Rexroth IndraDrive C Project Planning Manual DOK-INDRV*-HCS03.1****-PRxx-EN-P
Drive Controllers
Power Sections HCS03.1
Rexroth IndraDrive Project Planning Manual DOK-INDRV*-ADDCOMP****-PRxx-EN-P
Additional Components
Rexroth IndraDrive Functional and Application DOK-INDRV*-SI*-**VRS**-FKxx-EN-P
Integrated Safety Technology Description
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 Connection Cables Selection Data DOK-CONNEC-CABLE*STAND-AUxx-EN-P
Rexroth IndraDyn A Project Planning Manual DOK-MOTOR*-MAD/MAF****-PRxx-EN-P
Asynchronous Motors
Rexroth IndraDyn H Project Planning Manual DOK-MOTOR*-MBS-H******-PRxx-EN-P
Frameless Synchronous Spindle Motors
Rexroth IndraDyn L Project Planning Manual DOK-MOTOR*-MLF********-PRxx-EN-P
Synchronous Linear Motors
Rexroth IndraDyn S Project Planning Manual DOK-MOTOR*-MSK********-PRxx-EN-P
Synchronous Motors
Rexroth IndraDyn T Project Planning Manual DOK-MOTOR*-MBT********-PRxx-EN-P
Synchronous Torque Motors
Third-Party Motors Project Planning and DOK-DRIVE*-3RDPART*MOT-AWxx-EN-P
Commissioning Manual
Safety Instructions for Electrical Drives Safety Guidelines DOK-GENERAL-DRIVE******-SVSx-MS-P
1) In the document typecodes, "xx" is a wild card for the current edition
of the documentation (example: PR01 means the first edition of a
Project Planning Manual)
Fig. 1-2: Documentations - overview
Box with Project Planning Manuals on Rexroth IndraDrive

You can order all the Project Planning Manuals on the drive system
Rexroth IndraDrive in a box; this box contains:
• Project Planning Manual Drive System
• Project Planning Manual Control Sections CSx
• Project Planning Manual Supply Units HMV01
• Project Planning Manual Power Sections HMx
• Project Planning Manual Power Sections HCS02.1
• Project Planning Manual Power Sections HCS03.1
• Project Planning Manual Additional Components
Order data of the box:

• part number: R911310293
• document typecode: DOK-INDRV*-PROJEKTIER*-8201-EN-P
Standards
German, European and international technical standards are mentioned
in this documentation. Standard documents and sheets are subject to
copyright protection and Rexroth mustn't pass them on. If required,
contact the authorized sales agencies; in Germany directly contact:
BEUTH Verlag GmbH
Burggrafenstrasse 6
10787 Berlin
Tel. +49-(0)30-26 01-22 60, Fax +49-(0)30-26 01-12 60
internet: http://www.din.de/beuth
e-mail: [email protected]
Your Feedback
Your experience is important for our improvement processes of products
and documentations.
Inform us about mistakes you discovered and change requests; we would
be grateful for your feedback.
Please send your remarks to:
Bosch Rexroth AG
Dept. BRC/EDY
Bürgermeister-Dr.-Nebel-Str. 2
D-97816 Lohr
1.2 Overview and Contents of the Documentations on the

Drive System Rexroth IndraDrive
Rexroth IndraDrive Platform The drive system is composed of the individual components of the
IndraDrive product range and established on the Rexroth IndraDrive
platform.
drive system
control sections power sections supply additional motors firmware

Basic Advanced modular compact units components
C* B C* H HM* HC* HMV-E HMV-R MS* M**
single / single / single / HNF, HNL,
single E E/R HLB, HLC...
double double double
Rexroth IndraDrive platform
Fig. 1-3: IndraDrive products
Hierarchical Levels of Rexroth The assignment of the fundamental components to the hierarchical levels
IndraDrive product platform, product type, product range, product line and
component is illustrated in the figure below.
01, 02, 03,
component W0012...70 W0070...210 W0018.. W0020.. W0012.. 02, 03 01
04, 05
line HCS02 HCS03 HMV01 HMS01 HMD01 CSB CDB CSH
range Rexroth IndraDrive C Rexroth IndraDrive M Basic Advanced
type Rexroth IndraDrive power sections Rexroth IndraDrive control sections
platform Rexroth IndraDrive platform
Fig. 1-4: Hierarchical levels
Docu House The technical data of the respective components are available in the form
of documentations. The figure below contains an overview of the available
documentations.
drive system
Project Planning Manual of system
specific Application Manuals (safety technology...)
control sections power sections supply additional motors firmware

units components description
Proj.Pl.Man. C** Proj.Pl.Man. HCS02 Proj.Pl.Man. HMV Proj.Pl.Man. Proj.Pl.Man. Functional~
Proj.Pl.Man. HCS03 Parameter~
Proj.Pl.Man. HM* Troubleshooting
Rexroth IndraDrive platform
Fig. 1-5: "House" of documentations
Contents of Project Planning Contents of the Project Planning Manuals of components are all technical
Manuals on Components data, such as
• current, voltage and performance data
• dimensions and weights
• pin assignment
1.3 Introducing the System

Drive System, Definition of Term The drive system Rexroth IndraDrive comprises all components from
mains supply to motor shaft. It consists of the components supply module
with mains connection phase, power section with control section incl.
firmware, as well as motor and possibly required additional components
and corresponding system connections.
Drive System Rexroth IndraDrive C

The figure below illustrates the individual components of the drive system
Rexroth IndraDrive C (system elements).
power section
firmware
DC bus braking resistor unit
DC bus capacitor unit
control section
24 V supply unit 1)
battery
braking resistor
mains supply
motor filter
encoder cable
transformer mains filter mains choke motor cable
mains contactor motor antriebssystem_c_v1.fh7
The components marked with gray background color are absolutely

necessary.
1) 24V power supply unit can be omitted when using devices with
integrated 24V power supply (HCS02.1E- or HCS03.1E-…-NNNV
with control section CSB01.1N-FU)
Fig. 1-6: Drive system Rexroth IndraDrive C
Note: If you use mains filter HNK at HCS03 devices, connect the
mains contactor between mains supply and mains filter.
Drive System Rexroth IndraDrive M

The figure below illustrates the individual components of the drive system
Rexroth IndraDrive M (system elements).
firmware
drive controller DC bus braking resistor unit
supply unit DC bus capacitor unit
24 V supply unit
RKS - ready-made encoder cable

battery
RKG - ready-made power cable
motor
mains supply
2) 1)
mains filter mains choke
components marked with gray background color are absolutely necessary antriebssystem_hmv.fh7
1) optional for HMV01.1E, required for HMV01.1R
2) mains filter to be used optionally and depending on the EMC
requirements
Fig. 1-7: Drive system Rexroth IndraDrive M
System Elements - Components of the System

The drive system Rexroth IndraDrive consists of the following system
elements:
System elements Types Characteristic

transformer autotransformer DST
isolating transformer DLT
mains filter 1-phase NFE
3-phase NFD03.1; HNF01.1;
combined filter with int. mains choke HNK01.1
mains choke standard HNL01.1E
to be used for regeneration back to the mains HNL01.1R
current compensated HNL01.1R-…S
mains contactor n.s. n.s.
mains supply infeeding HMV01.1E
System elements Types Characteristic

regenerative HMV01.1R
HMV02.1R
power sections single-axis HMS01.1
modular inverters
double-axis HMD01.1
modular inverters
power sections with compact converters HCS02.1
integrated mains supply mounting depth 265
compact converters HCS03.1
mounting depth 322
control sections scope of functions Basic CSB01.1
scope of functions Advanced CSH01.1
firmware scope of functions Basic MPB
scope of functions double-axis MPD
scope of functions Advanced MPH
24V power supply unit n.s. n.s.
battery n.s. n.s.
DC bus resistor unit mounting depth 265 HLB01.1C
mounting depth 322 HLB01.1D
braking resistor HLR01.1
DC bus capacitor unit mounting depth 265 HLC01.1C
mounting depth 322 HLC01.1D
output filter n.s. n.s.
motor cable shielded RKL
motor rotary motors MSK, MBS, MBA etc.
linear motors M
encoder cable n.s. RKS
accessories basic accessories HAS01.1
other accessories HAS02, HAS03, HAS04,
HAS05
cooling fan unit external cooling fan unit for HMV01.1R-W0120 HAB01
Fig. 1-8: System elements Rexroth IndraDrive
Differences between Rexroth IndraDrive C and Rexroth IndraDrive M

The product ranges IndraDrive C and IndraDrive M were created on the
IndraDrive platform.
Rexroth IndraDrive C
Rexroth IndraDrive C is the compact form of the product range.
Compact Converters The drive controllers HCS02 and HCS03 are the fundamental
components of IndraDrive C, they are compact converters containing the
mains supply.
mains HCS
DST HNF HNL Con-

tactor
Cable Motor
gray optional
Fig. 1-9: Block diagram Rexroth IndraDrive C
Basic features of Rexroth IndraDrive C:

• integrated power supply
• integrated braking resistor (as an option, external for HCS03)
• integrated 24V control voltage supply (optional for HCS02)
• additional components DC bus resistor units and DC bus capacitance
modules, as well as braking resistors
Rexroth IndraDrive M - Modular Inverters

Rexroth IndraDrive M is the modular form of the product range.
Modular Inverters The combination of an HMV supply module and HMS and HMD drive
controllers to form a modular drive system allows operating several
motors.
HMV HMS HMS

mains HMD HMD
DST HNF HNL ....
Cable Cable
...
Motor Motor
...
optionally required components are marked with gray background color

Fig. 1-10: Block diagram Rexroth IndraDrive M
Basic features of Rexroth IndraDrive M:

• scaleable power supply
• integrated mains contactor
• modular extension of number of axis is possible
• additional components DC bus resistor units and DC bus capacitance
modules
Combination of Rexroth IndraDrive C and Rexroth IndraDrive M

On the common platform Rexroth IndraDrive it is possible to combine the
components of the product ranges IndraDrive C and IndraDrive M to form
drive systems of optimum costs and performance. For information on the
allowed combinations see chapter "Configuration of the Drive System
Rexroth IndraDrive".
1.4 Basic Design of the Devices
Basic Design of Drive Controllers
DR000002v01_nn.fh9
1: power section
2: control section
Fig. 1-11: Basic design
The drive controller consists of two essential parts:

• power section
• control section
Power Section
The power section incorporates the control section and has the following
connections:
• mains voltage connection (at supply modules and HCS devices)
• motor connection (with optional motor holding brake and motor
temperature monitor)
• 24 V control voltage
• DC bus connection
• module bus connection for cross communication in the case of DC
bus connection with other devices
• connection for external braking resistor (at HCS devices)
Control Section
The control section is a separate component that is plugged into the
power section; it consists of
• the basic control section circuit board with interfaces
• the optional modules in the case of configurable control sections
The optional modules are included on the basic control section circuit
board in optional slots. As an example, the figure below illustrates optional
slots Option1…4.
Fig. 1-12: Optional slots on control section
The drive controller is supplied complete with factory-installed (possibly

configured) control section.
Note: The control section may only be replaced by qualified

personnel.
1.5 Available Type Currents and Performances

To allow you selecting appropriate drive controllers for a multitude of
applications the Rexroth IndraDrive product range provides a wide range
of type currents and performances. The table below shows fundamental
data of drive controllers and supply modules, for further details see the
corresponding data sheets.
Selecting the Drive Controllers

Order with ascending continuous current.
Compact Modular Type Contin. Peak Nominal

converters inverters current current current motor
Iout_cont1 Iout_max power
[A] (1) [A] (1) [kW] (2)
HCS02 -- 4 12 1,5
W0012
-- HMD01 tbd 12 --
-- HMS01 12,1 20 --
W0020
-- HMD01 12,1 20 --
HCS02 -- 11 28 4,0
W0028
HMS02 13 28 --
-- HMS01 21,3 36 --
W0036
-- HMD01 20 36 --
HCS02 -- 22 54 7,5
HMS01 W0054 35 54 --
-- HMS02 25 54
HCS02 -- 28 70 11
HCS03 -- W0070 45 70 18,5
-- HMS01 42,4 70 --
HCS03 -- W0100 73 100 30
HMS01 W0110 tbd 110 --
HCS03 -- 95 150 45
W0150
-- HMS01 100 150 --
HCS03 -- 145 210 75
W0210
-- HMS01 145 210 --
tbd to be defined
(1) at fs=4 kHz; without overload
(2) for standard motor, with use of mains choke HNL01; at 3 AC 400 V
variable torque, low degree of overload
Fig. 1-13: Type current and type performances
Selecting the Component for Mains Supply

Order with ascending continuous power.
Compact Modular Type Contin. Peak Contin. Max.

converters mains current or power power braking braking
supply power "ON" "ON" power power
PDC_cont PDC_peak
[kW] (1) [kW] (1) [kW] [kW]
HCS02 -- E-W0028 4,2 10 0,15 10
HCS02 -- E-W0054 9,1 16 0,35 18
HCS02 -- E-W0070 13,3 19 0,5 25
-- HMV01 R-W0018 18 45 0,4 36
HCS03 -- E-W0070 25 40 opt. opt.
-- HMV01 E-W0030 30 45 1,5 36
HCS03 -- E-W0100 43 59 opt. opt.
HCS03 -- E-W0150 56 89 opt. opt.
-- HMV02 R-W0015 15 37,5 0,3 33
-- HMV01 R-W0045 45 112 0,4 90
-- HMV01 R-W0065 65 162 0,4 130
-- HMV01 E-W0075 75 112 2 90
HCS03 -- E-W0210 85 124 opt. opt.
-- HMV01 E-W0120 120 180 2,5 130
-- HMV01 R-W0120 120 180 0 0
opt. equipment to be optionally ordered
(1) with use of mains choke HNL01; at 3 AC 400 V
Fig. 1-14: Performance data of mains supply units
Note: The data of peak power and continuous power show the
maximum possible limit values. For the actually available
performance profiles please see the corresponding data
sheets.
Notes
Rexroth IndraDrive 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
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 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
• 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 Brief Description, Applications 4-1
4 Brief Description, Applications

In terms of "Appropriate Use", cases of operation and applications not
mentioned in this chapter are not allowed.
4.1 Applications of the Drive System Rexroth IndraDrive

The digital intelligent automation system Rexroth IndraDrive is the cost-
efficient solution with a high degree of functionality for single-axis and
multi-axis drive and control tasks.
The IndraDrive automation system can be used for realizing a large
number of drive tasks in the most varied applications.
Applications Typical applications are the industrial sectors
• printing and paper converting
• packaging and food
• mounting and handling
• wood machining
• machine tools
• metal forming
• general automation
For these applications there are different device types of graduated
performance available.
4.2 Mains Transformers DST and DLT
Applications
DST and DLT transformers are used to transform mains voltages to the
allowed nominal voltage of the device.
DLT transformers are used to

• prevent overvoltage between outer conductor and ground
• keep away leakage currents from other loads
Device type Application

DST autotransformer adjusting voltage range in grounded
mains
DLT isolating transformer adjusting voltage range in
ungrounded mains
Fig. 4-1: Transformer applications
Note: As a matter of principle, DLT isolating transformers have to be

used at ungrounded mains.
4-2 Brief Description, Applications Rexroth IndraDrive
4.3 Mains Filters HNF, HNK, NFE, HNS02, and NFD
Applications
Mains filters are used to
• reduce radio interference
• reduce mains pollution
The different mains filters can be used as follows:

NFE01.1 mains filter for interference suppression of supply units
up to 230 V
NFE02.1 mains filter for interference suppression of single-
phase drive controllers up to 230 V
NFD03.1 mains filter for interference suppression of three-
phase drive controllers up to 480 V for 1-6 axes and
motor cable lengths up to max. 75 m single-axis /
120 m multi-axis (HCS02.1E)
HNF01.1 mains filter for interference suppression of three-
phase drive controllers up to 480 V for drive systems
with a high number of axes and long motor cables, as
well as for reduction of leakage current
HNK01.1 mains filter for interference suppression of three-
phase drive controllers HCS03.1E up to 500 V
HNS02 mains filter for interference suppression of three-
phase drive controllers up to 480 V for drive systems
with a maximum of 12 axes and a maximum of 150 m
motor cable; integrated switch-disconnector
Fig. 4-2: Mains filter applications
Note: Use only expressly allowed components at the mains filters.

Example: You are not allowed to operate fans, pumps etc. at
mains filters HNF.
See also section 8.3 Measures to Reduce Noise Emission section

Protecting Mains Filters Against Overload.
4.4 Mains Chokes HNL01 and HNL02
Applications HNL01.1E, HNL01.1R and HNL02.1R

(Standard) mains chokes HNL01.1E, HNL01.1R and HNL02.1R are used
to
• reduce harmonics in the mains current
• increase the allowed DC bus continuous power
• operate regenerative supply modules at the mains
Current-compensated mains chokes HNL01.1E-****-S and HNL01.1R-

****-S are used to reduce line-frequency, asymmetric currents in the
mains connection phase of the drive system.
The different types can be used exclusively as follows:

HNL01.1R mains chokes for connection to components with
regeneration to the supply mains (HMV01.1R)
HNL01.1E mains chokes for connection to components without
regeneration to the supply mains (HMV01.1E, HCS02.1E;
HCS03.1E)
HNL01.1*-****-S current-compensated chokes for use with HNL01.1 mains
chokes to reduce line-frequency leakage currents
(HMV01.1E, HMV01.1R; HCS02.1E; HCS03.1E)
HNL02.1R mains chokes in housing for control cabinet mounting for
connection to components with regeneration to the supply
mains (HMV02.1R)
Fig. 4-3: Mains choke applications
4.5 Supply Units HMV01 / HMV02
Applications
HMV supply modules are used to supply modular devices HMS and HMD.
The different supply modules can be used as follows:

HMV01.1E infeeding
to supply drive controllers HMS01 and HMD01
HMV01.1R regenerative
to supply drive controllers HMS01 and HMD01
HMV02.1R regenerative
to supply drive controllers HMS01, HMS02 and HMD01
Fig. 4-4: Supply module applications
4.6 Drive Controllers HMD01, HMS01
Applications
Drive controllers HMS and HMD are used to operate single axes or two
axes in modular systems.
The different drive controllers can be used as follows:

HMD01.1 have two power outputs to operate two motors
independently of each other
are used at HMV supply modules and HCS drive controllers
HMS01.1 have a power output to operate a motor
are used at HMV01 supply modules and HCS02 and
HCS03 drive controllers
HMS02.1 have a power output to operate a motor
are used at HMV02 supply modules and HCS02 drive
controllers
Fig. 4-5: Drive controller HM* applications
4.7 Control Sections CSH01, CSB01, CDB01
Applications
Control sections CSH, CSB and CDB are used to operate drive
controllers HMS, HMD and HCS.
The different control sections can be used as follows:

CSH01 Advanced
is used in HMS, HCS02 and HCS03 drive controllers
CSB01 BASIC single-axis
is used in HMS, HCS02 and HCS03 drive controllers
CDB01 BASIC double-axis
is used in HMD01 drive controllers
Fig. 4-6: Control section applications
4.8 Drive Controllers HCS02
Applications
Drive controllers HCS02 are used to operate single axes.

HCS02 have a power output to operate a motor
cover the power range from 1.5 kW to 11 kW
Fig. 4-7: Drive controller HCS applications
4.9 Drive Controllers HCS03
Applications
Drive controllers HCS03 are used to operate single axes.

HCS03 have a power output to operate a motor
cover the power range from 18,5 kW to 75 kW
Fig. 4-8: Drive controller HCS applications
Note: In their standard design -NNNV, drive controllers HCS03 are

not regenerative.
For applications where regenerative power is generated, use
HCS03.1 of the -NNBV design and HLR braking resistors as
additional components.
4.10 DC Bus Resistor Unit HLB01
Applications
DC bus resistor units HLB01 are used to
• convert generated kinetic energy into thermal energy
• increase the continuous regenerative power in the drive system
• increase the peak regenerative power in the drive system
• have the DC bus short circuit function available in the drive system
The different DC bus resistor units can be used as follows:
Device type Applications

HLB01.1C in drive systems with components of the product range
Rexroth IndraDrive C and Rexroth IndraDrive M
HLB01.1D in drive systems with components of the product range
Rexroth IndraDrive M
Fig. 4-9: DC bus resistor unit HLB applications
4.11 Braking Resistor HLR01
Applications
Braking resistors HLR01 are used to convert generated kinetic energy
into thermal energy.
The different braking resistors can be used as follows:

HLR01 in drive controllers of the Rexroth IndraDrive C range;
for this purpose, the drive controllers have to be
equipped with a standard or optional brake chopper
Fig. 4-10: DC bus resistor units HLR
4.12 DC Bus Capacitor Units HLC01
Applications
DC bus capacitor units HLC01 are used to store energy in the DC bus of
the drive system.
The different DC bus capacitor units can be used as follows:

HLC01.1C in drive systems of the product ranges
HLC01.1D in drive systems of the product ranges
Fig. 4-11: DC bus capacitor unit HLC applications
4.13 Motor Filters HMF01
Applications
HMF01 motor filters are used to
• reduce the rise of the output voltage of drive controllers
• reduce leakage currents of the motor lines
• reduce interference voltage on the motor lines
The different motor filters can be used as follows:

HMF01.1 at the motor output of HCS03 drive controllers
Fig. 4-12: Motor filter HMF01 applications
4.14 Accessories HAS
Applications
HAS accessories are used to support the operation and combination of
components in the drive system Rexroth IndraDrive.
The different accessories and their use are described in chapter
"Accessories".
4.15 Housing HAC01 for Control Sections
Applications
The additional component HAC01 is used to
• insert control sections in it
• supply control sections with 24V control voltage

HAC01.1-002-NNN-NN to insert CDB01 control sections in it
Fig. 4-13: HAC01 type
Rexroth IndraDrive Specifications for the Components of the Drive System 5-1
5 Specifications for the Components of the Drive

System
5.1 Tests and Certifications
Certifications
Declaration of Conformity For Rexroth IndraDrive components there are declarations of conformity
available. These declarations confirm, that the components are designed
according to valid EC directives. If required, you can ask your sales
representative for these declarations.
CE Label
CEf1.fh7
Fig. 5-1: CE label
C-UL-US Listing The components are labeled:
Fig. 5-2: C-UL-US label
C-UL-US Listed Components Product Component File Number

HMS01.1N- W0020, W0036, W0054, W0070, W0150, E 134201
W0210
HMS02.1N- W0028, W0054 E 134201
HMD01.1N- W0012, W0020, W0036 E 134201
HCS02.1E- W0012, W0028, W0054, W0070 E 134201
HCS03.1E- W0070, W0100, W0150, W0210 Manufacturer REFU
E254781
HMV01.1E- W0030-A-07, W0075-A-07, W0120-A-07 E 134201
HMV01.1R- W0018-A-07, W0045-A-07, W0065-A-07 E 134201
HMV02.1R- W0015 E 134201
5-2 Specifications for the Components of the Drive System Rexroth IndraDrive
Product Component File Number

HLB01.1C- 01K0-N06R0-A-007-NNN E 134201
HLB01.1D- 02K0-N03R4-A-007-NNN E 134201
HLC01.1C- 01M0-A-007, 02M4-A-007 E 134201
HLC01.1D- 05M0-A-007 E 134201
NFD03.1- -007, -016, -030, -055, -075, -130, -180 E 172117 and CSA
Cert. 1038841Master
Contr. 171321
HNL01.1- ..... CSA Cert.
1492099Master
Contr. 222887
HNF01.1 In Vorbereitung E 134201
HNK01.1 In Vorbereitung E 134201
HLR01.1 In Vorbereitung E 134201
Fig 5-3: c-UL-US listed Rexroth IndraDrive components
Note: The components are listed by the file number of "Underwriters

Laboratories Inc.®" (UL). The documented evidence of listing
can be seen on the internet:
http://www.ul.com, "Certifications", enter file number or
"Company name": Rexroth.
The control sections are included in the listing of the power
sections. The control sections are not listed separately.
Note: For using the devices in the scope of C-UL, take the C-UL limit
values of the individual devices into account. In addition, take
the following aspects into account:
• use 60/75 °C copper wire only for mains connection
• use Class 1 wire only or equivalent for mains connection
• mains connection 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)
CCC (China Compulsory The CCC test symbol comprises a required certification of safety and
Certification) quality for certain products, which are mentioned in the product catalog
"First Catalogue of Products Subject to Compulsory Certification" and the
CNCA document "Application Scope for Compulsory Certification of
Products acc. first Catalogue" and are put in circulation in China. This
required certification has been existing since 2003.
CNCA is the responsible Chinese authority for directives of certifications.
When a product is imported in China, the certification will be checked at
the customs by means of entries in a data base. For requirement of
certification three criteria are normally relevant:
1. Customs goods number (HS code) according to the CNCA document
"Application Scope for Compulsory Certification of Products acc. first
Catalogue".
2. Applicable scope according to the CNCA document "Application
Scope for Compulsory Certification of Products acc. first Catalogue".
3. For the IEC product standard used, there must be a corresponding
Chinese GB standard.
For Rexroth drive components described in this documentation a

certification is not required yet, thus they are not CCC certified.
Negative certifcations will not be issued.
Tests
Tests high-voltage test routine test according to EN50178
high voltage and insulation test routine test according to EN50178
separation between control and power
safe separation according to EN50178
voltage circuits
clearances and creepage distances according to EN50178
Fig. 5-4: Tests
Applied-Overvoltage Withstand Observe the following note before you carry out a high voltage test or an
Test applied-overvoltage withstand test.
Note: Disconnect all connections to the devices or disconnect the

plug-in connections to protect the electronic components.
5.2 Transport and Storage
Transport of the Devices

Conditions
temperature -25…70 °C
relative humidity 5…95%;
climatic category 2K3
3
absolute humidity 1…60 g/m
moisture condensation not allowed
icing not allowed
shock test out of operation according half sine in 3 axes: 10g / 11ms
to EN 60068-2-27
Fig. 5-5: Conditions for transport
Storage of the Devices

Conditions
temperature -25…55 °C
relative humidity 5…95%;
3
moisture condensation not allowed
icing not allowed
Fig. 5-6: Conditions for storage
Extended Storage
Some devices contain electrolytic capacitors which may deteriorate during
storage.
Note: When storing these devices for a longer period of time,

operate them once a year for at least 1 hour with power ON:
• devices HCS and HMV with mains voltage ULN
• devices HMS, HMD, HLC with DC bus voltage UDC
5.3 Installation Conditions
Ambient and Operating Conditions

The drive controllers and their additional components are designed for
control cabinet mounting!
Note: The user must check that the ambient conditions, in particular
the control cabinet temperature, are complied with by
calculating the heat levels in the control cabinet and making
the corresponding measurements.
In the Technical Data the power dissipation is indicated as an
input value for calculating the heat levels.
Designation Data
degree of protection IP20 according to IEC529
ambient temperature 0…+40 °C
ambient temperature with power 0…+55 °C; see characteristic in Fig. 5-8
reduction
temperature during storage see section 5.2 Transport and Storage
temperature during transport see section 5.2 Transport and Storage
installation altitude with nominal data < 1000 m above sea level
installation altitude with power see characteristic in Fig. 5-9
reduction *
maximum installation altitude * 4000 m
(upper temperature level reduced to 40 °C instead of 55 °C)
relative humidity 5%…95%
(operation) Cl.3K5 with restriction, as not –5 °C
3
climatic category Cl. 3K3 according to IEC721
degree of dirt contamination degree of dirt contamination 2 in accordance with EN50178
dust, steam allowed according to EN 50178, table A.2
sine vibration during operation amplitude and frequency: 0.15 mm (peak-peak)

according to EN 60068-2-6 at 10…57 Hz
acceleration and frequency: 1 g at 57…150 Hz
tolerance: ±15 %
noise vibration (random) during frequency: 20…150 Hz
operation according to IEC 68-2-36 2
spectral acceleration density amplitude: 0.005 g /Hz
tolerance: ± 3 dB
rms value of the total acceleration: 1.0 g
* For installation altitudes of more than 2000 m, an overvoltage limiter
for transient overvoltage 1.2/50 µs must be installed in the
installation or building in order to limit the voltage to 1.0 kV between
the outer conductors and to 2.5 kV between conductor-ground.
Fig. 5-7: Ambient and operating conditions
Compatibility with Foreign All Rexroth controls and drives are developed and tested according to the
Matters state-of-the-art technology.
As it is impossible to follow the continuing development of all materials
(e.g. lubricants in machine tools) which may interact with our controls and
drives, it cannot be completely ruled out that any reactions with the
materials used by Bosch Rexroth might occur.
For this reason, before using the respective material a compatibility test
has to be carried out for new lubricants, cleaning agents etc. and our
housings/our housing materials.
Capacity Utilization
Where installation conditions differ, the following performance data are
reduced in accordance with the diagrams (see "Fig. 5-8: Capacity
utilization at higher ambient temperature" and "Fig. 5-9: Capacity
utilization at higher installation altitude"):
drive controller:
• allowed continuous DC bus power
• continuous power of braking resistor
• continuous current
motor:
• power
• continuous torque at standstill
• S1 continuous torques
• short-time service torque MKB
If differing ambient temperatures and higher installation altitudes occur

simultaneously, both capacity utilization factors must be multiplied. The
installation altitude must only be taken into account once, deviating
ambient temperatures must be taken into account separately for motor
and drive controller.
1
Load factor
0,7
5 40 45 50 55
Ambient temperature in °C
DK000073v01_en
Fig. 5-8: Capacity utilization at higher ambient temperature
0,9
0,8
Load factor
0,7
0,6
0 1000 2000 3000 4000

Installation altitude above sea level in meters
DK000074v01_en
Fig. 5-9: Capacity utilization at higher installation altitude
5.4 Supply Voltages
Control Voltage 24V Supply

For the devices of the IndraDrive range, the specifications for supply with
control voltage contained in the table below are generally valid.
Standard Range and Extended Range of Control Voltage

Designation Symbol Unit Value
standard range of control voltage UN3 V • 24 ± 5%
extended range of 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% at motor cable length < 50 m
26 ± 5% at 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)
Fig. 5-10: 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 equipment 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.
Assignment of Control Voltage Ranges
Designation Supply units Drive Additional

controllers components
standard range of HMV01.1E HLB01.1D
control voltage
HMV01.1R
HMV02.1R
extended range of HMS01.1 HLB01.1C
control voltage HMS02.1
HMD01.1
HCS02.1E
HCS03.1E
Abb. 5-11: Assignment of control voltage
Note: Observe section 10.4 Limit Values for Interference-Free

Operation at Mains also for the 24 V voltage supply.
For HMV supply units use 24 V supplies with buffer times of
100 ms at least (e.g. UPS), if commutation drops and short-
time interruptions in the application exceed the specified
values.
Power Voltage Supply

For the devices of the IndraDrive range, the specifications for supply with
power voltage contained in the table below are generally valid.
The indicated values represent the common standard range.
Standard Range of Power Voltage

Designation Symbol Unit Values
allowed range of mains input
voltage, three-phase; ULN V 3 * AC (400…480) +10% -15%
TN-S, TN-C, TT mains
voltage, three-phase; ULN V 3 * AC 230 +10% -10%
IT mains
rotary field no rotary field condition
allowed range of mains
fLN Hz (50…60) + - 2
frequency
max. allowed mains frequency
d fLN /t Hz/s 2% * fLN
change
Fig. 5-12: Standard range of power voltage
Depending on the device characteristic, the following extended range

can be used for power voltage supply.
Extended Range of Power Voltage

Designation Symbol Unit HCS02.1E HMV01.1E HCS03.1E
HMV01.1R
allowed range of mains input 3 * AC 3 * AC
3 * AC (200…500)
voltage, three-phase; ULN V (230…480) +- (400…500)
+-10%
TN-S, TN-C, TT mains 10% +10% -15%
3 * AC (200…230) 3 * AC 230
voltage, three-phase; ULN V not allowed
+-10% +-10%
IT mains
allowed range of mains input 1 * AC (200…250)
ULN V not allowed not allowed
voltage, single-phase +-10%
Fig. 5-13: Extended range of power voltage
Note: When using HCS02 and HCS03 devices in the mains voltage
range up to 3 * AC 500 V, make sure the additional
components you use may be operated in this mains voltage
range. NFD mains filters, for example, can only be used up to
3 * AC 480 V.
Rexroth IndraDrive Configuration of the Drive System Rexroth IndraDrive 6-1
6 Configuration of the Drive System

Rexroth IndraDrive
6.1 Allowed Combination of Individual Components in Drive

System Rexroth IndraDrive
Within the product range Rexroth IndraDrive you may combine
components of the subranges Rexroth IndraDrive C and
Rexroth IndraDrive M.
Allowed Combination of Range Components from IndraDrive M and

IndraDrive C
Drive controller or supply Range components

unit
HMS01 HMS02 HMD01 HCS02 HCS03
HMV01 X -- X -- --
HMV02 -- X -- -- --
HCS02 X -- X X --
HCS03 X -- X -- X
X: allowed
--: not allowed
Fig. 6-1: Combination of range components
Allowed Combinations with Additional Components

Drive controller or supply HLB01.1C HLB01.1D HLC01.1C HLC01.1D HLR01.1 HMF01.1
unit
HMV01.1E -- X X X -- --
HMV01.1R -- X X X -- --
HMV02.1R X -- X -- -- --
HCS02.1 X X X X X --
HCS03.1 -- X -- X (1) X X
X: allowed
--: not allowed
(1) only allowed for HCS03.1E-…-W0210 (not allowed for W0070,
W0100, W0150)
Fig. 6-2: Combinations with additional components
Note: For simultaneous operation of HLR01 and HLB01 at HCS02

and HCS03 observe the following aspects:
• The continuous power of the selected HLR01 has to be at
least as high as the continuous power of the HLB used.
• Due to differences in balance, the total continuous power
available is lower than the sum of the individual continuous
powers.
6-2 Configuration of the Drive System Rexroth IndraDrive Rexroth IndraDrive
Allowed Components in Mains Connection Phase
Note: Operating supply units with regeneration back to the mains

requires components mains choke and mains filter
appropriate for this purpose in the mains connection phase.
Make sure the type code sections -R or -E are matching.
Drive Auto- Isola- Mains filter Mains filter with Mains choke
controller transf. ting
or supply transf.
unit mains switch
choke discon-
nector
DST DLT NFD HNF01.1*- HNF01.1*- HNK HNS HNL01.1E; HNL01.1R; HNL
03.1 ****-R**** ****-E**** 01.1 02.1 HNL01.1E- HNL01.1R- 02.1
****-S ****-S
HMV01.1E X X -- -- X -- -- X -- --
HMV01.1R X X -- X -- -- -- -- X --
HMV02.1R X X -- -- -- -- X -- -- X
1) 1)
HCS02.1E X X X X X -- -- X -- --
1) 1)
HCS03.1E X X -- X X X -- X -- --
X: allowed
--: not allowed
1) take minimum capacitance against ground at DC bus into account
Fig. 6-3: Combination in mains connection phase
Minimum Capacitance against Ground
Note: Using HNF01.1 mains filters requires minimum capacitance

against ground at the DC bus of the connected drive
controllers.
The minimum capacitance is 330 nF against ground at each of
L+ and L-.
The required capacitance at L+ and L- against ground is made available

by the drive controllers or supply units. For the value see the technical
data "capacitance power section against housing - CKop"; the table below
contains an excerpt and indicates whether additional capacitances
against ground are required.
Drive controller / Capacitance Additional capacitances against

supply unit against housing ground required?
[nF]
HMS01 2 * 100 for supply via HCS;
not at HMV
HMD01 2 * 68 for supply via HCS;
not at HMV
HCS02 2 * 100 for less than 4 HCS02 drive
controllers;
for supply of less than 3
HMS01 / HMD01
HCS03 2 * 100 for less than 4 HCS03 drive
controllers;
for supply of less than 3
HMS01 / HMD01
HAS04 2 * 470 --
HMV01.1E 2 * 470 no
HMV01.1R 2 * 470 no
HMV02.1R 2 * 470 no
Fig. 6-4: Capacitances at L+ and L-
The requirement of minimum capacitance is, for example,

• fulfilled when using 4 * HMS01
• not fulfilled when using 4 * HMD01
• fulfilled when using 1 * HAS04 (accessory for HCS)
• fulfilled when using the HMV01 and HMV02 supply units
• fulfilled when using 1 * HAS04 at an HCS02 in group supply without
DC bus connection
Combination HMV01, HMV02 with HMS/HMD (Rexroth IndraDrive M)

Group Supply with DC Bus Connection HMV01, HMV02
(Parallel Operation)
Parallel operation of HMV01.1 supply units increases the available DC
bus power.
Parallel operation of HMV01 supply units
• is only allowed with HMV01.1E supply units of the same type current
• requires an individual mains choke for each supply unit (for current
sharing)
• does not increase the max. allowed number if drive controllers or axes
for operation without mains filter
• requires a control circuit master-slave; see chapter "Control Circuits"
• for detailed information on derating and mounting, the specification
with document number 109-1261-4102-** is available on request.
Supply unit type Max. allowed number of supply units at common

DC bus
E-W**** (infeeding) R-W**** (regenerative)
HMV01.1
0030 0075 0120 0018 0045 0065 0120 0016
HMV01.1E-W0030 -- -- -- -- -- --
HMV01.1E-W0075 -- 2 -- -- -- --
HMV01.1E-W0120 -- -- 2 -- -- --
HMV01.1R-W0018 -- -- -- 1 -- --
HMV01.1R-W0045 -- -- -- -- 1 --
HMV01.1R-W0065 -- -- -- -- -- 1
HMV01.1R-W0120 -- -- -- -- -- -- 1
HMV02.1R-W0015 -- -- -- -- -- -- -- 1
--: not allowed
Fig. 6-5: Parallel operation HMV01
Note: Instead of using two W0030 devices connected in parallel, it is

better to use one W0075 device.
Central Supply HMV01, HMV02

Up to the indicated maximum allowed number, drive controllers may be
combined at the common DC bus according to the table below. The
number is limited by the ability of HMV to charge Y-capacitors in
connected components.
Note: At the common DC bus means that the DC bus connections of

the involved devices are interconnected.
Allowed IndraDrive M components at common DC bus with supply via HMV01.1 devices
max. allowed
supply unit HMS HMD01.1N HLB01.1 HLC01.1
number of axis
HMV01.1E-W0030 up to max. W0070 up to max. W0036
HMV01.1E-W0075 up to max. W0210 up to max. W0036
HMV01.1E-W0120 up to max. W0210 up to max. W0036 21 take max.

allowed
HMV01.1R-W0018 up to max. W0054 up to max. W0036 (21 * HMS01 external DC
or 2 bus
HMV01.1R-W0045 up to max. W0150 up to max. W0036 11* HMD01) capacitance
CDCext into
HMV01.1R-W0065 up to max. W0210 up to max. W0036 account
HMV01.1R-W0120 up to max. W0210 up to max. W0036
HMV02.1R-W0015 up to max. W0054 -- 12 (12 * HMS02)
Fig. 6-6: Allowed Rexroth IndraDrive M components at common DC bus
Damage to the supply unit!

⇒ Do not exceed allowed peak and continuous powers
in the DC bus.
CAUTION ⇒ Observe minimum value of mean phase control
factor ā (see section "Calculations").
Note: Depending on the mains filter used and the mains choke, the
number of axes is additionally restricted.
Combination HCS02 with HCS02 (Rexroth IndraDrive C)

Group Supply with DC Bus Connection HCS02
(Parallel Operation)
Note: Group supply with DC bus connection is only allowed with

HCS02.1E drive controllers of the same type current.
Up to the indicated maximum allowed number of axes, drive controllers

with braking resistor may be combined at the common DC bus according
to the table below.
Note: At the common DC bus means that the DC bus connections of

the involved devices are interconnected.
Type of mains connect. (1) Maximum number of IndraDrive C components at common DC bus
HCS02.1E- HLB01.1 HLC01.1
group supply with DC bus

W0012 W0028 W0054 W0070
connection
HCS02.1E-W0012 -- -- -- -- -- --
HCS02.1E-W0028 -- 8 -- -- 1 1
HCS02.1E-W0054 -- -- 6 -- 1 1
HCS02.1E-W0070 -- -- -- 4 1 1
--: not allowed
(1) for explanation see chapter "Types of Mains Connection"
Fig. 6-7: Maximum number of IndraDrive C components at common DC bus
Central Supply HCS02 with HCS02

Up to the indicated maximum allowed number of axes, drive controllers
with braking resistor may be combined at the common DC bus according
to the table below. The number is limited by the ability of the supplying
HCS02 to charge Y-capacitors.
You may make replacements up to the maximum allowed sum of the type
currents.
max. allowed sum of max. allowed
HCS02.1E HLB01.1C HLC01.1C
type currents number of axes
central supply via
HCS02.1E-W0028
-- -- -- 1 1
central supply via

HCS02.1E-W0054 without up to max. W0054 166 12 1 1
assigned mains choke
central supply via
HCS02.1E-W0054 with up to max. W0054 222 12 1 1
central supply via
HCS02.1E-W0070 without up to max. W0070 264 12 1 1
central supply via
HCS02.1E-W0070 with up to max. W0070 402 12 1 1
--: not allowed
Example central supply via HCS02.1E-W0070 with assigned HNL01.1 mains

choke:
• 1 * HCS02.1E-W0070 (supplying device)
• 7 * HCS02.1E-W0028
• 2 * HCS02.1E-W0054
• 1 * HCS02.1E-W0070
• 1 * HLB01.1C
• 1 * HLC01.1C
Checking the combination:

Checking the sum of type currents to be supplied:
7*28 + 2*54 + 1*70 = 374; 374 < 402
Sum of type currents is allowed
Checking the sum of drive controllers:
1*1 + 7*1 + 2*1 + 1*1 = 11; 11 < 12
max. allowed number of axes is not exceeded
Ckecking the sum of drive controllers with braking resistor:
1*1 + 7*1 + 2*1 + 1*1 + 1*1 = 12; 12 <= 12
max. allowed number of drive controllers is not exceeded
Damage to the drive controller!

in the DC bus.
CAUTION
Combination HCS03 with HCS03 (Rexroth IndraDrive C)
Note: Group supply with DC bus connection is only allowed with

HCS03.1E drive controllers of the same type current.
Note: At HCS03.1E drive controllers, do not operate any external

additional capacitances at the DC bus.
Exceptions:
For drive controllers HCS03.1E-…-W0210 this is allowed.
Operating HAS accessories with capacitances against housing
is allowed.
Group Supply with DC Bus Connection HCS03 (Parallel

Operation)
HCS03.1E- HLB01.1 HLC01.1
group supply with DC bus

W0070 W0100 W0150 W0210
connection
HCS03.1E-W0070 10 -- -- -- 1 --
HCS03.1E-W0100 -- 8 -- -- 1 --
HCS03.1E-W0150 -- -- 6 -- 1 --
take max. allowed
external DC bus
HCS03.1E-W0210 -- -- -- 4 1
capacitance CDCext
into account
--: not allowed
Example parallel operation of HCS03.1E: 6 * HCS03.1E-W00150
Central Supply HCS03

Central supply of HCS03.1E is not allowed with HCS03.1E drive
controllers.
Combination HCS02 with HMS / HMD (Rexroth IndraDrive C with

Rexroth IndraDrive M)
Combining HCS02 drive controllers with HMS / HMD requires using
• accessory HAS04 (capacitances at DC bus against ground)
• accessory HAS03 (to adjust different mounting depths)
• additional capacitors at the DC bus (external DC bus capacitance
CDCext), if
• the output currents Iout, in the arithmetical mean, are greater than
Iout of the device to be supplied
• the resulting load profiles of the output currents Iout and the DC bus
power PDC (superposition of the individual load profiles) are
greater than the allowed load profiles.
Note: To determine the required capacitance values the following

guide values apply when using HLC01.1 DC bus capacitor
unit:
• 10 uF per A type current for HMS01 drive controllers
• 20 uF per A type current for HMD01 drive controllers
Central Supply HCS02 with HMS / HMD

Up to the indicated maximum allowed number of axes, drive controller
axes may be combined at the common DC bus according to the table
below.
currents.
HMD01.1N drive controllers add the double value of their type currents to
the sum of allowed type currents.
Allowed IndraDrive M components at common DC bus with supply via HCS02.1E

Type of mains connect. (1)
devices
max. allowed max. allowed
HMS01.1N- HMD01.1N- sum of type number of HLC01.1
currents axes
central supply via
HCS02.1E-W0028
-- -- -- --
central supply via

up to max. up to max.
HCS02.1E-W0054 without 120
W0036 W0020
assigned mains choke 12
central supply via take max.
up to max. up to max. (12 * HMS01 allowed
HCS02.1E-W0054 with 198
W0054 W0020 or external DC
2 * HMS02 bus
central supply via or capacitance
up to max. up to max. 6 * HMD01)
HCS02.1E-W0070 without 120 CDCext into
W0036 W0020
assigned mains choke account
central supply via
up to max. up to max.
HCS02.1E-W0070 with 270
W0054 W0036
--: not allowed
Fig. 6-10: Maximum number of IndraDrive M components at common DC bus

choke:
• 1 * HMS01.1N-W0054
• 1 * HMS01.1N-W0036
• 1 * HMS01.1N-W0020
• 1 * HMD01.1N-W0036
• 1 * HMD01.1N-W0020
• 2 * HMD01.1N-W0012

1. Checking the sum of type currents to be supplied:
54 + 36 + 20 + 36 + 20 + 2*12*2 = 214; 214 < 270
2. Checking the sum of drive controller axes:
1 + 1 + 1 + 1 + 1 + 1 + 2*2 = 9; 9 < 12
Note: HMS01, HMS02 and HMD01 are generally mounted to the

right.
Mount the required HAS04 at the HCS02 mounted to the left.
Place the additional capacitance module HLC01.1 at the
junction between HCS02.1 and HMS01.1 or HMD01.1.

in the DC bus.
CAUTION
Combination HCS03 with HMS / HMD
Note: For combinations HCS03 with HMD01 and HMS01 we

recommend using brake chopper and braking resistor.
Using external DC bus capacitances CDcext is not required.
Central Supply HCS03 with HMS / HMD

Up to the indicated maximum allowed number of axes, drive controller
axes may be combined at the common DC bus according to the table
below.
currents.
HMD01.1N drive controllers add the double value of their type currents to
the sum of allowed type currents.
Allowed IndraDrive M components at common DC bus with supply via HCS03.1E

Type of mains connect. (1)
devices
max. allowed sum max. allowed
HMS01.1N- HMD01.1N-
of type currents number of axes
central supply via
HCS03.1E-W0070 without
up to W0054 up to W0036 120
HNL01.1
central supply via
HCS03.1E-W0070 with
up to W0054 up to W0036 270
HNL01.1
central supply via
up to W0070 up to W0036 270
HNL01.1
central supply via
HCS03.1E-W0100 with
up to W0070 up to W0036 270 12
HNL01.1
(12 * HMS01
central supply via or
HCS03.1E-W0150 without 6 * HMD01)
up to W0070 up to W0036 270
HNL01.1
central supply via
HCS03.1E-W0150 with
up to W0070 up to W0036 270
HNL01.1
central supply via
up to W0150 up to W0036 270
HNL01.1
central supply via
HCS03.1E-W0210 with
up to W0150 up to W0036 270
HNL01.1
--: not allowed
X: allowed
Fig. 6-11: Maximum number of IndraDrive M components at common DC bus

choke:
• 1 * HMS01.1N-W0054
• 1 * HMS01.1N-W0036
• 1 * HMS01.1N-W0020
• 1 * HMD01.1N-W0036
• 1 * HMD01.1N-W0020
• 2 * HMD01.1N-W0012

1. Checking the sum of type currents to be supplied:
54 + 36 + 20 + 36 + 20 + 2*12*2 = 214; 214 < 270
2. Checking the sum of drive controller axes:
1 + 1 + 1 + 1 + 1 + 1 + 2*2 = 9; 9 < 12

in the DC bus.
CAUTION
Combinations at Common DC Bus that are Not Allowed
Property damage caused by combinations that

are not allowed!
⇒ Only operate allowed combinations.
CAUTION
Operating the following combinations at the common DC bus is not

allowed
• HCS02 with HMV
• HCS03 with HMV
• HCS02 with HCS03
• HMS02 with HMS01
Note: Operating components not mentioned in this documentation at

the common DC bus with Rexroth IndraDrive components
requires Rexroth's explicit confirmation.
6.2 Allowed Combinations in Mains Connection Phase with

Mains Chokes HNL, Mains Filters HNF and Mains Chokes
HNK
The modular structure of the Rexroth IndraDrive system allows a
multitude of combinations for mains connection.
The combinations of mains filters and mains chokes listed below are
functionally allowed in the mains connection phase.
For the behavior of the combinations regarding EMC limit values, as well
as restrictions, such as number of axes, see chapter "Electromagnetic
Compatibility (EMC)".
You can use the following combinations up to the nominal power of the
supply unit. If you want to use components with lower nominal data, you
have to calculate the actually developed load in detail and make sure that
the load is lower than the allowed load of the individual components in the
mains connection phase.
Mains Connection Phase for HMV with Mains Chokes HNL and Mains
Filters HNF
HMV01.1E Supply Units
Supply unit Mains chokes Mains filters Explanation
HMV01.1E-W0030 HNL01.1E-0400-N0051 HNF01.1A-F240-E0051 standard combination
without HNF01.1A-F240-E0051 red. performance data see Project
Planning Manual
HNL01.1E-0400-N0051 HNF01.1A-M900-E0051 standard combination
without HNF01.1A-M900-E0051 red. performance data see Project
Planning Manual
HNL01.1E-0400-N0051 with customer-side standard mains choke connected in
HNL01.1E-5700-S0051 series with current-compensated
mains choke to reduce line-frequency
leakage currents
without without not allowed
Planning Manual
Planning Manual
leakage currents
without without red. number of axes and allowed
motor cable length see fig. 8-6

Planning Manual
Planning Manual
leakage currents
without without red. number of axes and allowed
motor cable length see fig. 8-6
Fig. 6-12: Mains connection phase HMV01.1E
HMV01.1R Supply Units

HMV01.1R-W0018 HNL01.1R-0980-C0026 HNF01.1A-F240-R0026 standard combination
without not allowed
HNL01.1R-0980-C0026 HNF01.1A-M900-R0026 standard combination
without not allowed
HNL01.1R-0980-C0026 with customer-side standard mains choke connected in
HNL01.1R-4200-S0026 series with current-compensated
leakage currents
without HNF01.1A-F240-R0065 not allowed
without HNF01.1A-M900-R0065 not allowed
leakage currents
without HNF01.1A-F240-R0094 not allowed
without HNF01.1A-M900-R0094 not allowed
leakage currents
HMV01.1R-W0120 HNL01.1R-0300-C0180 HNF01.1A-H350-R0180 standard combination
without HNF01.1A-H350-R0180 not allowed
Fig. 6-13: Mains connection phase HMV01.1R
HMV02.1R Supply Units

HNL02.1R-0980-C0023 HNS02.1A-Q150-R0023 standard combination
Fig. 6-14: Mains connection phase HMV02.1R
Mains Connection Phase for HCS with Mains Chokes HNL and Mains
Filters HNF resp. NFD
HCS02 Drive Controller with HNF01.1 resp. NFD03.1
Mains Filters
It is allowed to use HNF01.1 resp. NFD03.1 mains filters at HCS02 drive
controllers. Observe the rules mentioned below:
Rules for Use of HNF01.1 resp. The mains current determined for the application has to be smaller than
NFD03.1 and HNL01.1 with the type current of the mains filter and the mains choke.
HCS02
Depending on the number of axes there are minimum capacitances
required at the DC bus of the drive controllers against ground
(Y-capacitors, e.g. HAS04).
For the interference limit values to be achieved see chapter
"Electromagnetic Compatibility (EMC)".
Note: HNF01.1 resp. NFD03.1 mains filters are not suited for
operation on mains grounded via outer conductor mains.
Observe allowed mains connection voltage in the respective
Project Planning Manual (max. 3AC480V)!
Note: For operation without mains choke take reduced performance

data of the supply units or HCS into account.
Observe performance data contained in the respective Project
Planning Manual!
HCS02 Drive Controllers

HCS02.1E-W0012 HNL01.1E-1000-N0012 NFD03.1-480-007 standard for operating one drive
controller at the mains filter
without NFD03.1-480-007 red. performance data see Project
Planning Manual of HSC02
Fig. 6-15: Mains connection phase HCS02
HCS03 Drive Controller with HNF01.1 Mains Filters

It is allowed to use HNF01.1 mains filters at HCS03 drive controllers.
Observe the rules mentioned below:
Rules for Use of HNF01.1 and The mains current determined for the application has to be smaller than
HNL01.1 with HCS03 the type current of the mains filter and the mains choke.
Depending on the number of axes there are minimum capacitances
required at the DC bus of the drive controllers against ground
(Y-capacitors).
For the interference limit values to be achieved see chapter
"Electromagnetic Compatibility (EMC)".
Note: HNF01.1 mains filters are not suited for operation on mains
grounded via outer conductor mains.
Note: For operation without mains choke take reduced performance

data of the supply units or HCS into account.
Observe performance data contained in the respective Project
Planning Manual!
HCS03 Drive Controller with HNK01.1 Mains Filters

HNK01 mains filters are intended exclusively for use at HCS03 drive
controllers and were designed for being mechanically mounted to the
HCS03. For assignment of HNK01 to HCS03 see the tables below.

integrated in HNK HNK01.1A-A075-E0050 standard for operating one drive
HNL01.1E-0571-N0050 standard for operating one drive
controller without mains filter
HNL01.1E-0571-N0050 HNF01.1A-F240-E0051 standard for operating several drive
controllers at the mains filter
HCS03.1E-W0070
HNL01.1E-0571-N0050 HNF01.1A-M900-E0051 standard for operating several drive
leakage currents
HNL01.1E-0362-N0080 standard for operating one drive
HCS03.1E-W0100
leakage currents

HNL01.1E-0240-N0106 without standard for operating one drive
HCS03.1E-W0150
leakage currents
HNL01.1E-0170-N0146 without standard for operating one drive
HCS03.1E-W0210
leakage currents
Fig. 6-16: Mains connection phase HCS03
6.3 Allowed Combinations with Motor Filters HMF01

In conjunction with long motor cables, the steep switching edges at the
motor output of the drive controllers cause transient overvoltages and
high rise of voltage at the motor.
Damage caused by too high switching

frequency!
⇒ Only operate HMF01 motor filters up to the
CAUTION maximum allowed switching frequency fs of 4 kHz.
Drive Controllers HCS03 with HMF01

The combinations of motor filters and HCS03 drive controllers listed
below are functionally allowed.
Assignment of HMF01 Motor Filters to HCS03 Drive

Controllers
Motor filter HNK01 Drive controller

HMF01.1A-N0K2-D0045-… HCS03.1E-W0070
HMF01.1A-N0K2-D0073-… HCS03.1E-W0100
HMF01.1A-N0K2-D0095-… HCS03.1E-W0150
HMF01.1A-N0K2-D0145-… HCS03.1E-W0210
Fig. 6-17: Assignment HMF01 to HCS03
6.4 Combinations of Firmware, Control Section and Drive

Controller
The modular structure of the IndraDrive controllers allows a multitude of
combinations of control sections and drive controllers. Depending on the
firmware design, the firmware of the Rexroth IndraDrive product range
supports the combinations of control section and power section listed
below.
Combination The table below contains allowed combinations of firmware components
Control Section - Firmware and control sections for the drive controllers.
Firmware MPB MPH MPD

Control section
1)
CSH01.1-C -- X --
2)
CSB01.1-N X -- --
1)
CSB01.1-C X -- --
1)
CDB01.1-C -- -- X
X: allowed
--: not allowed
1) control section can be configured
2) control section cannot be configured
Fig. 6-18: Combination control section - firmware
Combination The table below contains allowed combinations of control sections and
Control Section - Power Section power sections.
Power HMS01 HMS02 HMD01 HCS02 HCS03

section
Control
section
1)
CSH01.1-C X X -- X X
2)
CSB01.1-N X X -- X X
1)
CSB01.1-C X X -- X X
1)
CDB01.1-C -- -- X -- --
X: allowed
--: not allowed
1) control section can be configured
2) control section cannot be configured
Fig. 6-19: Combination control section - power section
Note: The allowed number of "plug control section into power

section" actions is limited to a max. of 20. If this number is
exceeded, the electrical data of the internal connection can be
above the specified minimum requirements.
This can cause malfunction of the drive controllers.
Required Equipment of Control Section for Motor

Encoder System
The control sections of the Rexroth IndraDrive product range support
different encoder systems. For the assignment of encoder system to
required equipment of control section with options see table below.
Note: For the motor encoder code see the type code of the selected
motor.
Abbrev. 1 2
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
Example: M S K 0 7 0 C - 0 4 5 0 - N N - S 1 - U G 0 - N N N N
6. Encoder
6.1 Optical encoder, singleturn hiperface,
with 128 increments . . . . . . . . . . . . . . . . . . . . . . . . . . . = S1
6.2 Optical encoder, singleturn EnDat2.1,
with 2048 increments . . . . . . . . . . . . . . . . . . . . . . . = S2
6.3 Optical encoder, multiturn-absolute hiperface,
with 128 increments . . . . . . . . . . . . . . . . . . . . . . . . . . . . = M1
6.4 Optical encoder, multiturn-absolute EnDat2.1,
with 2048 increments . . . . . . . . . . . . . . . . . . . . . . . = M2
DT000002v01_de.EPS
Fig. 6-20: Type code section of motor
Code of Brief description of motor encoder (informal) Equipment / Cable for

motor options of control direct
encoder section connection 1)
ENS EN1 EN2
R0 resolver -- X -- IKS 4043
R1 resolver with integrated absolute multi-turn encoder -- X -- IKS 4043
S0 optical encoder single-turn IIC, 512 increments, -- X -- IKS 4042
supply voltage 8 V
S1 optical encoder single-turn HIPERFACE, 128 increments, X -- -- RKG 4200
supply voltage 7…12 V
S2 optical encoder single-turn EnDat2.1, 2048 increments, X -- -- RKG 4200
supply voltage 12 V
M0 optical encoder multi-turn absolute IIC, 512 increments, -- X -- IKS 4042
supply voltage 8 V
M1 optical encoder multi-turn absolute HIPERFACE, 128 X -- -- RKG 4200
increments,
supply voltage 7…12 V
M2 optical encoder multi-turn absolute EnDat2.1, 2048 increments, X -- -- RKG 4200
supply voltage 12 V
C0 optical encoder incremental 1 Vpp, 2048 increments (sin/cos) -- -- X RKG 0014
1) without control cabinet ducts and cable extension
X: allowed
--: not allowed
Fig. 6-21: Combination control section equipment - motor encoder
Note: Operating other encoder systems than the ones listed above
requires detailed control of the technical data of the encoder
system used and the interface specification of the control
section. In particular, take the supply voltage data into

account.
6.5 Combination with Other Rexroth Components
Combination with Components of the Control Range

Rexroth IndraControl V
Small Operator Terminals VCP
For comfortable operation of the Rexroth IndraDrive drive system with the
IndraControl V control range there are small operator terminals of the
VCP series available.
The small operator terminals VCP 01, VCP 02, VCP 05, VCP 08, VCP 20
and VCP 25 are suited for control cabinet mounting and are operated via
the serial interface RS232 (X2) of the control sections.
Note: The optional equipment "C" and "S" that can be plugged in is
similar to the VCP 01 small operator terminal. In the Project
Planning Manual of the control sections the hardware of the
options is described as comfort control panel ("C") or standard
control panel ("S"). The function of the control panels is
described in the Functional Description of the firmware.
Simultaneous operation of VCP small operator terminals and
standard control panels or comfort control panels is allowed.
Combinations with Components of the Drive Range ANAX

To modernize machines the drive range Rexroth IndraDrive provides the
possibility of operating drive controllers of the ANAX range with analog
command value input.
SERCOS Analog Converter

The SERCOS analog converter is used to
• connect control units with SERCOS interface to components with
analog interface
• convert SERCOS position command values to analog speed
command values
The following components are required for SERCOS analog converters:

• housing for HAC01.1-002 control sections
• configurable control section with SERCOS master communication, e.g.
BASIC CDB01.1C-SE-NNN-NNN-MA1-NNN-NN-S-NN-FW
• firmware, e.g. FWA-INDRV*-MPD-04VRS-**-*-***-**
Note: Observe, that parameter P-0-0860, Converter configuration

is set to "operation as SERCOS analog converter" (Bit 15 = 1).
A wrong setting generates the error message F8091 Power
section defective.
6.6 Selecting Connection Cables to Motor

Keep in mind, that the allowed maximum motor cable length is depending
on the switching frequency of the power output stage. On principle, the
higher the switching frequency, the shorter the allowed cable length (in
order to protect the drive controllers against overload).
Note: Always use switching frequencies supported by the

components of your drive system. Observe the technical data
of the drive controllers and motors.
See also Parameter Description "P-0-0001, Switching frequency of

the power output stage".
Limited Length of Motor Power The lengths indicated in the table below are recommended as guide
Cables values (at an ambient temperature of ≤ 40 °C in accordance with
EN 60 204).
Allowed line lengths for motor connection without filter measures at

motor output:
PWM frequency [kHz] Max. allowed line length [m]

1)
Shielded line Unshielded line
2)
2 100 175
4 75 150
8 38 150
12 25 not allowed
16 18 not allowed
1) only allowed at HCS drive controllers
2) depending on the drive controller
Fig. 6-26: Line lengths
Operation with unshielded motor cables of up to 150 m

• aims at applications with "operation without encoder" (Open-Loop)
• does not include the control voltage lines to the motor
• requires additional measures with regard to EMC on the part of the
operating company
Allowed line lengths for motor connection with additional components

HMF or HML:
PWM frequency [kHz] Max. allowed line length [m]

1)
Shielded line Unshielded line
2)
4 75 200
1) only allowed at HCS03 drive controllers
2) higher PWM frequencies are not allowed
Fig. 6-27: Line lengths
Documentation Motor Power The documentation "Rexroth Connection Cables; Selection Data" is
Cables available for selecting the motor power cables and other connections,
such as encoder cables.
Rexroth IndraDrive drive systems have to be equipped with shielded

motor power cables of the RKL line.
Third-Party Motor Power Cables Requirements on third-party motor power cables:

Maximum allowed cable length at A1, A2, A3:
• see Fig. 6-26
Maximum allowed capacitance per unit length at A1, A2, A3:

• against ground, each: 0.5 nF/m
• against each other: 0.5 nF/m
Maximum allowed inductance per unit length at A1, A2, A3:

• 100 nH/m each
Note: If you use third-party motor power cables not corresponding to

the requirements, Rexroth's guarantee for the drive system will
expire.
Use ready-made Rexroth cables.
6.7 Third-Party Motors at IndraDrive Controllers
General Information on Third-Party Motors

Why Use Third-Party Motors at IndraDrive?
Today machine axes are mainly moved with electric drives. Motors of
standard design are used in most cases as this is the most cost-efficient
solution.
Special Requirements Due to special requirements at machine axes, constructional or safety-
related aspects, it may be necessary for the machine manufacturer to use
a motor construction diverging from the standard.
Undeliverable Motor Design For these cases there is the demand on the drive supplier to realize, apart
from the deliverable standard drive consisting of (standard) motor,
controller, cable and, if required, machine control unit, drives with motors
that are not included in his own product range due to the special design.
Check Before Using Third-Party At Rexroth controllers of the IndraDrive range it is also possible to use
Motors third-party motors. For this purpose, check whether the third-party motor
complies with the requirements of use.
Which are the Important Directives?

Additional Aspects to be According to the legal requirements
Observed
• of the EU directives EMC89/336/EEC and
• the German EMC laws
installations and machines have to be designed and built according to the
present state of standardization. In order to comply with the machine
directives regarding "electromagnetic compatibility (EMC)", a conformity
test of the drive system (motor with controller and connection design) has
to be carried out. The test of the drive system and compliance with the
directives have to be guaranteed by the machine manufacturer.
Third-Party Motors to be Controlled

Motor Types The following motor types can be controlled:
• asynchronous motors, rotary
• asynchronous motors, linear
• synchronous motors, rotary
• synchronous motors, linear
These motors can be operated within the scope of the technical data of
the selected IndraDrive controller. If motors have been provided with a
holding brake, it should be controlled via the controller. Make sure that the
relevant technical data of the motor holding brake are complying with
those of the holding brake output.
Note: For third-party motors Bosch Rexroth, as a matter of principle,

does not assume the guarantee for the power data at the
motor shaft!
Synchronous Motors In the case of synchronous motors, the commutation offset has to be set
during commissioning. The drive firmware provides several methods for
determining this offset so that it is possible to determine the value for
different motor characteristics.
Note: Observe the restrictions in conjunction with the commutation

offset determination when using synchronous motors!
See Functional Description of Firmware "Motor Control:
Commutation Setting" in chapter "Drive Control"
Possibly available reluctance property cannot be used for synchronous

third-party motors! For third-party motors it is impossible to determine fail-
safe motor parameter values for using the reluctance property; the
respective bit of P-0-4014, Type of construction of motor therefore
mustn't be set!
Requirements on Third-Party Motors

For successful and fail-safe use of a third-party motor check
• whether the third-party motor to be controlled satisfies the voltage
loads,
• which controller, including supply, is suitable due to the motor power to
be delivered,
• whether the third-party motor has the required minimum inductance,
• whether the motor can be protected against inadmissible temperature
rise in the case of overload (temperature evaluation),
• whether the mounted position measuring system can be evaluated by
the controller or which position measuring system can be selected for
kit motors.
Voltage Load of the Third-Party Motor

The voltage load of the insulation system of a motor occurring in practical
application is mainly influenced by the following characteristics:
• The output variables of the drive controller which is used (feed the
transmission distance).
• The cable parameters depending on cable design and length
(determine the properties of the transmission distance, such as the
attenuation).
• The motor design regarding capacitive and inductive properties (form

the end of the transmission distance).
As a result of the variables, the insulation system of the third-party motor,
as regards voltage, is loaded by the values
• peak voltage Upp and
• voltage change dv/dt.
The occurring peak voltages at the motor are caused by reflections in the
motor cable. The insulation of the motor is thereby loaded with other peak
voltages and voltage changes than the ones occurring at the output of the
power section.
Note: Determine the occurring voltage load at the terminals of the

third-party motor in the application with all involved
components.
Use of Voltage-Reducing Use voltage-reducing components (e.g. motor filter HMF), if one of the
Components, Motor Filter HMF following criteria applies:
• allowed voltage change (dv/dt) of third-party motor smaller than
5kV/µs
• allowed peak voltage (crest value) of third-party motor between phase-
phase and phase-housing smaller than 1500V
• motor cable length smaller than 25 m
• mains voltage greater than AC440V
Note: Apart from the nominal current IN, especially take the
maximum allowed switching frequency of the power output
stage (fs) into account with which the motor filter HMF may be
operated.
Verify the success of the voltage-reducing measure.
Minimum Inductance of Third-Party Motor

Depending on the controller used, the motor has to have a minimum
value for inductance. The actually available inductance of a motor can be
measured directly between two motor terminals by means of an
inductance measuring bridge. The measurement has to be made for a
complete motor wired for normal operation but not yet connected. During
the measurement one motor terminal remains open!
For asynchronous motors the measured value can only be used if the
rotor doesn't have closed slots!
Controller type Minimum required motor inductance

HCS with 3*AC230V LU-V = 60* 4/(√2 * ITyp * fs) (in mH)
HMS, HMD at HMV (3*AC400V)
LU-V = 80* 4/(√2 * ITyp * fs) (in mH)
HMS, HMD at HCS (3*AC400V)
HMS, HMD at HMV (3*AC480V)
HMS, HMD at HCS (3*AC480V) LU-V = 116* 4/( √2 * ITyp * fs) (in mH)
ITyp: maximum controller current acc. to type code (rms value)

fs: desired switching frequency in kHz
Fig. 6-28: Minimum inductance depending on controller data, supply units and
supply voltage
Use a three-phase choke in the motor feed wire, if the inductance of the
third-party motor is smaller than indicated in the table above. This choke
has to increase the inductance that can be measured between two motor
terminals to the minimum value.
Note: When the inductance is measured, different inductance values

can be determined at different rotor positions within one pole
pair distance of the motor. The average value is relevant for
the check of the minimum value.
Correct values can only be determined when the motor is in
standstill!
Available third-party motor Planned third-party motor

Calculating the leakage inductance
LU-Vmin LU-V
(asynchronous motor) or
U inductance (synchronous motor) of
V
the third-party motor by means of
Motor the single-phase equivalent circuit
W
diagram (manufacturer's
3x LDr specification!).
Determine choke by means of
LDr = 0,5 * (LU-Vmin - LU-V) calculation, if necessary.
(inductance measurement with 1 kHz)
It is recommended to contact
mounting of 3x LDr (three-phase choke) Rexroth!
Requirements on the choke:
- In_Dr ≥ In_Mot
The rated current of the choke has to be greater than or equal to
the rated motor current.
- Depending on the maximum speed, the choke is loaded with the respective
output frequency and the PWM frequency of the controller.
- The insulation class has to correspond at least to that of the motor or
has to be dimensioned for higher temperatures.
- The voltage load of the choke depends on the controller used.
Fig. 6-29: Data for possibly required choke
Temperature Evaluation of Third-Party Motor

Only operate such motors with incorporated temperature sensor at
IndraDrive controllers so that the motor can be thermally monitored by the
controller and protected against destruction by too high temperature rise
(see P-0-0512, Temperature sensor).
When, in exceptional cases, you want to operate third-party motors
without temperature sensor at IndraDrive controllers, you must determine
the thermal time constants of motor housing (P-0-4035) and motor
winding (P-0-4034, P-0-4037). The firmware-internal motor temperature
model can thereby reflect the cooling situation of the motor correctly.
Note: In case the motor housing or blower is dirty, this worsens the
cooling situation of the motor and protection against thermal
overload is therefore insufficient!
Requirements on the Encoder of the Third-Party Motor

Motor Encoder of Asynchronous Third-Party Motor
Asynchronous motors can also be controlled by IndraDrive controllers in
"open-loop" operation (without motor encoder). In "closed-loop" operation
(with motor encoder) a relative measuring system is sufficient for
asynchronous motors.
Motor Encoder of Synchronous Third-Party Motor

For fail-safe drives with synchronous third-party motors at IndraDrive
controllers the following possible combinations or restrictions have to be
taken into account when selecting the measuring system:
Drive range Motor measuring system Synchronous third-

party motor
absolute +
IndraDrive
relative o
+… advantageous combination
o… Combination is possible (restrictions specific to application),
commissioning may be more complicated!
Fig. 6-30: Possible combinations of synchronous third-party motor and motor
measuring system
Note: The control section integrated in the controller can evaluate

measuring systems as a motor encoder if they are contained
in P-0-0074, Encoder type 1 (motor encoder) (see also
Project Planning Manual of the IndraDrive control sections).
For information on absolute and relative measuring systems
see section "Measuring Systems" of Functional Description of
firmware!
Notes on Selection and Commissioning

Selecting the Controller as Regards Continuous Current
The controller required for the respective motor and the supply unit are
determined by comparing the motor data to the data of these devices (see
documentation for HMS/HMD and HMV or HCS).
Note: The continuous current of the controller should be greater than

that of the motor, the continuous power of the supply must be
greater than the sum of all average powers of the axes of the
drive system!
Selecting the Connection Technique

The available power and encoder cables are described in the
documentation "Connection Cables; Selection Data" (DOK-CONNEC-
CABLE*STAND-AU...).
Notes on Commissioning
Note: For further information, notes on commissioning and

supporting documents (e.g. forms for entering the required
data) see Functional Description of firmware.
Notes
Rexroth IndraDrive Arranging the Components in the Control Cabinet 7-1
7 Arranging the Components in the Control Cabinet
7.1 Arranging Components in Control Cabinet from Mainly

Mechanical Point of View
Position of Normal Use and Mounting Position

Mounting Positions The drive controllers and additional components mustn't be operated in
all indicated positions of normal use and mounting positions. The allowed
positions of normal use and mounting positions are described in the figure
below.
Rexroth
a
G1 G4
a
g
a
G2 G5
Rexroth
a
G3
Rexroth
Einbaulagen.fh9
a mounting surface
g direction of gravitational force
Fig. 7-1: Positions of normal use and mounting positions
Brief Description of Positions of Normal Use and

Mounting Positions
Normal Mounting Position • G1: Normal mounting position. The natural convection supports the
forced cooling air current. This avoids the generation of pockets of
heat in the drive controller. G1 is the preferred mounting position for
Rexroth IndraDrive components.
• G2: 180° to normal mounting position
• G3: turned by 90° from vertical to horizontal mounting position
• G4: bottom mounting, mounting surface on bottom of control cabinet
• G5: top mounting, mounting surface at top of control cabinet
Allowed Mounting Positions Positions of normal use and mounting positions allowed for the individual
devices and reduction factors connected with them are contained in the
table below.
7-2 Arranging the Components in the Control Cabinet Rexroth IndraDrive
Allowed positions of normal use and mounting positions with

reduction factor
Component Mounting position / reduction factor Notes
G1 G2 G3 G4 G5
HCS02.1E 100% -- -- -- --
HCS03.1E 100% -- -- -- --
HMV01.1E 100% -- -- -- --
HMV01.1R 100% -- -- -- --
HMS01.1 100% -- -- -- --
HMS02.1 100% -- -- -- --
HMD01.1 100% -- -- -- --
reduction of maximum allowed
NFD03.1 100% 100% 80% 100% 80%
continuous current
HNF01.1 100% -- -- -- --
HNL01.1 100% 100% 100% 100% 100%
HNL02.1 100% -- -- -- --
HNK01.1 100% -- -- -- --
HNS02.1 100% -- -- -- --
HLB01.1C 100% -- -- -- --
HLB01.1D 100% -- -- -- --
HLC01.1C 100% -- -- -- --
HLC01.1D 100% -- -- -- --
HLR01.1 100% -- -- -- --
-- not allowed
Fig. 7-2: Allowed positions of normal use and mounting positions
Example "NFD03.1 in position of normal use G5":

In position of normal use G5 the mains filter NFD03.1 may only be loaded
with 80% of the maximum allowed continuous current. The reduced load
must be guaranteed by the application.
Main Dimensions of the System Components

The main differences in the dimensions of the individual products of the
range are contained in the figure and table below.
Note: The mounting depths of the IndraDrive product range have

been optimized for mounting in control cabinets with 300 mm
or 400 mm.
The figure and table contain a rough overview of the main dimensions; for
details and required mounting dimensions see the dimension sheets of
the components.
Device Depths and Device Heights
seitenansicht_indraDrive.jpg
Fig. 7-3: Main dimensions in [mm]
Device Depths, Heights and Widths
Min.
moun-
Device Device ting Device
width C width height Device depth
[mm] [mm] 1) [mm] 2) [mm] 3)
HNL02.1R-0980 165 165 352 120
HLC01.1C-01M0
50 50 352
HLC01.1C-02M4
HCS02.1E-W0012 290
HCS02.1E-W0028 65 70
HLB01.1C 265
HCS02.1E-W0054 for control cabinets with
105 110 at least 300 mm of
HCS02.1E-W0070 depth
352
HMV02.1R-W0015 150 150
HMS02.1N-W0028 50 50
HMS02.1N-W0054 75 75
HNS02.1A-Q150 80 80
HMS01.1N-W0020
HMS01.1N-W0036 50 50
HMD01.1N-W0012
HMS01.1N-W0054
HMD01.1N-W0036 75 75
HLC01.1D-05M0
HMS01.1N-W0070
100 100
HLB01.1D
HCS03.1E-W0070 125 125 322
HMS01.1N-W0150 440 for control cabinets with

150 150 at least 400 mm of
HMV01.1E-W0030 depth
HMV01.1R-W0018 175 175
HMS01.1N-W0210 200 200
HCS03.1E-W0100
225 225
HCS03.1E-W0150
HMV01.1E-W0075
250 250
HMV01.1R-W0045
HCS03.1E-W0210
350 350
HMV01.1R-W0065
1) incl. minimum distance between the components
2) device body without mounting flange on top and bottom, as well as
minimum distances for ventilation and installation
3) incl. touch guard, connector housing, bending radius of fiber optic
cable, control panel "C"
Fig. 7-4: Mounting dimensions
Distances for Drive Controllers

In addition to the mounting dimensions, the components of the
Rexroth IndraDrive range require additional mounting clearance
• to ventilate the components
• to mount accessories and connections
• to take temperature limits of neighboring mounting parts, such as
cable ducts etc., into account
To determine the required mounting clearances in the control cabinet,

take additional distances between the components and on their tops and
bottoms into account.
Distance between Drive Controllers

Owing to power dissipation in the components, especially due to installed
braking resistors in compact devices, the temperatures of neighboring
components are rising. In the case of lateral mounting, trouble-free
operation therefore requires the following minimum distances in [mm]
between the components.
from to
HCS02 HCS03 HMV01 HMV02 HMS01 / HMS02
(HNK01, HMD01
HLR01)
HCS02.1E 5 -- -- -- 5 5
HCS03.1E
with HNK01 -- 0 -- -- 0 --
and HLR01
HMV01.1E /
-- -- 0 -- 0 --
HMV01.1R
HMS01.1 /
5 0 0 -- 0 --
HMD01.
HMV02.1R -- -- -- -- -- 0
HMS02.1 5 0 0 0 0 0
-- not allowed
Fig. 7-5: Minimum distance in [mm]
Note: For arrangement of the components in the control cabinet,

take their dimension sheets and the required minimum
distances into account.
Distances on Top and Bottom of Components

Owing to power dissipation in the components, the temperature of the
cooling air current at the device outlet is rising to values higher than
ambient temperature at device inlet.
Property damage due to temperatures higher

than 105 °C!
⇒ Comply with indicated minimum distances!
CAUTION
In order that drive controllers can discharge the power dissipation

generated inside of them, they need space on their top (A) and
bottom (B).
d
B
kuehlluft.FH7
A: air intake
B: air outlet
C: mounting surface in control cabinet
d: distance to top of device
Fig. 7-6: Air intake and air outlet at drive controller
For sufficient ventilation of the components you have to comply with the
minimum distances below. At components without integrated braking
resistor, there will be temperatures of up to 105 °C at the air outlet (B)
(with an air intake temperature of 45 °C).
Component Minimum distance for Notes

ventilation
at the bottom at the top
(A) (B)
[mm] 1) [mm] 2)
HMS01; HMD01 100 80
HCS02 80 80 additionally take power
at braking resistor into
HCS03 100 80 account
HMV01 100 300 take additional distance
to the side into account
HMV02 80 300
HMS02 80 80
HLC01.1C 80 80
HLC01.1D 80 80
HLB01.1C 80 300
HLB01.1D 100 300
1) for additional mounting parts, such as HAS, see dimensional
drawings
2) integrated braking resistors require additional distance
Fig. 7-7: Minimum distance for ventilation
Note: If there are different minimum distances for the individual

components in a drive system, the greatest value determines
the minimum distance to be observed.
Minimum Distance to Braking For components with integrated braking resistor (supply units, DC bus
Resistor resistor units, HCS02 drive controllers) their higher outlet temperatures
have to be taken into account.
To determine the required distances the resulting outlet temperatures are
indicated in diagrams in the technical data of the components.
Input value in the diagrams is the generated power of the braking
resistors or the individual output current. See exemplary diagram below:
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
PBD: average continuous braking resistor power

d: distance to top of device
Fig. 7-8: Exemplary diagram
The minimum distance for these mounting parts results from the
intersection of the input value with the allowed temperature rise.
Minimum Distance at HMV The braking resistor in the HMV01.1E heats up during operation, the
Devices braking resistor in the HMV01.1R and HMV02.1R after power is switched
off. For materials that can be damaged by heat generation, such as lines
or cable ducts, a minimum distance of 300 mm to the top and 40 mm to
the side has to be observed.
40 300
bleeder_abstand.fh7
Fig. 7-9: Minimum distance at HMV supply units
Boring Dimensions for the Mounting Plate

Individually Arranged Drive Controllers
K M
N
P
HNF_bohrbild.fh7
Fig. 7-10: Boring dimensions
Note: The figure shows the back of the devices.
K L M P R
Device Notes
[mm] [mm] [mm] [mm] [mm]
HCS02.1E-W0012 0 316 32,5 13 7 observe additional distance to lateral
neighboring devices
HCS02.1E-W0028 0 378 32,5 13 7 observe additional distance to lateral
neighboring devices
HCS02.1E-W0054 55 378 25 13 7 observe additional distance to lateral
neighboring devices
HCS02.1E-W0070 55 378 25 13 7 observe additional distance to lateral
neighboring devices
HCS03.1E-W0070 75 466 25 13 7
HCS03.1E-W0100 175 466 25 13 7
HCS03.1E-W0150 175 466 25 13 7
HCS03.1E-W0210 250 466 50 13 7
HMV01.1E-W0030 100 466 25 13 7
HMV01.1E-W0075 200 466 25 13 7
HMV01.1E-W0120 300 466 25 13 7
HMV01.1R-W0018 125 466 25 13 7
HMV01.1R-W0045 200 466 25 13 7
HMV01.1R-W0065 300 466 25 13 7
HMV02.1R-W0015 100 378 25 13 7
HMS01.1N-W0020 0 466 25 13 7
HMS01.1N-W0036 0 466 25 13 7
HMS01.1N-W0054 0 466 25 13 7
HMS01.1N-W0070 50 466 25 13 7
HMS01.1N-W0150 100 466 25 13 7
HMS01.1N-W0210 150 466 25 13 7
HMS02.1N-W0028 0 378 25 13 7
HMS02.1N-W0054 0 378 25 13 7
HMD01.1N-W0012 0 466 25 13 7
HMD01.1N-W0020 0 466 25 13 7
HMD01.1N-W0036 0 466 25 13 7
HNL02.1 100 378 20 13 7
HNS02.1 0 378 55 13 7
HLB01.1C 0 378 32,5 13 7
HLB01.1D 50 466 25 13 7
HLC01.1C-01M0 0 378 25 13 7
HLC01.1C-02M4 0 378 25 13 7
HLC01.1D-05M0 0 466 25 13 7
Fig. 7-11: Boring dimensions
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.
2. Use the supplied mounting screws and fix the screws with a
tightening torque of typ. 6 Nm.
3. Connect the mounting surface of the control cabinet in conductive
form to the equipment grounding system.
Combination of Drive Controllers of the

Rexroth IndraDrive M Product Range
Fig. 7-12: Rexroth IndraDrive M components
Note: The prevailing grid of fixing bores within the

Rexroth IndraDrive M product range is 25 mm.
For performance-dependent arrangement of the components
see Rexroth IndraDrive M Fig. 7-21: Example of an
arrangement.
The HAS02 accessories in the figure require additional
mounting clearance.
Dimension Z is significantly determined by the involved components. The

table below contains the dimensions Z between the component arranged
to the left and the component arranged to the right.
Dimension Z
Component left Component right
[mm]
HMV01.1E-W0030
HMV01.1E-W0075 HMS01.1N-W0020
HMV01.1E-W0120 HMS01.1N-W0036
HMV01.1R-W0018 HMS01.1N-W0054
HMV01.1R-W0045 HMS01.1N-W0070
HMV01.1R-W0065 HMS01.1N-W0150
HMS01.1N-W0020 HMS01.1N-W0210 50
HMS01.1N-W0036 HMD01.1N-W0012
HMS01.1N-W0070 HMD01.1N-W0020
HMS01.1N-W0150 HMD01.1N-W0036
HMS01.1N-W0210 HLC01.1D-05M0
HMD01.1N-W0012 HLB01.1D
HMD01.1N-W0020
HMV01.1E-W0030
HMV01.1E-W0075
HMV01.1E-W0120
HMV01.1R-W0018
HMV01.1R-W0045
HMV01.1R-W0065
HMS01.1N-W0054 HMS01.1N-W0020
HMD01.1N-W0036 HMS01.1N-W0036 75
HLC01.1D-05M0 HMS01.1N-W0070
HMS01.1N-W0150
HMS01.1N-W0210
HMD01.1N-W0012
HMD01.1N-W0020
HLC01.1D-05M0
HLB01.1D
Dimension Z
[mm]
HMV01.1E-W0030
HMV01.1E-W0075
HMV01.1E-W0120
HMV01.1R-W0018
HMV01.1R-W0045
HMV01.1R-W0065
HMS01.1N-W0020
HLC01.1C-01M0
HMS01.1N-W0036 57,5
HLC01.1C-02M4
HMS01.1N-W0070
HMS01.1N-W0150
HMS01.1N-W0210
HMD01.1N-W0012
HMD01.1N-W0020
HLC01.1D-05M0
HLB01.1D
HLC01.1C-01M0 HLC01.1C-01M0
65
HLC01.1C-02M4 HLC01.1C-02M4
Fig. 7-13: Table for dimension Z

Rexroth IndraDrive C Product Range
Fig. 7-14: Rexroth IndraDrive C components
Note: Observe that using HAS04 accessory at the HCS arranged at

the utmost left position requires additional space (dimensions:
see section "Accessories in the Drive System
Rexroth IndraDrive").
Rexroth IndraDrive components are arranged in line to the
right starting from the supplying device. Arrange the drive
controllers with high capacity as close to the supplying unit as
possible.
The HAS02 accessories in the figure require additional
mounting clearance.

Dimension Z
[mm]
HCS02.1E-W0012 HCS02.1E-W0012
HCS02.1E-W0028 HCS02.1E-W0028 70
HLB01.1C HLB01.1C
HCS02.1E-W0054 HCS02.1E-W0054
55
HCS02.1E-W0070 HCS02.1E-W0070
HLC01.1C-01M0
50
HLC01.1C-02M4 HLC01.1C-01M0 (without distance
HCS02.1E-W0054 HLC01.1C-02M4 between the
components)
HCS02.1E-W0070
HCS02.1E-W0012 57,5
HLC01.1C-01M0 (without distance
HCS02.1E-W0028
HLC01.1C-02M4 between the
HLB01.1C components)
HCS02.1E-W0054
HCS02.1E-W0012
HCS02.1E-W0070
HCS02.1E-W0028 62,5
HLC01.1C-01M0
HLB01.1C
HLC01.1C-02M4
HCS03.1E-W0070 HCS03.1E-W0070 50
(without distance
HCS03.1E-W0100 HCS03.1E-W0100
between the
HCS03.1E-W0150 HCS03.1E-W0150 components)
100
(without distance
HCS03.1E-W0210 HCS03.1E-W0210
between the
components)
HCS03.1E-W0070 75
(without distance
HCS03.1E-W0100 HCS03.1E-W0210
between the
HCS03.1E-W0150 components)
HCS03.1E-W0070 75
(without distance
HCS03.1E-W0210 HCS03.1E-W0100
between the
HCS03.1E-W0150 components)

Rexroth IndraDrive C and IndraDrive M Product Ranges
Note: Observe that using HAS04 accessory at the HCS arranged at

the utmost left position requires additional space (dimensions:
see section "Accessories in the Drive System
Rexroth IndraDrive").
Rexroth IndraDrive M components are arranged in line to the
right starting from the supplying drive controller HCS.

Component left Component right Dimension Z [mm]
HMS01.1N-W0020
HMS01.1N-W0036
HMS01.1N-W0054
50
HCS02.1E-W0054 HMD01.1N-W0012 (without distance
HCS02.1E-W0070 HMD01.1N-W0020 between the
components)
HMD01.1N-W0036
HLC01.1D-05M0
HLB01.1D

Component left Component right Dimension Z [mm]
HMS01.1N-W0020
HMS01.1N-W0036
HMS01.1N-W0054
HCS03.1E-W0070
HMS01.1N-W0070 50
HCS03.1E-W0100 (without distance
HMS01.1N-W0150
HCS03.1E-W0150 between the
HMS01.1N-W0210 components)
HCS03.1E-W0210
HMD01.1N-W0012
HMD01.1N-W0020
HMD01.1N-W0036
HMS01.1N-W0020
HMS01.1N-W0036
HMS01.1N-W0054
HMS01.1N-W0070 75
(without distance
HCS03.1E-W0210 HMS01.1N-W0150
between the
HMS01.1N-W0210 components)
HMD01.1N-W0012
HMD01.1N-W0020
HMD01.1N-W0036
Note: For the dimensions Z between other combinations see

previous tables.

Thermal Point of View
Multiple-Line Arrangement of Drive Controllers

Control Cabinet with Multiple-Line Structure
Note: Particular attention should be paid to the maximum allowed air

intake temperature of components when they are arranged in
multiple lines in the control cabinet. Where necessary, cooling
air guides are to be provided with blowers specially used for
this purpose.
conveying direction of heated air

in flow-off area
outlet air to
cooling unit
intake area of cooling air for

upper device line
air guide
addit-
ional
blower
conveying direction of heated air
in flow-off area
intake area of cooling air for supply air

lower device line from cooling
unit
Fig. 7-18: Example of arrangement for multiple-line structure with components
Arrangement of Cooling Units
Possible damage to the drive controller

Operational safety of the machine endangered!
Note the following instructions!
CAUTION
Avoiding Dripping or Sprayed Due to the operating principle, condensation water is formed when cooling
Water units are used. For this reason, please observe the following information:
• Always position cooling units in such a way that condensation water
cannot drip onto electronic equipment in the control cabinet.
• Position the cooling unit in such a way that the blower of the cooling
unit does not spray accumulated condensation water onto electronic
equipment.
correct incorrect
cooling unit cooling unit
warm cold warm cold
air duct
electronic electronic
equipment equipment
control cabinet control cabinet
Eb0001f1.fh7
Fig. 7-19: Arranging the cooling unit on the control cabinet
correct incorrect
control cabinet control cabinet

air intake air intake
air air outlet

duct
cooling cooling
unit unit
electronic electronic
equipment equipment
Eb0002f1.fh7
Fig. 7-20: Arranging the cooling unit at the front of the control cabinet
Avoiding Moisture Condensation Moisture condensation occurs when the temperature of the device is
lower than the ambient temperature.
• Set cooling units with temperature adjustment to the maximum
surrounding temperature and not lower!
• Set cooling units with follow-up temperature in such a way that the
interior temperature of the control cabinet is no lower than the
temperature of the surrounding air. Set the temperature limitation to
the maximum surrounding temperature!
• Only use well-sealed control cabinets so that moisture condensation
cannot arise as a result of warm and moist external air entering the
cabinet.
In the event that control cabinets are operated with the doors open
(commissioning, servicing etc.) it is essential to ensure that after the
doors are closed the drive controllers cannot at any time be cooler than
the air in the control cabinet, as otherwise moisture condensation can
occur. For this reason sufficient circulation must be provided inside the
control cabinet to avoid pockets of heat.

Electrical Point of View
The section below contains information and recommendations on the
arrangement of the components in the control cabinet from mainly
electrical points of view. These points of view include aspects of
performance-dependent arrangement and installation in compliance with
EMC.
Performance-Dependent Arrangement
Performance-Dependent Arrangement
The HMV01 supply units can supply HMS and HMD drive controllers on
both sides.
Arrange drive controllers according to their performance.
drive controllers drive controllers

low power high power high power low power
supply unit
versorg_antrieb_sym.FH7
Fig. 7-21: Example of an arrangement
Note: When you use HNS02 and HNL02, the supply units HMV02
only allow mounting them on one side to the right.
Arrangement of Additional Components

• Arrange drive controllers with high performance as close to the supply
unit as possible. Ideally the drive controllers should be distributed
equally to the left and right side of the supply unit.
Note: If you operate HCS drive controllers with the type of mains
connection "central supply", arrange the supplied drive
controllers at the right side of the HCS drive controllers.
• Position DC bus capacitor unit next to drive controller with the

greatest DC bus continuous power.
• Position DC bus resistor unit next to drive controller with the greatest
regenerative power.
• Arrange HLR braking resistors in "standard" design above the HCS03
drive controller.
• When using DC bus resistor unit and DC bus capacitor unit in a drive
system, arrange the DC bus capacitor unit between supply unit and
DC bus resistor unit.
EMC Measures for Design and Installation

Rules for Design of Installations with Drive Controllers in
Compliance with EMC
The following rules are the basics for designing and installing drives in
compliance with EMC.
Mains Filter Correctly use a mains filter recommended by Rexroth for radio
interference suppression in the supply feeder of the AC drive system.
Control Cabinet Grounding All metal parts of the cabinet have to be connected with one another over
the largest possible surface area to establish a good electrical connection.
This, too, applies to the mounting of the EMC filter. If required, use
serrated washers which cut through the paint surface. The cabinet door
should be connected to the cabinet using the shortest possible grounding
straps.
Line Routing Avoid coupling routes between lines with high potential of noise and
noise-free lines, therefore signal, mains and motor lines and power cables
have to be routed separately from another (this eliminates mutual
interference!). Minimum clearance: 10 cm. Provide separating sheets
between power and signal lines. Separating sheets have to be grounded
at several points.
Lines with high potential of noise at the drive controller are lines for the
mains supply (incl. mains synchronization), lines at the motor connection
and DC bus connections.
Generally, interference injection are reduced by routing cables close to
grounded sheet steel panels. For this reason, cables and wires should not
be routed freely in the cabinet, but close to the cabinet housing or
mounting panels. The incoming and outgoing cables of the radio
interference suppression filter have to be separated.
Interference Suppression Contactors, relays, solenoid valves, electromechanical operating hour
Elements counters etc. in the control cabinet must be provided with interference
suppression combinations. These combinations must be connected
directly at each coil.
Twisted Wires Non-shielded cables belonging to the same circuit (feeder and return
cable) have to be twisted or the surface between feeder and return cable
has to be kept as small as possible. Ground cables that are not used at
both ends.
Lines of Measuring Systems Lines of measuring systems have to be shielded. The shield has to be
connected to ground at both ends and over the largest possible surface
area. The shield may not be interrupted, e.g. using intermediate terminals.
Digital Signal Lines The shields of digital signal lines have to be grounded at both ends
(transmitter and receiver) over the largest possible surface area and with
low impedance. Bad ground connection between transmitter and receiver
requires additional routing of a bonding conductor (min. 10 mm²). Braided
shields are to be preferred to foil shields.
Analog Signal Lines The shields of analog signal lines generally have to be grounded at one
end (transmitter or receiver) over the largest possible surface area and
with low impedance, in order to avoid low-frequency interference current

(in the mains frequency range) on the shield.
Connection of Mains Choke to Keep connection lines of mains chokes as short as possible and twist
Drive Controller them.
Installation of Motor Power Preferably use the motor power cables with shield provided by Rexroth. If
Cable you use other motor power cables, they have to be run in shielded form.
Keep length of motor power cable as short as possible.
Ground shield of motor cable at both ends over the largest possible
surface area to establish a good electrical connection.
Run motor lines in shielded form inside the control cabinet.
Do not use any steel-shielded lines.
The shield of the motor cable mustn't be interrupted by mounted
components, such as output chokes, sine filters, motor filters.
EMC-Optimal Installation in Facility and Control Cabinet

With regard to EMC-optimal installation, a spatial separation of the
interference-free area (mains connection) and the interference-
susceptible area (drive components) is recommended, as shown in the
figures below.
Note: For EMC-optimal installation in the control cabinet use a

separate control cabinet panel for the drive components.
Division into Areas (Zones)

The arrangement in the control cabinet can be seen from Fig. 7-22:
Separation of interference-free area and interference-susceptible
area in control cabinet.
There are three areas to be distinguished:
1. Interference-free area of control section (area A):

This includes:
• supply feeder, input terminals, fuse, main switch, mains side of mains
filter for drives and corresponding connecting lines
• control voltage or auxiliary voltage connection with power supply unit,
fuse and other parts unless connection is run via the mains filter of
the AC drives
• all components that aren't electrically connected with the drive system
2. Interference-susceptible area (area B):

• mains connections between drive system and mains filter for drives,
mains contactor
• interface lines of drive controller
3. Strongly interference-susceptible area (area C):

• motor cable including single strands
Never run lines of one of these areas in parallel with lines of another area
so that there isn't any unwanted interference injection from one area to
the other and that the filter is jumpered with regard to high frequency.
Keep connection lines as short as possible.
For complex systems it is recommended to put the drive components into
a cabinet and the controls into a separate second cabinet.
Badly grounded control cabinet doors act as antennas. It is recommended

to connect the doors to the control section on top, in the middle and on
the bottom via short equipment grounding conductors with a cross section
2
of at least 6 mm or, even better, via grounding straps with the same
cross section. Make sure connection points have good contact.
Fig. 7-22: Separation of interference-free area and interference-susceptible

area in control cabinet
Design and Installation in Interference-Free Area of

Control Cabinet (Area A)
Arranging the Components in When arranging the components in the control cabinet, it is
the Control Cabinet recommended that you place the components and electrical elements
(switches, pushbuttons, fuses, terminal connectors) in the interference-
free zone A with a distance of at least d1 = 200 mm to the components in
both other zones B and C.
In particular, a distance of at least d2 = 500mm has to be kept in zone A
between magnetic components, such as transformers, line reactors and
DC-link reactors, that are directly connected to the power terminals of the
drive system and the interference-free components and lines between
supply system and filter including the mains filter. If this distance is not
kept, the magnetic leakage fields are injected to the interference-free
components and lines connected to the mains so that the limit values at
the supply connection are exceeded in spite of the installed filter.
Cable Routing of the The distance between the power input line and the lines between filter
Interference-Free Lines to the and exit point from the control cabinet in area A and the lines in areas B
Mains Connection and C must be at least 200 mm (distances d1 and d3 in the figure) at all
points.
If this is impossible, there are two alternatives:
• Install these lines with a shield and connect the shield, at several
points, but at least at the beginning and at the end of the line, to the
mounting plate or the control cabinet housing over a large surface
area, or:
• Separate these lines from the other interference-susceptible lines in
zones B and C by means of a grounded distance plate vertically
attached to the mounting plate.
In addition, these lines have to be kept as short as possible within the
control cabinet and installed directly on the grounded metal surface of the
mounting plate or of the control cabinet housing.
Mains supply lines from zones B and C must not be connected to the
mains without a filter.
Note: In case the information on cable routing given in this section is

not observed, the effect of the mains filter is totally or partly
neutralized. You must therefore expect the noise level of the
interference emission to be higher within the range of 150 kHz
to 40 MHz and the limit values at the connection points of the
machine or installation to be exceeded.
Routing and Connecting a If a neutral conductor is used together with a three-phase connection, it
Neutral Conductor (N must not be installed unfiltered in zones B and C, in order to keep
interference off the mains.
Connecting Motor Blowers Single-phase or three-phase supply lines of motor ventilators, that are
usually routed in parallel with motor cables or interference-susceptible
lines, also have to be provided with a filter. They either have to be filtered
via a separate single-phase filter (NFE type) or three-phase filter (HNF,
NFD type) near the supply connection of the control cabinet, or to be
connected at the load side of the existing three-phase filter for the power
connector of the drive system. When switching power off, make sure the
ventilator is not switched off.
Shielding Mains Supply Lines in If there is a high degree of interference injection to the power input line
Control Cabinet within the control cabinet, in spite of you having observed the above
instructions (to be found out by standard EMC measurement), the lines in
area A have to be routed in shielded form. In this case the shields have to
be connected to the mounting plate at the beginning and the end of the
line by means of clips. The same procedure may be required for long
cables of more than 2 m between the point of power supply connection of
the control cabinet and the filter within the control cabinet.
Mains Filters for AC Drives
The mains filter ideally should be mounted on the parting line between
area A and B. Make sure the ground connection between filter housing
and housing of the drive controllers has good electrically conductive
properties. If single-phase loads are connected on the load side of the
filter, their current may only be a maximum of 10% of the three-phase
operating current. A highly imbalanced load of the filter would deteriorate
its interference suppression capacity.
If the mains voltage is more than 480 V, the filter has to be connected on
the output side of the transformer and not on its supply side.
Grounding In the case of bad ground connections in the installation, the distance
between the lines to the grounding points E1, E2 in area A and the other
grounding points of the drive system should be at least d4 = 400 mm, in
order to minimize interference injection from ground and ground cables to
the power input lines.
See also Fig. 7-22: Separation of interference-free area and
interference-susceptible area in control cabinet
Point of Connection for The equipment grounding conductor of the power cable of the machine,
Equipment Grounding installation or control cabinet of the has to be firmly connected at point
2
Conductor of Machine, PE and have a cross section of at least 10 mm or to be complemented
Installation, Control Cabinet by a second equipment grounding conductor via separate terminal
connectors (according to EN50178/ 1997, section 5.3.2.1). If the cross
section of the outer conductor is bigger, the cross section of the
equipment grounding conductor has to be adjusted accordingly.
Design and Installation in Interference-Susceptible Area

of Control Cabinet (Area B)
Arranging Components and Modules, components and lines in area B should be placed at a distance
Lines of at least d1 = 200 mm from modules and lines in area A or shielded by
distance plates mounted vertically on the mounting plate. As an
alternative, the lines can be shielded.
Power supply units for auxiliary or control voltage connections in the drive
system mustn't be directly connected to the mains, but have to be
connected to the mains via a mains filter, as indicated in Fig. 7-22:
area in control cabinet.
Keep line length between drive controller and filter as short as possible.
Avoid unnecessary lengths.
Control Voltage or Auxiliary Only in exceptional cases should a connection of power supply unit and
Voltage Connection fusing for the control voltage connection be made at phase and neutral
conductor. In this case these components have to be mounted and
installed in area A, far away from the areas B and C of the drive system.
For details see chapter "Design and Installation in Interference-Free Area
of Control Cabinet (Area A)".
The connection between control voltage connection of the drive system
and power supply unit used has to be run through area B over the
shortest distance.
Line Routing Run the lines along grounded metal surfaces, in order to minimize
radiation of interference fields to area A (transmitting antenna effect).
Design and Installation in Strongly Interference-

Susceptible Area of Control Cabinet (Area C)
Area C mainly concerns the motor cables, especially at the connection
point at the device.
Influence of the Motor Power The discharge capacitance is limited to ensure compliance with the limit
Cable values. The calculation of the discharge capacitance can be found in the
"Calculations" chapter.
If the applications allows this, the cable length should always be kept
short. Avoid unnecessary line lengths.
Routing the Motor Cables The motor cables have to be run in shielded form. Besides they are
always to be routed with a distance of d5 = 100 mm to the other
interference-free lines and to signal cables and lines, or to be separated
from them by a grounded distance plate. The latter is not required for the
feedback cables of Rexroth motors.
At the drive controller connection the motor cables and the (unfiltered)
power connection lines may only be routed in parallel for a distance of
300 mm. After that distance, motor cables and power supply cables have
to be routed in opposite directions in separate cables ducts, as illustrated
in the following figures (Fig. 7-23: Option 1: separate routing of motor
cable and mains connection lines via 2 cable ducts; Fig. 7-24: Option 2:
separate routing of motor cable and mains connection lines) by the
example of a drive system with separate mains connection per drive axis
IndraDrive HCS.
Area B drive controllers Area C
parallel routing:
cable duct 1: length max. 300 mm
mains connection
lines
cable duct 2:
motor cable
motor cable:
shield contact via clips at least at one point: with a distance of at least 100 mm
alternatively at device or on mounting plate at or separated by grounded
control cabinet outlet distance plate
Fig. 7-23: Option 1: separate routing of motor cable and mains connection lines
via 2 cable ducts
Area B drive controllers Area C
parallel routing:
length max. 300 mm
cable duct 1:
mains connection
lines
cable duct 2:
motor cable
motor cable:
shield contact via clips at least at one
point: alternatively at device or on
mounting plate at control cabinet outlet
control cabinet outlet

motor cables
Fig. 7-24: Option 2: separate routing of motor cable and mains connection lines
Additional Recommendations on The motor cables should be routed along grounded metal surfaces, both
Cable Routing inside the control cabinet and outside of it, in order to minimize radiation
of interference fields. If possible the motor cables should be routed in
metal-grounded cable ducts.
The outlet of the motor cables at the control cabinet should ideally be
provided in a distance of at least d3 = 200 mm from the (filtered) power
supply cable.
Connection of Motor Cable to Drive Controller

There are the following minimum requirements for connecting the motor
cables to the drive controller:
• Connect the shield of the motor cable over the largest possible
surface area (with low impedance) to the drive controller. The
connection of cable shields by means of round wires (so-called "pig
tails") at the cable ends to ground and housing is normally insufficient.
• Make sure there is sufficient strain relief for the motor cable itself.
Shield Connection with Accessory HAS02

Optional accessory HAS02 to be used with connection over a large
surface area directly to the device. This is the best solution. The figure
below illustrates this by the example of HCS02 drive controllers:
DG000004v01_NN.tif
Fig. 7-25: Connecting HAS02 to HCS02
Shield Connection without Accessory HAS02

For shield connection without HAS02 accessory connect the cable shield
with the lowest possible impedance to the drive controller.
The following paragraphs describe two basic alternatives of this kind of
connection.
Alternative 1 Connect cable shield to a ground bus. The maximum distance between
ground bus and device connection is 100 mm. For this purpose take the
given length of the single strands at the cable end into account for ready-
made Rexroth motor power cables.
6 5
2
4 3
motorkabel_schirmauflage_b.fh7
1: drive controller
2: clip for shield contact
3: overall shield of the motor power cable folded back
4: ground bus in control cabinet
5: single strands of motor power cable
6: connection of ground bus to supplying device
7: strain relief (as near as possible to control cabinet outlet)
Fig. 7-26: Shield contact, alternative 1
• With a clip (2) connect overall shield of motor power cable (3) to
ground bus (4).
(If you use your own cable make sure the shields of the two inner
pairs of wires are in contact with the overall shield.)
• With a cable (6) (line cross section at least 10 mm2) connect ground
bus (4) to ground connection at supplying device (Rexroth IndraDrive
supply unit or Rexroth IndraDrive drive controller HCS).
Alternative 2 Connect cable shield to a ground bus. The cable length between device
and ground bus mustn't be more than a max. of 1 m. For this purpose
prepare the motor cable in accordance with the description below:
A
7
4 5
8
motorkabel_schirmauflage_a.fh7
1: drive controller
2: cable tie
3: overall shield of the motor power cable folded back
4: ground bus in control cabinet
5: connection between overall shield of motor power cable laying bare
and ground bus
6: connection of ground bus to supplying device
7: strain relief (as near as possible to the drive-side cable end)
8: strain relief (as near as possible to control cabinet outlet)
A: cable length between ground bus and device: < 1m
Fig. 7-27: Shield contact, alternative 2
• With a cable tie (2) press the drive-side cable end in such a way that
the shields of the two inner pairs of wires (motor temperature, holding
brake) have good contact with the overall shield of the motor power
cable (3).
(If you use your own cable make sure the shields of the two inner
pairs of wires are in contact with the overall shield.)
• On the level of the ground bus in the control cabinet remove a piece
of the cable sheath from the motor power cable in order to lay bare
the overall shield (5).
• Connect overall shield (5) to ground bus in the control cabinet with an
appropriate connection (clip). The connection must have a cross
section of at least 10 mm2.
• With a cable (6) (line cross section at least 10 mm2) connect ground
bus (4) to ground connection at supplying device (Rexroth IndraDrive
supply unit or Rexroth IndraDrive drive controller HCS).
• Make sure there is sufficient strain relief for the motor power cable as
near as possible to the drive-side cable end (7).
• In addition, make sure there is sufficient strain relief for the motor
power cable as near as possible to the control cabinet outlet of the
motor power cable (8).
Note: Do not remove the shield of the motor cable between ground
bus and device.
If the motor cables are routed to the control cabinet via flange boxes, the
shield is directly connected to the wall of the control cabinet over a large
surface area via the housing of the flange box. Make sure there is
sufficient separate strain relief.
Bonding Conductor Bad ground connection between motor housing and control cabinet
housing, as well as long motor cables, can require additional routing of a
bonding conductor of a cross section of normally 10 mm² between control
cabinet housing and motor housing.
Note: For cable lengths of more than 50 m the cross section should
2
be at least 35 mm .
Shield Connection of Kit Motors For kit motors make sure that the connection lines are run in shielded
form or under metal between winding and terminal box, if the terminal box
is not directly mounted on the spindle case.
Shield Connection for Linear For linear motors connect the shield of the connection cable between
Motors primary part and terminal box via clips to machine housing or metal shell.
Shielding of Temperature The inner shields of temperature monitor and brake in the motor cable are
Monitor and Brake connected to the drive controller at one end.
Ground Connections
Housing and Mounting Plate By means of appropriate ground connections it is possible to avoid the
emission of interference, because interference is discharged to earth on
the shortest possible way. Ground connection of the metal housings of
EMC-critical components such as filters, devices of the drive system,
connection points of the cable shields, devices with microprocessor and
switching power supply units have to be over a large surface area and
well contacted. This also applies to all screw connections of between
mounting plate and control cabinet wall and to the mounting of a ground
bus to the mounting plate.
For this purpose it is recommended to use a zinc-coated or chromatized
mounting plate. Compared to a lacquered plate, the connections in this
case have a good long-time stability.
Connection Elements For lacquered mounting plates always use screw connections with tooth
lock washers and zinc-coated, tinned screws as connection elements. At
the connection points selectively scratch off the lacquer so that there is
safe electrical contact over a large surface area. Contact over a large
surface area is established by means of bare connection surfaces or
several connection screws. For screw connections the contact to
lacquered surfaces is ensured by using tooth lock washers.
Metal Surfaces In any case use connection elements with good electroconductive
surface.
Bare zinc-coated, tinned and chromatized metal surfaces have good
electroconductive properties. Anodized, yellow chromatized, black
gunmetal finish or lacquered metal surfaces have bad electroconductive
properties and therefore shouldn't be used for connection elements
(screws, nuts, plain washers).
Ground Wires and Shield For connecting ground wires and shield connections it is not the cross
Connections section but the size of contact surface that is important, as the high-
frequency interference currents mainly flow on the surface of the
conductor.
Any connection of cable shields, especially of shields of the motor power
cables with ground potential (see section "Connection of Motor Cable to
Drive Controller") always has to be provided over a large surface area.
Installing Signal Lines and Cables

Line Routing For measures to prevent interference see the Project Planning Manuals
of the respective device. In addition, observe the following
recommendations:
Signal and control lines have to be routed separately from the power
cables with a minimum distance of d5 = 100 mm (see Fig. 7-22:
area in control cabinet) or with a grounded separating sheet. The
optimum way is to route them in separate cable ducts. If possible, lead
signal lines into control cabinet at one point only.
Exception: If there is no other way to do it, motor feedback cables can be
routed together with the motor power cables.
If signal lines are crossing power cables, they should be routed in an
angle of 90° in order to avoid interference injection.
Spare cables that are not used and have been connected should be
grounded at least at both ends so that they don't have any antenna effect.
Avoid unnecessary line lengths.
Run cables as close as possible to grounded metal surfaces (reference
potential). The ideal solution are closed, grounded cable ducts or metal
pipes which, however, is only obligatory for high requirements (sensitive
instrument leads).
Avoid suspended lines or lines routed along synthetic carriers, because
they are functioning both like good reception antennas (noise immunity)
and like good transmitting antennas (emission of interference).
Exceptional cases are trailing cable installations over short distance of a
max. of 5 m.
Shielding The cable shield has to be connected immediately at the devices in the
shortest and most direct possible way and over the largest possible
surface area.
The shield of analog signal lines is connected at one end over a large
surface area, normally in the control cabinet at the analog device. Make
sure the connection to ground/housing is over a large surface area and
short.
The shield of digital signal lines is connected at both ends over a large
surface area and in short form. In the case of potential differences
between beginning and end of the line, run an additional bonding
2
conductor in parallel. The guide value for the cross section is 10 mm .
You absolutely have to equip separable connections with connectors with
grounded metal housing.
In the case of non-shielded lines belonging to the same circuit, twist
feeder and return cable.
Installing the 24V Supply

As a matter of principle, the 24V supply of the components of the drive
system Rexroth IndraDrive has to be installed in star-shaped form, i.e. for
each group of drive controllers or third-party components it is necessary
to run separate supply lines. This, too, applies to multiple-line
arrangement in the case of supply from a supply unit, for example.
HCS02
HCS02
HMV
HMS
HMD
24V
1)
2)
PE
DA000006v01_nn
1) third-party component (e.g. PLC, valve etc.)
2) connection to central ground point (e.g. earth-circuit connector)
Fig. 7-28: Installing the 24V supply
Note: If you use several power supply units for 24 V supply, make
sure that
• the reference conductors 0V of the individual power supply
units are interconnected with low impedance
• the output voltages of the power supply units are within the
allowed voltage range
• the power supply units are synchronously switched on and off.
General Measures of Radio Interference Suppression for Relays,

Contactors, Switches, Chokes, Inductive Loads
If, in conjunction with electronic devices and components, inductive loads,
such as chokes, contactors, relays are switched by contacts or
semiconductors, appropriate interference suppression has to be provided
for them. In the case of d.c. operation, this is achieved by arranging free-
wheeling diodes and in the case of a.c. operation, by arranging usual RC
interference suppression elements depending on the contactor type,
immediately at the inductance. Only the interference suppression element
arranged immediately at the inductance serves this purpose. Otherwise
the emitted noise level is too high which can affect the function of the
electronic system and of the drive.
If possible, mechanical switches and contacts should only be realized as
snap contacts. Contact pressure and contact material must be suited for
the corresponding switching currents.
Slow-action contacts should be replaced by snap switches or by solid-
state switches, because slow-action contacts strongly bounce and are in
an undefined switching status for a long time which emits electromagnetic
waves in the case of inductive loads. These waves are an especially
critical aspect in the case of manometric or temperature switches.
Notes
Rexroth IndraDrive Electromagnetic Compatibility (EMC) 8-1
8 Electromagnetic Compatibility (EMC)
8.1 EMC Requirements

The electromagnetic compatibility (EMC) or electromagnetic interference
(EMI) includes the following requirements:
• sufficient noise immunity of an electric installation or an electric device
against external electric, magnetic or electromagnetic interference via
lines or through air
• sufficiently low noise emission of electric, magnetic or electromagnetic
noise of an electric installation or an electric device to other
surrounding devices via lines or through air
Noise Immunity in Drive System

Basic Structure for Noise Immunity
The figure below illustrates the interfaces for definition of noise immunity
requirements in the drive system.
enclosure port 1
drive system/machine unit enclosure port 2 Application examples:

• SERCOSinterface
cabinet/enclosure drive unit • parallel and serial
interfaces
external
• single-wire connections equipment
for operation
outside of the
drive module
machine unit
ports for process measurement
power port (mains connection)
control lines
power power control
supply section section
24 V power interface unit other electronic enclosure port 6
signal interface
supply or electrical
device
signal interface Application
other power interface examples:
power • PROFIBUS
device signal interface • INTERBUS
enclosure port 3 • DeviceNet
other • CANopen
power interface electronic HMI or
device control
device
enclosure port 4
motor
signal interface enclosure port 5
enclosure port 3
encoder
earth port
Fig. 8-1: Basic structure and noise immunity
8-2 Electromagnetic Compatibility (EMC) Rexroth IndraDrive
Noise Immunity Limit Values

No Place of effect Pheno- Standard Conditions Coupling Test values Perfor-
menon according mance
standard EN level
61800-3
Enclosure port IEC 61000-4-2 CD, AD 6 kV CD, 8kV AD, B
if CD not possible
RF Field IEC 61000-4-3 Via antenna on 10 V/ m A
EUT
Power port Burst IEC 61000-4-4 length > 3 m mains connection 4 kV/ 2,5 kHz B
I < 100 A: (clamp)
discoupling
network
I > 100 A:
clamp
Surge IEC 61000-4-5 Only mains Line – line 1 kV (2 B
connection; Ohm)
I < 63 A, Line – earth 2 kV
(12 Ohm)
light load test
IEC 61000-4-6 length > 3 m clamp 10 V, 0,15 – 80 A
MHz
Power Interface Burst IEC 61000-4-4 length > 3 m clamp B
Signal Interface Burst IEC 61000-4-4 length > 3 m clamp B
IEC 61000-4-6 length > 3 m Clamp or CDN 10 V, 0,15 – 80 B
MHz
Ports of Burst IEC 61000-4-4 length > 3 m clamp B
process;
measurement
control lines
IEC 61000-4-6 length > 3 m Clamp or CDN 10 V, 0,15 – 80 A
MHz
Fig. 8-2: Noise immunity limit values
Evaluation Explanation
criterion (abbreviated form from EN 1800-3)
A Deviations within allowed range
B Automatic recovery after interference
C Switched off without automatic recovery.
Device remains undamaged
Fig. 8-3: Evaluation criterion
Noise Emission of Drive System

Causes of Noise Emission
Controlled variable-speed drives contain converters containing snappy
semiconductors. The advantage of modifying the speed with high
precision is achieved by means of pulse width modulation of the converter
voltage. This can generate sinusoidal currents with variable amplitude and
frequency in the motor.
The steep voltage rise, the high clock rate and the resulting harmonics
cause unwanted but physically unavoidable emission of interference
voltage and interference fields (wide band interference). The interference

mainly is asymmetric interference against ground.
The propagation of this interference strongly depends on

• configuration
• conditions of mounting
• mounting site
• radiation conditions
• wiring and installation
• of the individual drive components in the machine or installation.
If the interference gets from the device to the connected lines in unfiltered
form, these lines can radiate the interference into the air (antenna effect).
This applies to power lines, too.
Limit Values for Line-Based Disturbances

According to IEC EN 61800-3 or CISPR 11, the limit values in the table
below are distinguished. For this documentation both standards are
combined in the limit value classes A2.1 to B1.
IEC / EN 61800-3 CISPR 11 Explanation In this docu- Curves of

mentation limit value
characteris-
tic
One of the following 3 requirements must have
been fulfilled: Mains connection current >400 A,
IT mains or required dynamic drive behavior not
Category C4 reached by means of EMC filter.
nd none none --
2 environment
Adjust limit values to use and operation on site.
User has to carry out and provide evidence of
EMC planning.
Category C3 Class A; limit value in industrial areas to be complied with A2.1 1.1
nd
2 environment; Group 2 for applications operated at supply mains with 1.2
I >100 A I >100A nominal currents > 100A
Category C3 Class A; limit value in industrial areas to be complied with A2.2 2.1
nd
2 environment; Group 2 for applications operated at supply mains with 2.2
I <100 A I <100A nominal currents < 100A
Category C2 Class A; Limit value in residential area or at facilities at A1 3.1

st
1 environment; Group 1 low-voltage mains supplying buildings in 3.2
restricted residential areas. To be complied with for
distribution applications with restricted distribution.
Category C1 Class B; limit value in residential areas to be complied B1 4.1

st
1 environment; Group 1 with for applications with unrestricted distribution 4.2
unrestricted
distribution
Fig. 8-4: Limit value classes
Limit values for line-based disturbances (IEC 61800-3)

1.1 Category C3: second environment,
130
1.2 1.1 QSP, I > 100A
125
120 (class A, group 2, I > 100A)
115 Category C3: second environment, AV,
115 1.2
I > 100A
105 (class A, group 2, I > 100A)
100
2.1 Category C3: second environment, QSP,
2.1 I < 100A
90 2.2
(class A, group 2, I < 100A)
86
Category C3: second environment, AV,
79 3.1 2.2
I < 100A
76 (class A, group 2, I < 100A)
73
66 70 Category C2: first environment,
3.2 3.1 restricted distribution, QSP
60 (first environment, even if source of
56 56 60 interference in second environment)
50 (class A, group 1)
46
Category C2: first environment,
4.1 restricted distribution, AV
3.2 (first environment, even if source of
4.2 interference in second environment)
(class A, group 1)
Category C1: first environment,

4.1 unrestricted distribution, QSP
(first environment, even if source of
interference in second environment)
(class B, group 1)
4.2 Category C1: first environment,

unrestricted distribution, AV
(first environment, even if source of
Notes: interference in second environment)
(1) Limit value for first environment is also relevant if source of interference of second environment affects first environment. (class B, group 1)
(2) Designations "class" and "group" according to IEC CISPR 11.
(3) QSP: measuring method quasi peak measurement; AV: measuring method arithmetic averaging
Fig. 8-5: Limit value characteristic through frequency range
Second Environment, Industrial Facilities not directly connected to a low-voltage mains to supply buildings
Area in residential areas.
If the limit values in an industrial area separated from public supply by a
transformer station only have to be complied with at the property
boundary or in the neighboring low-voltage mains, the filter might not be
necessary. In the vicinity of broadcast receivers or other sensitive devices
as regards high-frequency, such as measuring sensors, measuring lines
or measuring devices, it is normally required to use the interference
suppression filter.
Increasing the noise immunity of a sensitive device can often be the
economically better solution compared to measures of interference
suppression at the drive system of the installation.
First Environment Environment containing residential areas and facilities directly connected,
without interstage transformer, to a low-voltage mains supplying buildings
in residential areas.
Medium-sized manufacturing plants and industrial establishments can be
connected to the public low-voltage mains together with residential
buildings. In this case there is a high risk for radio and television reception
if there aren't any measures for radio interference suppression taken.
Therefore, the indicated measures are generally recommended.
Nominal Current of Supply The nominal current of the supply mains (>100A or <100A) is specified by
Mains the local power supply company at the connection point of the mains. For
industrial companies, for example, such connection points are the
interconnecting stations from the power supply system.
Unrestricted Distribution Channel of distribution for which placing on the market is independent of
the EMC expert knowledge of the customer or user of electric drives.
Restricted Distribution Channel of distribution for which the placing on the market is restricted to
traders, customers or users who individually or together have technical
expert knowledge of EMC for the use of electric drives.
Since it is impossible to obtain the lower limit values for residential areas
with all applications by means of the usual measures (like for example in
the case of large and electrically not closed installations, longer motor
cables or a high number of drives), the following note included in
EN 61800-3 has to be observed.
Note: Components of the drive system Rexroth IndraDrive are

products of category C3 (with restricted distribution)
according to IEC 61800-3. They are not provided for use in a
public low-voltage mains supplying residential areas. If they
are used in such a mains, high-frequency interference is to be
expected. This can require additional measures of radio
interference suppression.
See the following chapters for the limit value classes (as per categories
C1, C2, C3, C4 according to EN 61800-3) which can be reached for the
individual drive systems and devices.
8.2 Ensuring the EMC Requirements

Standards and Laws On the European level there are the EU directives. In the EU states these
directives are transformed into laws valid on a national level. The relevant
directive for EMC is EU directive 89/336/EWG which was transformed on
the national level in Germany into the law EMVG ("Law concerning
electromagnetic compatibility of devices") of 1992-11-09.
EMC Properties of Components Drive and control components by Rexroth are designed and built, in
accordance with the present state-of-the-art of standardization, according
to legal regulations of the EU directive 89/336/EWG and the German
EMC law.
The compliance with EMC standards was tested by means of a typical
arrangement with a test setup conforming to standard with the indicated
mains filters. The limit values according to product standard EN 61800-3
have been complied with.
Apart from the internal test at the factory, a conformity test was carried
out for individual drive systems in an accredited laboratory of a CE-
responsible authority.
Applicability for End Product Measurements of the drive system with an arrangement typical for the
system are not in all cases applicable to the status as installed in a
machine or installation. Noise immunity and noise emission are strongly
depending on
• configuration of the connected drives
• number of the connected drives
• conditions of mounting, mounting site
• radiation conditions, wiring
• installation of individual drive components
in the machine or installation.
In addition, the required measures depend on the requirements of electric

safety technology and economic efficiency in the application.
In order to prevent interference as far as possible, notes on mounting and
installation are contained in the application manuals of the components
and in this documentation.
Note: Observe the descriptions and notes in chapter "Arranging the

Components in the Control Cabinet".
Cases to Distinguish for For validity of the harmonized standards, we distinguish the following
Declaration of EMC Conformity cases:
• Case 1: Delivery of the drive system. According to the regulations, the
product standard EN 61800-3 is complied with for Rexroth drive
systems. The drive system is listed in the declaration of EMC
conformity. This fulfills the legal requirements according to EMC
directive.
• Case 2: Acceptance test of a machine or installation with the installed
drive systems. The product standard for the respective type of
machine/installation, if existing, applies to the acceptance test of the
machine or installation. In the last years, some new product standards
were created for certain machine types and some are being created at
present. These new product standards contain references to the
product standard EN 61800-3 for drives or specify higher-level
requirements demanding increased filter and installation efforts. When
the machine manufacturer wants to put the machine/installation into

circulation, the product standard relevant to his machine/installation
has to be complied with for his end product "machine/installation". The
authorities and test laboratories responsible for EMC normally refer to
this product standard.
This documentation specifies the EMC properties which can be achieved,

in a machine or installation, with a drive system consisting of the standard
components.
It also specifies the conditions under which the indicated EMC properties
can be achieved.
8.3 Measures to Reduce Noise Emission

To reduce noise emission there are mainly three possible measures:
• filtering by means of mains filter
• shielding by mounting and shielded cables
• grounding by electrical bonding
Noise Emission of the Drive In order to comply with the limit values for noise emission (mainly line-
Systems based radio interference of more than 9 kHz) at the connection points of
the machine or installation, observe the notes on application contained in
this documentation.
Shielding
Sufficient metallic shielding prevents radiation into the air. This is
achieved by mounting the devices in a grounded control cabinet or in a
housing (metallic encapsulation). The shielding of line connections is
realized by shielded cables and lines, the shield has to be grounded over
a large surface area.
Grounding
Grounding discharges interference to ground and makes it flow back to
the source of interference over the shortest distance. Realize grounding
via a sufficiently short connection over the largest possible surface
area in order to achieve low inductive resistance with a low degree of line
inductance. The higher the frequency of disturbances, the lower the line
inductance of grounding has to be.
Note: In ungrounded mains the measure "grounding" cannot be

generally used.
Filtering
Filtering prevents emission of noise via the lines, especially via the mains
connection. For this purpose there are special interference suppression
filters available, with which
• the allowed limit values of the line-based interference emission can be
complied with in the range of 50 kHz to 30 MHz.
• interference via the mains connection to devices connected near by
(e.g. control unit components) can be reduced.
Selecting the Mains Filter

For Rexroth drive systems there are the following mains filters for radio
interference suppression available:
• NFE01.1, NFE02.1, NFD03.1, HNF01.1, HNK01.1; HNS02.1
These filters have been especially dimensioned for Rexroth drive
systems. If you use other filters by other manufacturers, Rexroth cannot
guarantee mains interference suppression with regard to allowed limit
values.
Criteria for Selecting the Mains For selecting the appropriate mains filter, take the following criteria into
Filter account:
• required EMC limit value class
• ambient conditions on site
• loading by harmonics on site
• loading by mains voltage and frequency on site
• loading by mains-side phase current
• total length of connected motor cables
• sum of leakage capacitances
How to Proceed for Selecting the There are the following criteria for selection of the mains filter; the criteria
Mains Filter are decisively determined by the operating conditions. To select the mains
filter proceed as follows:
1. Determine required EMC limit value class for application.
2. Check or determine max. occurring ambient temperature.
3. Determine max. applied mains voltage.
Observe that not all Rexroth IndraDrive mains filters are suited for
mains voltage of 3AC500V.
4. Determine kind of mains connection, such as central supply, group
supply etc. (to do this it is useful to outline involved components and
their interaction).
Mains-Side Phase Current 5. Calculate mains-side phase current of mains filter.
For selecting components calculate the effective rms value. For help
on calculations see chapter "Calculations" under "Calculations for
Mains Connection".
6. Select a mains contactor the nominal current of which does not
exceed nominal current of mains filter.
7. Determine number of drive axes, take into account that HMD01 are
equipped with 2 axes.
8. Determine total length of connected motor cables.
9. Calculate sum of leakage capacitance on load side of mains filter.
Determine sum of leakage capacitance from number of operated
axes and length of connected motor cables. Chapter "Calculations",
section "Determining the Leakage Capacitance" helps you with the
calculation.
10. Select appropriate mains filter from tables in chapter "Limit Value
Classes to be Achieved with Mains Filters".
Note: Observe that the capacity of the mains filters regarding the
max. allowed number of drive controllers and max. allowed
total motor cable length depends on whether you use an HMV
supply module or supply other drive controllers with HCS drive
controllers.
For supply by HMV both the allowed number and allowed total
length are higher.
Allowed Operating Data 11. Calculate allowed operating data of mains filter according to chapter
"Calculations for Determining the Allowed Operating Data of Mains
Filters". If necessary, make sure the harmonics are reduced on site.
Note: The selected mains filter has to comply with the criteria
determined before.
Within a mains filter line you can replace mains filters of lower
type current by such ones with higher type current.
Protecting Mains Filters Against Overload

The mains filters are provided for operation with Rexroth IndraDrive
devices and risk overload in the case of incorrect use.
Property damage due to mains filter overload!

⇒ Avoid series connection of mains filters as this can
cause resonance effects on current and voltage.
CAUTION ⇒ Use only expressly allowed components at mains
filters.
⇒ When using mains filters at compensation units,
make sure there aren't any resonance effects on
current and voltage.
⇒ Observe the allowed harmonic limit values (THD) of
the filter components.
⇒ Observe that the nominal current of the mains
contactor does not exceed the nominal current of the
mains filter.
To connect the shield at the motor, a suitable PG gland with shield

connection can be used (e.g. "SKINDICHT SHV/SRE/E" from the Lapp
Company, Stuttgart). Make sure that the connection between the motor
terminal box and the motor housing has a low impedance. If necessary,
use an additional grounding strap between them. Never use plastic motor
terminal boxes!
Ungrounded Mains For operation at ungrounded mains it is recommended to galvanically
decouple the drive system with the mains filter from the mains via an
isolating transformer, if ground fault detection or monitoring is to remain
effective in the installation.
Please note that residual-current-operated circuit-breakers trigger
accidentally as a result of larger leakage current when connecting mains
filters.
If the drive system is nevertheless operated directly at the ungrounded

mains, make sure that
• the ground fault detection of the mains does not trigger accidentally
and
• the interference suppression, that now is only activated via the
parasitic mains capacitances of the ungrounded mains, is still
sufficient to comply with the limit values required by the application.
8.4 Limit Value Classes to be Achieved with Mains Filters

For explanations on the dimensioning criterion limit value class see
chapter 0 "Noise Emission of Drive System" under "Limit Values for Line-
Based Disturbances".
For calculation formulas for determining the allowed leakage
capacitances see chapter "Determining the Leakage Capacitance".
Mains Filters for Supply Modules HMV01.1E and HMV01.1R with HMS01/
HMD01
Limit Value Classes for HMV01.1E Supply Units
Observe the notes and proceeding in chapter "Selecting the Mains Filter".
Supply unit type Mains filter type Max. allowed Max. allowed PWM Allowed leakage
number of total length of frequ. capacitance to comply
axes motor cable [kHz] with limit value class
[m] [nF]
assigned mains choke HNL01.1 optional A2.1 A2.2 A1 B1
12 280 4
(12 * HMS01 8
HMV01.1E-W0030 HNF01.1A-F240-E0051 tbd 290 290 -
or 12
6 * HMD01) 110 16
HMV01.1E-W0030 without not allowed
21 4
1050
(21 * HMS01 8
HMV01.1E-W0030 HNF01.1A-M900-E0051 tbd 1100 1100 -
or 12
270
11 * HMD01) 16
1
(1 * HMS01 4
HMV01.1E-W0075 without 40 40 -- -- --
or 8
1 * HMD01)
12 280 4
(12 * HMS01 8
HMV01.1E-W0075 HNF01.1A-F240-E0125 tbd 290 - -
or 12
6 * HMD01) 110 16
21 1050 4
(21 * HMS01 8
HMV01.1E-W0075 HNF01.1A-M900-E0125 tbd 1100 - -
or 12
11 * HMD01) 270 16
1
(1 * HMS01 4
HMV01.1E-W0120 without 40 40 -- -- --
or 8
1 * HMD01)
12 280 4
(12 * HMS01 8
HMV01.1E-W0120 HNF01.1A-F240-E0202 tbd 290 - -
or 12
6 * HMD01) 110 16
21 1050 4
(21 * HMS01 8
HMV01.1E-W0120 HNF01.1A-M900-E0202 tbd 1100 - -
or 12
11 * HMD01) 270 16
tbd in preparation
Fig. 8-6: Supply modules HMV01.1E with / without mains filter HNF
Limit Value Classes for HMV01.1R Supply Units

Note: Damage caused by missing mains choke! Always operate

HMV01.1R supply units with the assigned mains choke
HNL01.1R.
Supply unit type Mains filter type Max. allowed Max. allowed PWM Allowed leakage
number of total length of frequ. capacitance to comply
axes motor cable [kHz] with limit value class
[m] [nF]
assigned mains choke HNL01.1R required A2.1 A2.2 A1 B1
12 280 4
(12 * HMS01 8
HMV01.1R-W0018 HNF01.1A-F240-R0026 tbd 290 290 -
or 12
6 * HMD01) 110 16
21 1050 4
(21 * HMS01 8
HMV01.1R-W0018 HNF01.1A-M900-R0026 tbd 1100 1100 -
or 12
11 * HMD01) 270 16
12 280 4
(12 * HMS01 8
HMV01.1R-W0045 HNF01.1A-F240-R0065 tbd 290 290 -
or 12
6 * HMD01) 110 16
21 1050 4
(21 * HMS01 8
HMV01.1R-W0045 HNF01.1A-M900-R0065 tbd 1100 1100 -
or 12
11 * HMD01) 270 16
12 280 4
(12 * HMS01 8
HMV01.1R-W0065 HNF01.1A-F240-R0094 tbd 290 - -
or 12
6 * HMD01) 110 16
21 1050 4
(21 * HMS01 8
HMV01.1R-W0065 HNF01.1A-M900-R0094 tbd 1100 - -
or 12
11 * HMD01) 270 16
8 350 4
(8 * HMS01 8
HMV01.1R-W0120 HNF01.1A-H350-R0180 tbd tbd - -
or 12
4 * HMD01) tbd 16
150 4
12 8
HMV02.1R-W0015 HNS02.1A-Q150-R0023 tbd tbd tbd -
(12 * HMS02) 12
tbd 16
tbd in preparation
Fig. 8-7: Supply modules HMV01.1R with / without mains filter HNF
Mains Filters for Drive Controllers HCS02
Note: With HCS02.1E drive controllers the limit value class A2.1
(see Noise Emission of Drive System) can already be
achieved without mains filters.
• Observe notes in chapter "Arranging the Components in
the Control Cabinet".
Limit Value Classes for HCS02 Drive Controllers

Drive controller Mains filter type Max. Max. all. PWM Max. all. Allowed leakage
type 2) allowed total frequ. leakage capacitance to comply
number length of [kHz] capac. 1) with limit value class
axes motor [nF] [nF]
cable
[m]
assigned mains choke HNL01.1
A2.1 A2.2 A1 B1
optional
group supply
4; 8 80 (70) 75 65 45
without DC bus
6 (6 *
connection NFD03.1-480-007 120 x
HCS02)
toHCS02.1E-
12, 16 tbd tbd tbd tbd
W0012
group supply
without DC bus 4; 8 70(65) 60 50 40
connection 6 (6 *
NFD03.1-480-016 120 x
toHCS02.1E- HCS02)
W0012, 12, 16 tbd tbd tbd tbd
HCS02.1E-W0028
group supply
without DC bus 6
connection to
HCS02.1E-W0012, 4; 8 100 (60) 80 50 --
(6 * HCS02
HCS02.1E-W0028 NFD03.1-480-030 or 120 x
or 6 * HMS01
12, 16 tbd tbd tbd --
HCS02.1E-W0054, 3 * HMD01)
HCS02.1E-W0070
group supply
without DC bus 6
connection to
HCS02.1E-W0012, 4; 8 130 (65) 100 70 52
(6 * HCS02
HCS02.1E-W0028 NFD03.1-480-055 or 120 x
or 6 * HMS01
HCS02.1E-W0054, 3 * HMD01)
HCS02.1E-W0070
group supply
without DC bus 6
connection to
HCS02.1E-W0012, 4; 8 150 (65) 110 70 55
(6 * HCS02
HCS02.1E-W0028 NFD03.1-480-075 or 120 x
or 6 * HMS01
HCS02.1E-W0054, 3 * HMD01)
HCS02.1E-W0070
Drive controller Mains filter type Max. Max. all. PWM Max. all. Allowed leakage
type 2) allowed total frequ. leakage capacitance to comply
number length of [kHz] capac. 1) with limit value class
axes motor [nF] [nF]
cable
[m]
group supply
without DC bus 6
connection to
HCS02.1E-W0012, 4; 8 350 350 300 89
(6 * HCS02
HNF01.1A- F240-
HCS02.1E-W0028 or 240 x
R0026
or 6 * HMS01
HCS02.1E-W0054, 3 * HMD01)
HCS02.1E-W0070
group supply
without DC bus 12
connection to
HCS02.1E-W0012, 4; 8 400 350 350 350
(12*HCS02
HNF01.1A-M900-
HCS02.1E-W0028 or 900 x
R0026
or 12*HMS01
HCS02.1E-W0054, 6 * HMD01)
HCS02.1E-W0070
group supply
without DC bus 12
connection to
HCS02.1E-W0012, 4; 8 400 350
(12*HCS02
HNF01.1A-M900-
HCS02.1E-W0028 or 900 x -- --
E0051
or 12*HMS01
12, 16 tbd tbd
HCS02.1E-W0054, 6 * HMD01)
HCS02.1E-W0070
1) saturation limit of filter
2) observe allowed current load of mains filter
x: limit value is observed without mains filter
() for unbalanced distribution; when leakage capacitance between axes
differs by more than 50%
tbd in preparation
Fig. 8-8: HCS02 with mains filter
grounded via outer conductor.
Mains Filters for Drive Controllers HCS03
Note: At HCS03.1E drive controllers, do not operate any external

additional capacitances at the DC bus.
Exception: For drive controllers HCS03.1E-...-W0210 this is
allowed.
Limit Value Classes for HCS03 Drive Controllers with

HNK01
Drive controller Mains filter type Max. Max. allowed PWM Allowed leakage capacitance
type allowed total length frequ. to comply with limit value
number of of motor [kHz] class
axes cable [nF]
[m]
A2.1 A2.2 A1 B1
4
8
HCS03.1E-W0070 HNK01.1A-A075-E0050 1 75 tbd tbd tbd tbd
12
16
4
8
12
16
4
8
12
16
4
8
12
16
tbd in preparation
Fig. 8-9: HCS03 with mains filter HNK
Limit Value Classes for HCS03 Drive Controllers with

HMS, HMD and HNF01 Drive Controllers
Drive controller Mains filter type Max. Max. allowed PWM Allowed leakage capacitance
type allowed total length frequ. to comply with limit value
number of of motor [kHz] class
axes cable [nF]
[m]
A2.1 A2.2 A1 B1
6 240 4
(6 * HMS01 8
HCS03.1E-W0070 HNF01.1A-F240-E0051 tbd tbd tbd tbd
or 12
3 * HMD01) 110 16
12 900 4
(12*HMS01 8
HCS03.1E-W0070 HNF01.1A-M900-E0051 tbd tbd tbd tbd
or 12
6 * HMD01) 270 16
6 240 4
(6 * HMS01 8
HCS03.1E-W0100 HNF01.1A-F240-R0094 tbd tbd tbd tbd
or 12
3 * HMD01) 110 16
12 900 4
(12*HMS01 8
HCS03.1E-W0100 HNF01.1A-M900-R0094 tbd tbd tbd tbd
or 12
6 * HMD01) 270 16
6 240 4
(6 * HMS01 8
or 12
3 * HMD01) 110 16
12 900 4
(12*HMS01 8
or 12
6 * HMD01) 270 16
6 240 4
(6 * HMS01 8
or 12
3 * HMD01) 110 16
12 900 4
(12*HMS01 8
or 12
6 * HMD01) 270 16
tbd in preparation
Fig. 8-10: HCS03 with mains filter HNF01
grounded via outer conductor.
Notes
Rexroth IndraDrive Types of Mains Connection 9-1
9 Types of Mains Connection

Drive systems with Rexroth IndraDrive controllers can be connected to
the mains in different ways. We distinguish the following types of mains
connection:
• individual supply
• group supply without DC bus DC bus connection
• group supply with DC bus connection
• central supply
The following table illustrates the allowed types of mains connection, they
are described in detail below.
Note: For further information on configuration and parameter setting

of the drive controllers see Functional Description in chapter
"Power Supply".
In this chapter you will find the settings for configuring the Bb
contact and involved parameters.
9.1 Allowed Types of Mains Connection

Drive controller or Individual Group supply without DC Group supply with DC bus Central
supply module supply bus DC bus connection connection supply
HMV01.1E x x x x
HMV01.1R x x -- x
HCS02.1E x x x x
HCS03.1E x x x x
HMV02.1R x x -- x
X: allowed
--: not allowed
Fig. 9-1: Allowed types of mains connection
9-2 Types of Mains Connection Rexroth IndraDrive
9.2 Individual Supply

The mains connection individual supply is the standard type of
connection. It is characterized by one mains connection (mains circuit
breaker, mains transformer, mains filter, mains choke) for each drive
system.
Individual Supply with HMV

It is possible to connect further drive controllers and additional
components to the supply module.
HMV HMS HMD
Fuse Trafo Filter Choke
Einzeleinspeisung HMV.EPS

Fig. 9-2: Individual supply HMV
Individual Supply with HCS

It is possible to connect further additional components to the HCS drive
controller.
HCS HLB HLC
DA000092v01_nn.FH9

Fig. 9-3: Individual supply HCS
Note: Apart from the connection of the drive controller to the mains,
the following connections have to be wired:
• Bb contact at control section (see Project Planning Manual
for control section)
• control voltage supply
• equipment grounding conductor
Note: When using the component HCS03.1E with HNK01.1 connect

the mains contactor electrically between the mains connection
and the HNK.
9.3 Group Supply

Group supply means that a component of the mains connection (mains
circuit breaker, mains transformer, mains filter, mains choke) is used by
several drive systems.
Group Supply without DC Bus Connection of the Groups
Note: Apart from the connection of the drive controller to the mains,
the following connections have to be wired:
Note: The device-specific power data are available at each drive

controller or drive system, particularly the allowed DC bus
continuous power and the continuous regenerative power.
Group Supply HMV without DC

Bus Connection of the Groups HMV HM* HM*
HMV HM* HM*

Fig. 9-4: Group supply HMV without DC bus connection of the groups
Group Supply HCS without DC

Bus Connection of the Groups HCS HMS HMD
HCS HMS HMD

Fig. 9-5: Group supply HCS without DC bus connection of the groups

and the HNK.
Group Supply with DC Bus Connection of the Groups

Group supply with DC bus connection increases the available
regenerative power, the continuous braking resistor and infeeding power
in the common DC bus of several drive controllers or drive systems.
Note: Apart from the illustrated connection of the drive controller to

the mains and to the DC bus, the following connections have
to be wired:
• Bb contacts at control section (see Project Planning
Manual for control section)
• module bus
Note: The connection lines to the drive controllers should preferably

have the same impedances in order to achieve balanced load
distribution at the power input of the drive controllers. From the
common node of the lines, you therefore have to make sure
that
• the lengths of the supply lines and
• the cross sections of the supply lines are the same.
Note: At the common DC bus there is less than the sum of the
device-specific power data available. This particularly applies
to the continuous DC bus power PDC cont and the continuous
regenerative power PBD. Both power data are included in the
sum in reduced form. The reduction takes place with the
corresponding balancing factors for parallel operation.
For these data see the Project Planning Manual of the
respective component.
Note: Only realize group supply with DC bus connection with drive
controllers or supply modules of the same type current or type
performance.
Group Supply HMV with DC Bus This type of mains connection is allowed for HMV01.1E (not allowed for
Connection of the Groups, HMV01.1R). This mains connection is used for high-performance drive
Parallel Operation HMV01.1E systems.
HMV HM* HM*
HMV HM* HM*
DA000093v01_nn.FH9

Fig. 9-6: Group supply HMV with DC bus connection
Note: Observe the control circuit "master-slave" for parallel operation

HMV01.1E.
Group Supply HCS with DC Bus This type of mains connection corresponds to parallel operation of HCS
Connection of the Groups drive controllers.
HCS
HCS

Fig. 9-7: Group supply HCS with DC bus connection

and the HNK.
9.4 Central Supply

With "central supply" only one drive controller or supply modules in central
form supplies power to several drive controllers via a common DC bus.
The characteristic aspect of "central supply" is central power supply by
one drive controller that is connected to mains voltage via a single mains
contactor, comparable to a modular supply unit.
Rules for Central Supply In the case of "central supply", mains supply take place at the drive
controller with the highest type current.
Note: Apart from the illustrated connection of the drive controller to

the mains and to the DC bus, the following connections have
to be wired:
• module bus
• equipment grounding conductor (connect to equipment
grounding system)
Central Supply HCS With the type of mains connection "central supply" the compact
IndraDrive C line is similar to the modular IndraDrive M line. We speak of
"central supply" when an HCS drive controller supplies other drive
controllers HCS, HMS or HMD which are not connected to the mains.
HCS HMS HMD
Zentrale Einspeisung HCS.EPS

Fig. 9-8: Central supply HCS

the mains contactor electrically before the HNK.
Notes
Rexroth IndraDrive Requirements to the Mains Connection 10-1
10 Requirements to the Mains Connection
Note: A permanent connection to the supply mains is required for

Rexroth IndraDrive controllers.
10.2 Mains Types

The devices can be operated at the following mains systems. The
requirements are indicated under the respective mains type.
TN-S System
The mains type TN-S is the usual mains type in Europe.
L1
U Tr L2
L3
V W N
S
PE
N
T = direct grounding of a point (station ground)

N = exposed conductive parts directly connected to station ground
Separate neutral conductor and equipment grounding conductor in entire
mains
Fig. 10-1: Mains type TN-S
10-2 Requirements to the Mains Connection Rexroth IndraDrive
TN-C System
L1
U
Tr L2
L3
V W PEN
C
N
1 3 5
2 4 6

N = exposed conductive parts directly connected to station ground
Neutral conductor and equipment grounding conductor functions in entire
mains combined in a single conductor, the PEN conductor.
Fig. 10-2: Mains type TN-C
IT System
L1
Tr L2
L3
I
1
RE
T
2
I = isolation of all active parts from ground or connection of one point to ground
via an impedance
T = exposed conductive parts directly grounded, independent of grounding of
current source (station ground)
Fig. 10-3: IT mains system
Compliance with EMC requirements in this case is only possible under

restricted conditions. Can therefore only be used for industrial area with
its own mains.
TT System
L1
U
Tr L2
L3
V W
N
T
T

Fig. 10-4: TT mains system

its own mains.
Mains with Grounded Outer Conductor (Corner Grounded Delta Mains)
U U L1
Tr V L2
V W W L3
RE
I = isolation of all active parts from ground, connection of one phase

- generally phase v - to ground or via an impedance
Fig. 10-5: Mains with grounded outer conductor

its own mains.
10.3 Mains Short-Circuit Power and System Impedance –

Minimum Values at Connection Point
The maximum possible connected load at the connection point of the
mains depends on its mains internal resistance (system impedance) or its
minimum mains short-circuit power.
The following criteria are decisive:
• For the protection of devices a mains choke has to be connected in
the incoming circuit in the case of high mains short-circuit power Sk.
• In order to limit mains pollution and have sufficiently high voltage
available for realizing the drive performance, the mains has to have
sufficiently high mains short-circuit power with reference to the
connected load of the drive system.
The mains short-circuit power indicated the power at nominal voltage UN

between the phases and the maximum mains short-circuit current IK at
the connection point:
Sk = 3 U N × I K
Sk: short-circuit power of the mains
Ik: short-circuit current
UN: mains voltage
Fig. 10-6: Mains short-circuit power
Note: For the mains short circuit power of the point of supply ask
your local power supply company.
IK results in the case of a short circuit at the point of power supply

connection. It is calculated as follows:
UN
Ik =
3X k
XK: system impedance
UN: mains voltage
Fig. 10-7: Mains short-circuit current
Mains Classes We basically distinguish the following mains, graded according to mains
short-circuit power and system impedance:
UN =400 V UN =480 V
Classification Sk Xk Lk Xk Lk
MVA mOhm uH mOhm uH
200 0,80 2,55 1,15 3,67
1 150 1,07 3,40 1,54 4,89
rigid mains 100 1,60 5,09 2,30 7,33

50 3,20 10,19 4,61 14,67
40 4,00 12,73 5,76 18,33
30 5,33 16,98 7,68 24,45
20 8,00 25,46 11,52 36,67
2
15 10,67 33,95 15,36 48,89
semi-rigid mains
10 16,00 50,93 23,04 73,34
5 32,00 101,86 46,08 146,68
4 40,00 127,32 57,60 183,35
3 53,33 169,77 76,80 244,46
3 2 80,00 254,65 115,20 366,69
non-rigid mains 1 160,00 509,30 230,40 733,39

0,6 266,67 848,83 384,00 1222,31
Sk: short-circuit power of the mains
XK: system impedance
Lk: inductance of mains phase
Fig. 10-8: Mains classified according to mains short circuit power and mains
internal resistance
Note: The minimum inductances of the mains connection specified

in the respective Project Planning Manual refer to the
inductances Lk mentioned above.
The specified minimum inductances protect the drive
controllers (especially the DC bus capacitances) during
operation at mains with low impedance and high mains short-
circuit power.
With a specified minimum inductance of 40 µH, for
example, it is necessary to use a mains choke at mains with
UN = 400 V SK >10 MVA (Lk < 40 µH).
Maximum Connected Load to a Mains

The maximum connected load to a mains depends on the allowed
distortion of the mains voltage due to the load current with harmonics
(mains pollution). The distortion is described by the distortion factor or the
total harmonic distortion (THD) of the mains current (see chapter
"Calculations").
In order to limit the distortion of the mains voltage take the mains short-
circuit ratio RSC (ratio of the source) into account:
Rsc = I k / I1N = S k / S A
Ik: mains short-circuit current
I1N: fundamental wave of nominal current of all loads at connection point
Sk: mains short-circuit power
SA: connected load of all electric loads at connection point (apparent
power of fundamental wave)
Fig. 10-9: Mains short-circuit ratio Rsc
Measures for Compliance with For public mains we distinguish

Allowed THD or Distortion
• Mains connections under 16 A: With an RSC ≥ 1000 there normally
Factor
isn't any restriction of the allowed mains current distortion (according
to EN 61000-3-2).
• Mains connections over 16 A for which the power supply company
determines the restrictions. Unless there are other values available,
the following data can be considered as guide values.
Allowed THD of mains Allowed distortion factor of

Rsc
current mains current
>= 1000 THD> 48% K>45%
>= 120 THD<= 48% K<=45%
> 33 THD< 13% K < 12 %
Fig. 10-10: Required THD/distortion factor with given Rsc of the mains
(U < 600 V)
Measures to comply with the maximum allowed THD or distortion factor

are
• use of mains chokes
• use of supply units with incorporated power factor correction PFC
Note: The following fact applies to mains chokes: the higher the
inductance of the choke, the lower the TDH/distortion factor
and the mains pollution.
Realizable
Realizable Drive controller or supply
Kind of drive distortion
THD of mains unit with and without mains
controller factor of
current choke
mains current
HMV01.1E
all devices THD>=50% K>=60% HCS03.1 without
HCS02.1
HMV01.1E
device with
THD< 48% K < 45 % HCS03.1 HNL01.1
mains choke
HCS02.1
devices with
HMV01.1R HNL01.1
Power Factor THD< 13% K < 12 %
HMV02.1R HNL02.1
Control (PFC)
Fig. 10-11: Realizable THD/distortion factor for drive controllers
Note: The allowed distortion factors can be achieved with the

indicated combinations of drive controller and mains choke.
Observe the assignment of mains choke to drive controller in
the corresponding Project Planning Manual.
Selecting Mains Connection We recommend the following procedure for selecting the required mains
Components connection components.
1. Determine max. current I of mains connection. Note: Classification for
public mains according to European standards in
• I < 16 A (EN 61000-3-2)
• 16 A < I < 75 A (EN 61000-3-12)
• I > 75 A (at present, not defined by any standard)
2. Determine mains short-circuit power Sk of mains at place of
destination of application (ask power supply company).
3. Determine sum of connected loads SA.
4. Determine ratio Rsc.
5. Determine allowed THD or distortion factor K of mains current at
place of destination of application (ask power supply company).
6. Select appropriate mains supply unit with additional component.
Note: The table below does not replace the recommended

procedure.
The table is used for first estimation of maximum allowed
connected load SA at point of power supply connection in low-
voltage mains at known mains short-circuit power SK.
Rsc=250 Rsc=200 Rsc=100 Rsc=50

Classification Sk SA SA SA SA
MVA kVA kVA kVA kVA
200 800,00 1000,00 2000,00 4000,00
1 150 600,00 750,00 1500,00 3000,00
rigid mains 100 400,00 500,00 1000,00 2000,00
50 200,00 250,00 500,00 1000,00
40 160,00 200,00 400,00 800,00
30 120,00 150,00 300,00 600,00
20 80,00 100,00 200,00 400,00
2
15 60,00 75,00 150,00 300,00
semi-rigid mains
10 40,00 50,00 100,00 200,00
5 20,00 25,00 50,00 100,00
4 16,00 20,00 40,00 80,00
3 12,00 15,00 30,00 60,00
3 2 8,00 10,00 20,00 40,00
non-rigid mains 1 4,00 5,00 10,00 20,00
0,6 2,40 3,00 6,00 12,00
RSC: mains short-circuit ratio
Sk: mains short-circuit power
SA: connected load of all electric loads at connection point (apparent
power of fundamental wave)
Fig. 10-12: Maximum allowed connected load
10.4 Limit Values for Interference-Free Operation at Mains

The data below specify the limit values under which the drive system can
be operated at the mains without interference.
Mains Frequency Tolerance

See chapter 5 "Specifications for the Components of the Drive System"
Voltage Tolerances and Voltage Changes

See chapter 5 "Specifications for the Components of the Drive System"
Mains Voltage Unbalance

The voltage unbalance is described by a three-phase system consisting
of the combination of a
• clockwise a.c. system (positive-sequence system Um)
• counter-clockwise a.c. system (negative-sequence system Ug)
• d.c. system (U0)
U X − U AVE
voltage unbalance % = 100
U AVE
Ux: phase-to-phase voltage with highest deviation from average value
UAVE: = (U12 + U23 + U31) / 3; U12 , U23 , U31 being voltages between the
phases.
Fig. 10-13: Definition of voltage unbalance
Max. allowed voltage unbalance Standard reference

3% IEC 61000-2-4, class 3
Fig. 10-14: Maximum allowed voltage unbalance
Commutation Drops
Drop on mains voltage Standard reference

depth 40% of mains amplitude, total surface IEC 60146-1-1, class 3
250% x degrees (see diagram)
Fig. 10-15: Maximum commutation drops in % of mains voltage
100
90
80
70 50 Hz
] 60 Hz
%
[ 60
N
L
U50
/
U
d 40
30
20
10
0
0 0,5 1 1,5 2 2,5
dt [ms]
Fig. 10-16: Maximum commutation drops in % of mains voltage
Short-Time Interruptions
A drive system is used for energy conversion and a voltage drop is a loss
of available energy.
The effect of the voltage drop (energy reduction) on the process cannot
be determined without detailed knowledge of the respective process. The
effect is a system and rating aspect and generally will be greatest when
the power demand (including the losses) of the drive system is greater
than the available power.
In the case of a voltage drop on the mains, thee voltage in the DC bus
can be reduced. This can cause the drive system to be cut off the mains
when voltage falls below certain levels and certain durations are
exceeded. When voltage returns the drive system has to be reactivated in
order to continue operation.
Harmonics of the Mains

The devices can be operated on a mains with the following THD:
Max. allowed THD Standard reference

10 % IEC 61000-2-4, class 3
Fig. 10-17: Maximum allowed harmonics
Maximum Allowed Mains Overvoltages

The devices were dimensioned only up to a certain level of mains over
voltage. Higher overvoltage has to be limited by other measures, e.g.
overvoltage protection on site.
Circuit Against Between the

environment and conductors within
ground (1) the circuit (1)
mains connection 230...500 V 2 kV 1 kV
supply connection 24V and relay
50 V 30 V
contact connections
other connections UN+5% UN+5%
(1): impulse withstand voltage 1,2/ 50µs and 8/ 20 µs
Fig. 10-18: Maximum allowed mains overvoltages
The figure below illustrates the voltage pulse.
DK000075v01_en.tif
Fig. 10-19: Impulse withstand voltage 1,2/ 50µs and 8/ 20 µs according to EN

61000
If higher overvoltage values can occur in the application, measures for

limitation of the values have to be taken in the electrical equipment of the
machine or installation.
Note: Overvoltage at the components can occur

• due to lightning strikes or
• due to inductive or capacitive coupling on lines.
Use overvoltage limiters at the machine or installation when
the overvoltage occurring at the Rexroth components is
greater than the max. allowed overvoltage.
Use the overvoltage limiters at long lines run through the
building / the hall and run in parallel with power and mains
cables.
Electrically place the overvoltage limiter at the control cabinet
input.
10.5 Power Factors and Emitted Mains Harmonics of the

Device
Due to their electric design, the drive controllers and supply units
generate harmonics in the mains current and on the mains voltage during
operation at the mains. Using appropriate mains chokes decisively
influences power factors and mains harmonics.
Power Factors cosϕ1 (DPF) and cosϕ (TPF)
Note: You find comments on the short terms used here in section
15.2 Calculations for Mains Connection.
The power factors are decisively influenced by mains chokes.
Type of drive controller Type of PDC_cont 3AC400V 3AC480V 3AC500V

or supply unit mains
choke
[%] DPF TPF DPF TPF DPF TPF
cosϕ1 λ cosϕ1 λ cosϕ1 λ
HCS02 W0012 without 100 0,97 0,59 tbd tbd tbd tbd
W0028 100 0,97 0,59 tbd tbd tbd tbd
W0054 100 0,97 0,55 tbd tbd tbd tbd
W0070 100 0,97 0,58 tbd tbd tbd tbd
W0012 HNL01 100 0,95 -- tbd tbd tbd tbd
W0028 100 0,95 0,83 tbd tbd tbd tbd
W0054 100 0,95 0,77 tbd tbd tbd tbd
W0070 100 0,95 0,66 tbd tbd tbd tbd
HCS03 W0070 without 100 0,97 0,57 tbd tbd tbd tbd
W0100 100 0,97 0,59 tbd tbd tbd tbd
W0150 100 0,97 0,61 tbd tbd tbd tbd
W0210 100 0,97 0,62 tbd tbd tbd tbd
W0070 HNK01 100 0,95 0,85 tbd tbd tbd tbd
W0100 100 0,95 0,83 tbd tbd tbd tbd
W0150 100 0,94 0,81 tbd tbd tbd tbd
W0210 100 0,93 0,78 tbd tbd tbd tbd
HMV01.1E W0030 without 100 0,97 0,64 tbd tbd -- --
75 0,97 tbd 0,99 0,64 -- --
W0075 100 0,97 0,64 0,99 0,64 -- --
W0120 100 0,97 0,63 0,97 0,86 -- --
75 0,97 tbd 0,99 0,64 -- --
W0030 HNL01 100 0,97 0,88 0,97 0,86 -- --
75 0,97 0,85 -- --
50 0,97 0,79 -- --
25 0,98 0,73 -- --
W0075 100 0,97 0,97 0,97 0,88 -- --

choke
[%] DPF TPF DPF TPF DPF TPF
cosϕ1 λ cosϕ1 λ cosϕ1 λ
75 0,97 0,87 -- --
50 0,97 0,83 -- --
25 0,97 0,75 -- --
W0120 100 0,97 0,88 0,97 0,86 -- --
75 0,97 0,85 -- --
50 0,97 0,79 -- --
25 0,98 0,74 -- --
HMV01.1R W0018 HNL01 100 0,99 0,99 tbd tbd -- --
W0045 100 0,99 0,99 tbd tbd -- --
W0065 100 0,99 0,99 tbd tbd -- --
HMV02.1R W0015 HNL02 100 0,99 0,99 tbd tbd -- --
--: not allowed
tbd: in preparation
UN: nominal voltage of mains between the conductors
Fig. 10-20: Power factor DPF, cosϕ1
Harmonics Factors THD and Distortion Factor k

The mains harmonics are decisively reduced by mains chokes.

choke THD k THD k THD k
[%] [%] [%] [%] [%] [%] [%]

HCS02 W0012 without 100 tbd tbd tbd tbd tbd tbd
W0028 without 100 tbd tbd tbd tbd tbd tbd
W0012 HNL01 100 tbd tbd tbd tbd tbd tbd
HCS03 W0070 without 100 tbd tbd tbd tbd tbd tbd
W0070 HNK01 100 tbd tbd tbd tbd tbd tbd
HMV01.1E W0030 without 100 120 77 tbd tbd -- --
75 120 77 -- --
W0075 without 100 122 77 120 77 -- --

choke THD k THD k THD k
[%] [%] [%] [%] [%] [%] [%]

W0120 without 100 122 77 120 77 -- --
W0030 HNL01 100 43 48 52 46 -- --
75 56 49 -- --
50 72 58 -- --
25 88 66 -- --
W0075 HNL01 100 42 39 46 42 -- --
75 49 44 -- --
50 61 52 -- --
25 83 64 -- --
W0120 HNL01 100 48 44 52 46 -- --
75 57 49 -- --
50 72 59 -- --
25 88 66 -- --
HMV01.1R W0018 HNL01 100 3 3 3 3 -- --
W0045 HNL01 100 2 2 2 2 -- --
W0065 HNL01 100 4 4 4 4 -- --
HMV02.1R W0015 HNL02 100 3 3 3 3 -- --
-- not allowed
tbd: in preparation
UN: nominal voltage of mains between the conductors
Fig. 10-21: Harmonics factors THD, k
Mains Current Harmonics

The data below represent typical harmonics on the mains current of an
HMV01.1E-W0030 supply unit at rated load (is up to 100% of PDC_cont).
f ILN
[Hz] [%]
with HNL01 without HNL01
3AC400V 3AC480V 3AC400V 3AC480V
50 100 100 100 100
75 0,5
88 0,9 0,5
113 1 0,6
125 0,7 0,6
175 0,7
188 0,7
213 0,5
250 43,7 46,6 85 84,6
350 17,8 20,8 71 70,9
475 1
550 6,9 7,0 40 39,8
f ILN
[Hz] [%]
with HNL01 without HNL01
3AC400V 3AC480V 3AC400V 3AC480V
650 3,6 4,2 26 25,4
850 3,1 3,2 5 5,8
950 1,7 1,8 3 4,2
1150 1,7 1,8 5 5,6
1250 1,2 1,2 4 4,4
Fig. 10-22: Mains current harmonics
Note: Amplitudes of frequencies not mentioned are below 0.5% of

the mains current.
With HMV01.1R supply units the relevant harmonics in the
frequency range (50…80)*fLN relating to the amplitude of the
crest value are below 3%.
Mains Voltage Harmonics

The voltage harmonics depend on the structure of the mains, especially
on the mains inductance or the mains short-circuit power at the
connection point. At different mains and mains connection points, the
same load can cause different voltage harmonics.
For a normal mains the harmonics content of the mains voltage when
operating drives generally is below 10%. Short-time drops in mains
voltage are below 20%.
More precise values can only be calculated with exact knowledge of the
mains data (mains topology), such as line inductance, line capacitance
related to the connection point.
These values, however, can temporally vary quite strongly, according to
the switch status of the mains. The harmonics of the mains voltage
thereby change, too.
Rough estimated values of the mains data are not sufficient for pre-
calculation of the harmonics, as mainly the resonance points always
present in the mains have a strong influence on the harmonics content.
In order to keep the degree of mains voltage harmonics as low as
possible, it is recommended not to connect capacitors or compensation
units (capacitor batteries) directly to the mains, if possible. If absolutely
required, only connect them to the mains via chokes.
10.6 Protection Systems for the Mains Connection
General Information
Protection against contact always depends on the kind and structure of
the supply mains and the mains conditions. For project planning of an
installation, the typical behavior of the loads and supply mains should
always be taken into account.
For protection against contact (indirect contact) in a machine or plant in
which a drive system is used, the overcurrent protective device normally
used is one with protective grounding according to IEC 364 and EN 50178
(Electronic equipment for use in power installations). This is also specified
in UL 508C (Industrial Control Equipment) for North America. Housing
cover or encapsulation by closed housing is used as protection against
direct contact with live conductors.
Fusing by Protective Grounding

Overcurrent protection normally is realized in the form of fuses or
overcurrent release devices (circuit breakers, motor circuit breakers)
installed at the mains connection. For details see fig. 1.
A grounding resistance of 2 Ohm is considered to be sufficient for
grounding.
Overcurrent protection generally is dimensioned or set with a release
current of 1.3 x nominal current of the loads connected to this connection
point.
In the case of an insulation error or a connection between mains phase
and device housing connected to the equipment grounding conductor, the
drive is disconnected from the mains.
Fusing by Protective Grounding in TN-S Mains

TN-S mains
L1
L2
L3
N
PE
control cabinet
HCS02 HCS02 HLB01.1 HMS HMS HMV HMS HMS HLB01.1

HCS03 HLC01.1 HMD HMD HCS03 HMD HMD HLC01.1
3 3 3 3 3 3
1 1 1 1 1
3 3 3 3 3 3
3
3
3 2
error
M M M M M M
M
1
joint bar of equipment grounding conductors
2
aim of protective measures: contact voltage < 50V at housing
3
DC bus connection L+/L-
DA000007_en.fh7
Fig. 10-23: Protection against contact by protective grounding with overcurrent

protection device in TN-S mains
Fusing by Protective Grounding in TN-C Mains

TN-C mains (grounded mains)
L1
L2
L3
PEN
control cabinet

3 3 3 3 3 3
1 1 1 1 1
3 3 3 3 3 3
3
3
3 2
error
M M M M M M
M
1
2
3
DA000008_en.fh7
Fig. 10-24: Protection against contact by overcurrent protection device in TN-C

mains
Fusing by Protective Grounding in IT Mains

(Ungrounded Mains)
IT mains (ungrounded mains)
L1
L2
L3
PE
control cabinet

3 3 3 3 3 3
1 1 1 1 1
3 3 3 3 3 3
3
3
3 2
error
M M M M M M
M
1
2
3
DA000009_en.fh7
Fig. 10-25: Protection against contact by overcurrent protection device in IT

mains
Connecting Equipment Grounding Conductor
Lethal electric shock when touching the

housing caused by faulty connection of
equipment grounding conductor!
WARNING ⇒ Observe the mentioned notes on installation in any
case, in order to prevent danger by electric shock
when touching the housing, even in case an
equipment grounding conductor connection is
broken.
Equipment Grounding Connection between the

Components
Observe the notes on installation in chapter "Connections of the
Components in the Drive System", section "Connection Point of
Equipment Grounding Conductor and Equipment Grounding
Connections".
Connecting Equipment Grounding Conductor to Mains

According to the standards "Electronic equipment for use in power
installations" (EN 50178, chapter 5.3.2.1) and "Adjustable speed electrical
power drive systems" (EN 61800-5-1, chapter 4.2.5.4.2), a stationary
connection of the equipment grounding conductor is required and one or
more of the following requirements have to be complied with:
2
• cross section of equipment grounding conductor at least 10 mm
(reason: sufficient mechanical stability required)
• mains and current supply automatically cut off when equipment
grounding conductor interrupted (case of error)
• Routing of a second equipment grounding conductor, via separate
terminal connectors, with the same cross section as the first
equipment grounding conductor. Mounting of an additional terminal
connector for this equipment grounding conductor.
Use of Residual-Current-Operated Circuit-Breakers (RCCB, RCD) as

Additional Fusing
The following designations are used for residual-current-operated circuit-
breakers:
• RCCB (Residual-Current-Operated Circuit-Breaker)
• RCD (Residual-Current-Operated Device)
• RCM (Residual-Current Monitoring Device)
Note: Rexroth IndraDrive drive systems can only be used with

residual-current-operated circuit-breakers to a limited extent.
If these circuit breakers are to be used, the company erecting the

installation has to check the mutual compatibility of the residual-current-
operated circuit-breakers and installation or machine with the drive
system, in order to avoid accidental triggering of the residual-current-
operated circuit-breaker. This has to be taken into account
• for switch-on processes, due to high asymmetric inrush currents and
• during operation of the installation, due to leakage currents produced
in normal operation.
Cause of Leakage Currents

For the purpose of stepless speed variation with a high degree of
positioning accuracy and dynamic response, certain modulation
procedures are indispensable for drive systems. For physical reasons,
these modulation procedures give rise to inevitable leakage current
produced during normal operation. Especially with unbalanced loads of
the mains phases or a large number of drives it can easily reach some
100 mA of rms value.
The leakage current is not sinusoidal but pulse-shaped. For this reason,
measuring instruments normally dimensioned for alternating currents in
the range of 50 Hz are not suited, as measuring errors occur. Use
measuring instruments with rms value measuring ranges up to at least
150 kHz.
The degree of leakage current depends on the following features of the

installation:
• kind of inrush current limitation
• number, kind and size drives used
• length and cross section of connected motor power cables
• grounding conditions of the mains at the mounting site
• imbalance of the three-phase system
• kind of filters and chokes connected in the incoming circuit
• EMC measures that are taken.
If measures are taken to improve the electromagnetic compatibility (EMC)
of the installation (mains filters, shielded lines), the leakage current in the
ground wire is inevitably increased, especially when switching on or in the
case of mains unbalance. Given these operating conditions, residual-
current-operated circuit-breakers can trigger without an error having
occurred.
The EMC measures are mainly based on capacitive short-circuiting of the
interference currents within the drive system. Inductive filter measures
can reduce the leakage currents, but affect the dynamic response of the
drive and bring about higher construction volume, higher weight and
expensive core material.
Possibilities of Use
Motor Cable Length Keep the motor cable length as short as possible. Only a short motor
cable length causes low leakage currents and enables a residual-current-
operated circuit-breakers to work.
Kinds of Residual-Current- We distinguish two kinds of residual-current-operated circuit-breakers:
Operated Circuit-Breakers 1. Residual-current-operated circuit-breakers sensitive to power pulse
current (type A acc. to IEC 60755)
These are normally used. However, it is only pulsating direct fault currents
of a max. of 5 mA and sinusoidal alternating fault currents that switch off
safely. This is why they are not allowed for devices that can generate
smoothed direct fault currents. In the case of smoothed direct fault
currents that can be produced in power supply units, mains rectifiers and
drive controllers with power converters in B6 circuit, the circuit breaker is
not triggered. The triggering of a residual-current-operated circuit-breaker
sensitive to power pulse current is blocked in the case of ground contact,
i.e. in the case of error.
Residual-current-operated circuit-breakers sensitive to power pulse
current do not provide any protection against inadmissible contact
voltage.
2. Residual-current-operated circuit-breakers sensitive to universal

current (type B acc. to IEC 60755)
These circuit breakers are suited for smoothed direct fault currents, too,
and safely switch off devices with B6 input rectifiers.
When a 30 mA residual-current-operated circuit-breaker triggers, it is
possible to use a residual-current-operated circuit-breaker with higher
trigger current for machine protection.
If this residual-current-operated circuit-breaker triggers accidentally, too,
check in how far the above conditions and dependencies can be
improved (for example, connecting current-compensated mains chokes in
the incoming circuit, increasing the inrush current limitation).
Using Isolating Transformer to If there is no improvement achieved and the residual-current-operated
Reduce Leakage Current in circuit-breaker, due to specific mains conditions on site, has to be used
Mains nevertheless on the mains input side, connect an isolating transformer
between mains connection and power connection of the drive system.
This reduces the leakage current in the ground wire of the mains that is
produced during normal operation which allows using the residual-
current-operated circuit-breaker. The neutral point of the secondary
winding of the isolating transformer is connected to the equipment
grounding conductor of the drive system.
The ground-fault loop impedance must then be adjusted to the
overcurrent protective device so that the unit can be switched off in the
case of failure.
Before operating enable please check for correct function including
activation in the case of failure.
Exclusive Fusing by Residual-Current-Operated Circuit-

Breaker
For drive systems with electronic drive controllers exclusive protection by
means of a residual-current-operated circuit-breaker normally is not
possible and not allowed.
Electronic equipment that has a nominal power higher than 4 kVA or is
destined for permanent connection does not need to have residual-
current-operated circuit-breakers.
According to IEC 364 and EN 50178, the supply-side protection against
contact for indirect contact, i.e. in the case of insulation failure, has to be
provided in a different way, for example by means of overcurrent
protective device, protective grounding, protective-conductor system,
protective separation or total insulation.
Using Residual-Current-Operated Circuit-Breakers with

A residual-current-operated circuit-breaker can be used at HCS02 drive
controllers under the following conditions:
HCS02 Drive Controllers with • residual-current-operated circuit-breakers of type B (IEC60755)
Residual-Current-Operated
Circuit-Breaker
• trip limit of residual-current-operated circuit-breaker is >= 300 mA
• supplying TN-S mains
• length of motor cable 20 m max. in shielded design
• use of a mains filter HNF01 or NFD03
• each residual-current-operated circuit-breaker only supplies one
HCS02 drive controller
• only Rexroth components and accessories including cables and filters
are used
Insulation Monitoring Devices

Insulation monitoring devices are normally used in IT mains with insulated
neutral point. The aim is to have a monitor triggered in the case of ground
fault - i.e. in the case of error - without having to switch off the electrical
equipment.
When the monitor signals an error, the ground fault is detected and
removed without operation being switched off. Switch-off only takes place
if a second ground fault occurs before the first one has been removed.
As insulation monitoring devices are also measuring the ground current at
the mains input of the building, too high leakage current can cause
accidental false triggering.
There are the same notes on application applying as mentioned in the
previous section "Use of Residual-Current-Operated Circuit-Breakers
(RCCB, RCD) as Additional Fusing".
Notes
Rexroth IndraDrive Control Circuits for the Mains Connection 11-1
11 Control Circuits for the Mains Connection

Application and Arranging the The HMV01.1 supply units of the Rexroth IndraDrive M range have an
Mains Contactor integrated mains contactor.
To supply HCS drive controllers of the Rexroth IndraDrive C product
range with mains voltage, external mains contactors are recommended.
High electric voltage and high working current!

Risk of death or severe bodily injury by electric
shock!
DANGER ⇒ Design the mains connection according to valid
standards.
⇒ Observe the protection goals "Electrical safety",
"Mechanical safety with incorrect movements" and
"Protection against fire".
⇒ Make sure you can provide evidence of the
mechanisms of protection by means of FMEA and
hazard analysis.
Note: You do not need to use external mains contactors if the safety-
related requirements of the application and the local safety
regulations on site allow this.
Before doing without external mains contactors, make sure
that operator protection is as good as with external mains
contactors!
11.1 Control Circuits for the Mains Connection –

General Information
Conditions of Control
The controls of mains contactor and DC bus short circuit for supply units
and drive controllers suggested in this documentation explain the
functional principles. The different possibilities of control are shown in this
chapter.
Note: The selection of the control and its effects depend on the
extent of the functions and the operating sequence of the
installation or machine. The selection falls to the installation or
machine manufacturer’s responsibility.
Conditions of Control with Rexroth IndraDrive C

Control Circuits HCS02 HCS02 drive controllers
• control via external mains contactor
• control via external mains contactor for devices with integrated control
voltage supply
• control via external mains contactor with DC bus resistor unit
HLB01.1C
11-2 Control Circuits for the Mains Connection Rexroth IndraDrive
Control Circuits HCS03 HCS03 drive controllers

• control via external mains contactor
Conditions of Control with Rexroth IndraDrive M
Note: Observe the following order when separating HMV01.1R

supply units from the mains voltage:
• request mains OFF (X32.6 / X32.7)
• delay time at least 10 ms
• switch mains supply off
You can make sure this order is observed by switch elements
(e.g. switch-disconnector as main switch) with leading auxiliary
contact. For this purpose connect the auxiliary contact in
series with mains OFF.
In case this order is not observed, the supply unit risks getting
damaged.
Control Circuits HMV HMV01.1E, HMV01.1R, and HMV02.1R supply units

• deceleration in the case of disturbed electronic system of drive
• deceleration in the case of E-Stop or mains failure
• control by E-Stop relay with DC bus short circuit
• control by E-Stop relay without DC bus short circuit
• control by control unit
• combination with DC bus resistor unit HLB01.1D
Control Circuit for Parallel For the type of mains connection "group supply with DC bus connection",
Operation HMV01.1E use the control circuit master-slave when using HMV01.1E supply units.
"Master-Slave" See the block diagram below:
1) braking resistor switch-on threshold activated

Fig. 11-1: Block diagram control circuit master-slave for parallel operation
HMV01.1E
Bb Contact Ready for The mains contactor depends on the error status of the drive controller or
Operation supply unit. At the control section of the HCS drive controllers and at the
supply units there is an isolated contact available for this purpose (relay
contact Rel1) that has been configured as Bb contact in the condition as
supplied (see Project Planning Manual for Control Section). When the Bb
contact closes, the drive or drive system is ready for power on.
Danger of damage!
⇒ Make sure that the mains contactor opens, too, when
the Bb contact opens.
CAUTION
Switch States See Project Planning Manual for control section

See also Functional Description of firmware: "Power Supply"
Note: When the internal line contactor is switched off, the contactor
coil causes overvoltages. These overvoltages may result in a
premature failure of the Bb contact. To attenuate overvoltages,
use overvoltage limiters with diode combination.
DC 24V
Bb
K1
Bb_relais_schutz.FH7
Fig. 11-2: Recommended suppressor circuit
Varistors and RC elements may not be used as suppressor circuit.

Varistors are subject to aging and increase their reverse currents. RC
elements overload the operating capacity of the Bb contact. This results in
premature failure of the connected components and devices.
Note: Comply with the load capability limits of the Bb contact.

Contactors with AC excitation and contactors exceeding the
load capability limits of the involved contact elements (Bb
contacts, etc.) should be controlled via contactor relays.
11.2 Control Circuits for Mains Connection of Drive

Controllers Rexroth IndraDrive C
The mains contactor connected in the incoming circuit controls the energy
flow to the drive controller allowing separation from the mains in the case
of error. The control circuit is decisively influenced by the Bb contact at
the control section of the drive controller or the Bb contact of the mains
supply.
Configuration Rel 1 as Power voltage is only switched to drive system after Bb contact signals
Bb contact readiness for power voltage on by its closed status.
For this purpose there is an isolated contact "Rel 1" available at the
control sections. You can configure the behavior of this contact of drive
controllers via parameter "P-0-0860, Converter configuration":
• behaves as converter if drive controller is to get supply voltage via
mains connection (e.g. for type of mains connection individual supply
or central supply)
• behaves as inverter if drive controller is to get supply voltage via
connection DC bus (L+, L-) (e.g. for type of mains connection central
supply as supplied device)
Include the converter contacts in the control circuit in such a way that they
make the mains contactor drop out in the case of error (when the contact
opens).
You can assign other information to the "Rel 1" contacts of the drive
controllers configured as inverters. Via this contact you can, for example,
control a second holding brake by entering a signal from "S-0-0398, IDN
list of configurable data in signal status word" in parameter "P-0-0300,
Digital I/Os, assignment list".
(See also Functional Description of firmware: "Power Supply" and
Parameter Description of firmware for P-0-0300 and P-0-0861)
Control via External Mains Contactor - HCS02 and HCS03
Damage to the device!

⇒ Before switching the drive controller on again, wait at
least for 300 ms plus the switch-off delay of the
mains contactor.
CAUTION
Standard Design for HCS02 and HCS03 Drive Controllers
ext. control voltage
Emergency stop
Safety limit switch
Power off
Control unit error

message
Bb 2)
1)
Power on K1
Mains contactor K1
steuersch_netzanschluss.FH7
1) integrating the Bb contacts of other devices and configuration (see

"Configuration Rel 1)
2) take switching capacity of Bb contact into account
Fig. 11-3: Control circuit
Design for HCS02 and HCS03 Drive Controllers with

Integrated 24V Control Voltage Supply
Drive controllers with integrated 24V control voltage supply are used, for
example, to maintain signal processing for controlled return motion in
case the external 24V control voltage supply fails.
Note: The integrated 24V control voltage supply cannot be used for
motor brake supply.
To supply the motor brakes use an external 24V supply.
Design for HCS02 and HCS03 Drive Controllers with

Integrated 24V Control Voltage Supply and CSB01.1N-FU
Control Sections
When using the drive controllers HCS02.1E-…-NNNV and HCS03.1E-
…-NNNV with control sections CSB01.1N-FU it is possible to do without
the external 24V control voltage supply.
Emergency stop
Safety limit switch
Power off
Control unit error

message
Bb 2)
Power on
1)
Mains contactor K1
steuersch_netzanschluss_NNNV.fh7

"Configuration Rel 1")
2) take switching capacity of Bb contact into account Project Planning
Manual of control section), CSB01.1N-FU control sections have
switch contacts with high switching capacity
Fig. 11-4: Control circuit for HCS02.1E-…-NNNV drive controllers
Note: Observe the allowed switching capacity of the Bb contact of

the CSB01.1-FU control sections.
Compared to other control sections, only the CSB01.1-FU
control section has a Bb contact with allowed switching voltage
of AC250V.
Note: During the time required until the internal supply voltages are
built up and the firmware is actively working in the drive
controller, the Bb contact at the control section of the drive
controller is open.
Take these times into account for the design of the mains
connection.
Control Circuits HCS02 with DC Bus Resistor Unit HLB01.1C

Application You should use this variant when
• only motors with permanent magnet excitation are connected.
• motors with permanent magnet excitation and asynchronous motors
(induction machines) are connected.
Features Due to the DC bus short circuit, motors with permanent magnet excitation
can be shutdown with deceleration even if the electronic system of the
drive is disturbed. (see also section Deceleration in the Case of E-Stop or
Mains Failure)
Personal injury caused by uncontrolled axis

motion!
The DC bus short circuit protects machines in the case of
WARNING drive errors. By itself it cannot assume the function of
personal protection. In the case of errors in the drive or
supply unit, uncontrolled drive motion can occur even
when the DC bus short circuit has been activated.
Asynchronous machines do not brake when the DC bus
has been short-circuited. Personal injury can occur
according to the machine design.
⇒ Provide additional monitors and protective devices on
the installation side.
Operating Principle When the E-Stop pushbutton is actuated, the mains contactor drops out
which activates the DC bus short circuit device in the HLB.
Emergency stop
Safety limit switch
Power off
Control unit error

message
Bb 2)
1)
+DC24V
Power on K1 K1 HLB01.1C
X32.8
(DC bus short circuit\)
Mains contactor K1
steuersch_netzanschluss_hlb_c_mit_hcs02.fh

"Configuration Rel 1")
2) take switching capacity of Bb contact into account (Project Planning
Manual of control section)
Fig. 11-5: Wiring diagram HLB01.1 and HCS
Note: Connect the Bb contact of HLB in series with the Bb contacts

of the involved IndraDrive components so that the mains
contactor can be opened even if the module bus is defective.
11.3 Control Circuits for Mains Connection of Supply Units

Rexroth IndraDrive M
Deceleration in the Case of Disturbed Electronic System of Drive

As a safety measure in addition to shutdown with deceleration of the
drives in case the electronic system is disturbed, it is possible to short-
circuit the DC bus voltage.
When the DC bus voltage is short-circuited, motors with permanent
magnet excitation are always shut down with deceleration. In this case it
is irrelevant whether the electronic system of the drive is still functioning
or not.
Note: Asynchronous drives do not decelerate when the DC bus

voltage has been short-circuited!
If the electronic system is disturbed and the DC bus voltage is not short-
circuited, motors with permanent magnet excitation coast in an
uncontrolled way.
Deceleration in the Case of E-Stop or Mains Failure

In the case of E-Stop or mains failures, the drives normally are shutdown
by drive control.
In the case of E-Stop or when the drive-internal monitors trigger, the drive
control inputs the command value "zero". The drives are thereby
decelerating in a controlled way with maximum torque.
In some applications (e.g. electronically coupled gear cutting machines) it
is required that the drive shutdown is controlled by the control unit in the
case of E-Stop or mains failures, In the case of E-Stop or when the drive-
internal monitors trigger, the control unit decelerates the drives in a
position-controlled way.
For further details see the Functional Description of the firmware under
the index entry "best possible deceleration".
Control by E-Stop Relay

With DC Bus Short Circuit
If you control the mains contactor in the supply unit by an E-Stop relay
and short-circuit the DC bus, you achieve a high degree of safety with little
effort. The monitoring functions of the drive system are used in the most
effective way.
Application You should use this variant when
• only motors with permanent magnet excitation are connected.
• motors with permanent magnet excitation and asynchronous motors
(induction machines) are connected.
• the E-Stop switch has to be duplicated or a safety door monitor, for
example, is required.
• your drive system has an extensive emergency stop circuit.
Note: The pickup current of the auxiliary relay for control of the
mains contactor flows via the emergency stop circuit. In order
that the mains contactor picks up reliably, the total resistance
of the emergency stop circuit taking effect between
connections X32/1 and X32/9 has to be below 45 Ω!
Features Due to the DC bus short circuit, motors with permanent magnet excitation
can be shutdown with deceleration even if the electronic system of the
drive is disturbed. In order to trigger a DC bus short circuit in such a case,
the Bb contacts of the drive controllers have to be connected in series
with the control contact and wired in the E-Stop circuit. The DC bus short
circuit only triggers in the case of drive failure. If E-Stop is actuated,
asynchronous drives therefore are braking, too.
When the Bb contacts of the supply unit are connected in series with
the control contact in the E-Stop circuit, the DC bus dynamic brake is only
triggered in the case of a supply unit error.
In the case of E-Stop or when the monitors of the supply unit trigger (e.g.
mains failure), the electronic system of the drives shuts them down
according to the error reaction that was set.
Personal injury caused by uncontrolled axis

motion!
The DC bus short circuit protects machines in the case of
WARNING drive errors. By itself it cannot assume the function of
personal protection. In the case of errors in the drive and
supply unit, uncontrolled drive motion can occur even
when the DC bus short circuit has been activated.
Asynchronous machines do not brake when the DC bus
has been short-circuited. Personal injury can occur
according to the machine design.
⇒ Provide additional monitors and protective devices
on the installation side.
⇒ Use the Integrated Safety Technology by Rexroth.
Operating Principle When the E-Stop pushbutton is actuated, the mains contactor in the
supply unit drops out. The E-Stop relay or an auxiliary contact of the
mains contactor switches off the drive enable signals. The drives are shut
down according to the error reaction set in the drive controller.
The mains contactor is switched off and the DC bus short circuit triggers
when there is a drive error message by the supply unit (Bb1 contact), an
error message by the control unit (servo error) or a limit switch has been
passed.
24 V +/-5% X3
0V X32/1
X32/9
X31/5
Bb1
X31/6
S2 braking
resistor K
control
CNC
X32/8
>1
L+
X32/7
2)
signal
A10 1) processing
L-
X32/6
DC bus
short circuit enable
X32/5 converter
1) K1
X32/4
&
K1
ON delay
ready-to- approx. 1.5 seconds ... 4 minutes 3)
operate
Power supply unit
1 2 Control voltage
+24V
+/- 5% RF
X33/1
X33/4 HMV01.1E/ K4
S11 S4
HMV01.1R
K1 K1
X33/3
X33/2
X31/4 A10
S1
UD S5
X31/3 S12
safety door
closed
Bb AF AF AF
Drive
U controllers
A10 Emergency-stop relay
K4
0V
Example. Depending on safety requirements at
A10 = Emergency-stop relay the machine, additional monitoring devices and
AF = drive enable of the drive controllers locks may be necessary!
Bb1 = power supply unit ready (drive system)
Bb = drive controllers ready
CNC = lag error message of control (use only contacts that do not open when E-stop switch is open)
K1 = mains contactor in power supply unit
K4 = drive enable signal control
RF = drive enable signal of the control unit
S1 = Emergency-stop
S2 = axis end position
S4 = power OFF
S5 = power ON
S11/S12 = safety door monitor
1) K1 control if no emergency-stop switch is used

2) unregulated rectifier in HMV01.1E; regulated one in HMV01.1R
3) depending on power supply unit and possibly connected external capacitors SS2HMV.fh7
Fig. 11-6: Controlling the supply unit when electronic system of drive disturbed
with DC bus short circuit
Designing the DC Bus Short Circuit

To design the DC bus short circuit there are the HLB01.1 components
available.
Calculating the resulting braking distance when using the DC bus short
circuit requires, apart from the Rexroth components, knowledge of the
following application parameters:
• velocities
• friction conditions
• …
With these data the resulting braking distance can be approximately

determined. For the calculation formulas see Appendix.
Note: It is not recommended to short-circuit the motor connections

with the drive controller connected.
Use the HLB01 components with integrated device for DC bus
short circuit.
Without DC Bus Short Circuit

Application • If unbraked coasting to stop of the drives does not damage the
installation.
• If only asynchronous motors are connected to the supply unit.
• If the end positions of the feed axes have been sufficiently cushioned.
• If external braking devices are used.
Features The DC bus voltage is not short-circuited.

mains failure), the drives are shut down according to the error reaction set
in the drive controller.
Operating Principle When the E-Stop circuit opens, the mains contactor in the supply unit
drops out immediately. The E-Stop relay or an auxiliary contact of the
mains contactor switches off the drive enable signals. The drives are shut
down according to the error reaction set in the drive controller.
Damage to machines caused by unbraked

coasting to stop of the drives in case their
electronic system is disturbed!
CAUTION ⇒ Use motors with mechanical brake (a holding brake
mustn't be used as service brake).
⇒ Sufficiently cushion end positions of feed axes.
24 V +/-5% X3
0V X32/1 X31/5
Bb1 for diagnostics
X32/9
X31/6
braking
resistor K
control
X32/8
>1
L+
X32/7
2)
signal
A10 1) processing
X32/6 L-
DC bus
X32/5 converter
1) K1
X32/4
&
K1
ON delay
ready-to- approx. 1.5 seconds ... 4 minutes 3)
operate
Power supply unit
+24V 1 2 Control voltage

+/- 5%
RF
X33/1
X33/4 HMV01.1E/ K4
S11 S4
K1 HMV01.1R K1
X33/3
X33/2
X31/4
S1
UD A10
S5
S12
X31/3
safety door
closed
Bb AF AF AF
Drive
U controllers
A10 Emergency-stop relay
K4
0V
A10 = Emergency-stop relay the machine, additional monitoring devices and
AF = drive enable of the drive controllers locks may be necessary!
Bb1 = power supply unit ready (drive system)
S1 = Emergency-stop
S4 = power OFF
S5 = power ON
Fig. 11-7: Controlling the supply unit without DC bus short circuit
Control by the Control Unit

If the mains contactor is controlled by the control unit, the drive, in the
case of E-Stop or when the drive-internal monitor triggers, can be shut
down in a position-controlled way by a control unit.
Application This kind of mains contactor control is mainly used for electronically
coupled drives that are shut down synchronously even in the case of
mains failure.
Features The DC bus voltage is not short-circuited so that there is energy available
for position-controlled shutdown of the drives.
Note: The energy stored in the DC bus or the regenerated energy

has to be greater than the energy required for excitation of
asynchronous machines or for return motions.
The parameter "Activation of NC reaction on error" has to be set

accordingly in the drive controller (P-0-0117, bit 0=1).
mains failure), the drives are shut down in a position-controlled way by the
positioning control.
Operating Principle When the E-Stop circuit opens or the monitors of the supply unit trigger
(e.g. mains failure), the mains contactor in the supply unit drops out.
For drives with SERCOS interface the error is signaled to the control unit
and the drives can be shut down in a position-controlled way.
For drives without SERCOS interface the control unit has to evaluate the
UD contact. When the UD contact triggers, the control unit has to shut
down the drives.
Damage to machines caused by unbraked

coasting to stop of the drives in case DC bus
voltage is too low!
CAUTION ⇒ The control unit should evaluate the UD contact and
shut the drives down when the contact triggers.
24 V +/-5% U V W
X3
0V X32/1 X31/5
Bb1 for diagnostics
X32/9 X31/6
braking
resistor K
control
X32/8
>1
L+
X32/7
signal 2)
A10 processing
1)
L-
X32/6
DC bus
X32/5 converter
1) K1
X32/4
&
K1
ON delay
ready-to-
operate approx. 1.5 seconds ... 4 minutes 3)
Power supply unit
1 2 3
+24V Control voltage
+/- 5%
X31/4 X33/1
UD S11 S4
RF Bb K1
X31/3
X33/2
S1
S5
S12
safety door
closed
Machine
AF AF AF control
Drive
controllers
A10 Emergency-stop ralay
0V
the machine, additional monitoring devices and
A10 = Emergency-stop relay locks may be necessary!
AF = drive enable of the drive controllers
Bb1 = power supply units ready (drive system)
S1 = Emergency-stop
S4 = power OFF
S5 = power ON
Fig. 11-8: Control for position-controlled shutdown of the drives by control unit
(without DC bus short circuit)
Combination of Supply Unit HMV01.1 and DC Bus Resistor Unit

HLB01.1D
Risk of damage to the device!

⇒ If the connection of HMV_X32/8 and HLB_X32/7 is
missing and the DC bus short circuit function is
used, the DC bus resistor unit can be damaged.
CAUTION
24V
HMV HLB01.1D
X32/1 0V
X32/1
X32/9
X31/5
Bb1
X31/6 X31/5
Bb2
X31/6
S2
CNC
X32/8 BRC
X32/7 >1
X32/8 L+
X32/7 X32/6
A10
1) L-
X32/6
X32/5
1)
X32/4
hlbd_hmv_installation.fh7
A10: E-Stop relay

BRC: (device-internal signal name) braking resistor control
CNC: lag error message of the control unit (only use contact that doesn't
open when the E-Stop switch is open)
S2: axis end position
1) control of K1 when there is no E-Stop relay used
Fig. 11-9: Wiring diagram HLB01.1D and HMV with HLB01.1D
Preferred Wiring of E-Stop Circuit
+24V 1 2
+/- 5%
RF
K4 X33/1
X33/4 HMV01.1E/ S11 S4
K1 HMV01.1R
K1
X33/3
X33/2
X31/4 A10
S1
UD S5
X31/3 S12
Bb AF AF AF
U
A10
K4
0V
hlb_notaus_kette.fh7
A10: E-Stop relay

AF: drive enable of drive controllers
Bb: readiness for operation of drive controllers
K1: mains contactor in supply unit
K4: control of drive enable
S1: E-Stop
S2: axis end position
S4: power Off
S5: power On
S11/S12: safety door monitor
Fig. 11-10: Preferred wiring of E-Stop circuit
Notes
Rexroth IndraDrive Connections of the Components in the Drive System 12-1
12 Connections of the Components in the Drive

System
12.1 System Connections of the Components

To operate the drive system Rexroth IndraDrive the following electrical
connections, for example, have to be established.
In the system environment
• connection PE of X3 to equipment grounding system
• connection X3 to supply with power voltage
• connection X13 or terminal block 0V / +24V to supply with control
voltage
• connection to control unit and/or master communication
Within the drive system connect, among other things

• equipment grounding conductors PE of X3 or PE joint bars
• DC bus connections L+ with bus bars
• DC bus connections L- with bus bars
• control voltage connections 0V with bus bars
• control voltage connections +24V with bus bars
• module bus connections X1 via supplied ribbon cable
• motor power connections via system cable to X5
• connections for motor temperature monitoring and motor holding
brake via system cable to X6
Note: The connections to X5 and X6 are made via a single Rexroth

motor cable.
12-2 Connections of the Components in the Drive System Rexroth IndraDrive
Position of System Connections
X1 out X1 in
+24 V
control voltage
0V
L+
DC bus
L-
equipment
grounding
conductor
hms0070_frontf2
Fig. 12-1: Connections at power section
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.
3. Connect the bare metal back panel of the mains filter in conductive
form to the mounting surface in the control cabinet and establish a
connection with the lowest possible impedance to the mounting
surface of the drive controllers (see item 1).
Connection Point of Equipment Grounding Conductor and Equipment

Grounding Connections
The connection points of the equipment grounding conductors of the drive
controllers and their connection to the equipment grounding system are
important parts of electrical safety.
Dangerous contact voltage at device housing!

Lethal electric shock!
⇒ Always operate drive controllers with connected
equipment grounding conductor.
⇒
DANGER
Observe the explanations below.
In the drive system Rexroth IndraDrive, the connection points of

equipment grounding conductors of all drive controllers and additional
components have to be connected to the equipment grounding system.
Establish the connection depending on the involved devices.
Involved Equipment grounding Connection to equipment

devices connections between grounding system in control
devices cabinet at devices
HMV01 HMV01
HCS03 HCS03
HMS01 interconnect joint HMS01 realized in central
HMV01
HMD01 bars at front of HMD01 form;
HCS03
HLB01.1D devices HLB01.1D one connection at
HLC01.1D HLC01.1D
HLC01.1C HLC01.1C
HCS02
HAS04
with
HLB01.1C
HAS04 interconnect joint realized in central
HLC01.1C
HLB01.1C bars at front of HMS01
form; HCS02
HLC01.1C devices HMS02
one connection at
HMS01 HMD01
HMD01
HCS02 one connection each
HCS02
without at all
HAS04 HMS01
HCS02 HMS02 HMS01
HMS01 interconnect joint HMD01 and HMS02
HMS02 bars at front of HLB01.1C HMD01
one connection at
HMD01 devices HLC01.1C HLB01.1C
connected drive
HLB01.1C HLB01.1D HLC01.1C
system, consisting of
HLC01.1C HLC01.1D HLB01.1D
all
HLB01.1D HLC01.1D
HLC01.1D
one connection each HNL02
at all HNS02
HMV02
interconnect joint and
HMS02 HMV02
bars at front of
HNL02 HMS02 one connection at
devices HMV02
HNS02 connected drive
HMS02
system, consisting of
all
Fig. 12-2: Equipment grounding connections
Equipment Grounding Connections Between Devices
1
masseanschluss_frontf2
1: joint bar
Fig. 12-3: Equipment grounding connections between devices
Connection to Equipment Grounding System in Control

Cabinet
2 1
erdungslasche_hmv
1: joint bar
2: connection point for connection to equipment grounding system in control
cabinet
Fig. 12-4: Equipment grounding connections
Note: Provide sufficient cross sections of the lines for connecting the
equipment grounding conductor of the device to the equipment
grounding system in the control cabinet.
If lines are used for the equipment grounding connections,
they must have a cross section of at least 10 mm2 for
HCS03.1E drive controllers and HMV01 supply units (however
not smaller than the supply feeder cross section). For
HCS02.1E drive controllers choose the cross section at least
as big as for the supply feeder.
Connection of Mains Choke

Via connection to the mains choke the supply units resp. the drive
controllers are connected to the mains power supply.
The connection wires to the mains choke carry a high potential of
interferences. Thus, keep them as short as possible and twist them.
Note: At supply units HMV, wires with a maximum length of 5 m

between mains choke and mains input are allowed.
See also within section 7.3 Arranging Components in Control Cabinet

from Mainly Electrical Point of View the section EMC Measures for Design
and Installation.
DC Bus Connection (L+, L-)
Property damage in case of error caused by too

low line cross section!
⇒ Observe the current carrying capacity of the
connection lines at the DC bus connections.
⇒
CAUTION
Realize the connection lines at the DC bus
connections in such a way that they are protected by
the line protection at the mains connection of the
supply unit.
Single-Line Arrangement The figure below illustrates the connection point and connection of the DC
bus connections for system components HMV01, HMS01, HMD01;
HLB01.1D and HCS03 in single-line arrangement with contact rails.
Design
schienen_zwkreis
Fig. 12-5: Contact bars
Multiple-Line Arrangement For multiple-line arrangement of drive controllers the connection for DC
bus and control voltage supply is realized with cables.

⇒ The DC bus connections of stacked drive controllers
must be correctly interconnected.
CAUTION ⇒ Connect L+ connections only to other L+
connections and L- connections only to other L-
connections.
⇒ Observe the measures regarding max. allowed line
lengths and min. required line cross sections.
Maximum Allowed Line Lengths at DC Bus Connection

The line length at the DC bus connection is limited to protect the devices.
For the maximum allowed values of line length between the electrical
connections see table below.
Allowed line length [m]

from to
HMV01 HMV02 HCS03 HCS02 HMS01/ HMS02 HLB01 HLC01
HMD01
HMV01 0,5 -- -- -- 2 -- 0,35 0,35
HMV02 -- 0,5 -- -- -- 0,35 0,35 0,35
HCS03 -- -- 0,5 -- 2 -- -- 0,35
HCS02 -- -- -- 0,5 2 0,35 0,35 0,35
HMS01/ -- -- -- -- 0,35 -- 0,35 0,35
HMD01
HMS02 -- -- -- -- -- 0,35 0,35 0,35
HLB01 -- -- -- -- -- 0,35 0,35
HLC01 -- -- -- -- -- -- 0,35
--: not allowed
Fig. 12-6: Max. allowed line lengths at DC bus
Note: Multiple-line arrangement or distance between the

components requires the accessory RKB 0001 (see chapter
"Accessories") to establish the module bus connection
between the components.
To arrange supply units supplying decentralized drive controllers you have

to take specific measures if the line lengths exceed 2 m.
• Use HLC01 DC bus capacitor modules at every drive system.
Dimension the minimum size of HLC01 according to the projected
continuous power of the respective drive system. Allow 47 µF per
kilowatt [kW] of continuous power.
Example: 50 kW calculated continuous power in DC bus requires

2350 µF at this system, thus at least 1 HLC01.1D-02M4.
Minimum Requirements to the Connection Lines

Dielectric Strength The connection lines from the supply unit to the axis systems and
between the axis systems have to have a dielectric strength of at least:
• 1000 V against each other
• 700 V against ground
Line Cross Section Determine the minimum line cross section from supply unit to axis
systems and between axis systems by means of the rated current. For
rated current use the higher value from the following calculations:
• calculate the mains-side phase current
• calculate the current in the branch with the greatest DC bus power
Note: To connect required line cross sections of xx mm² use our

accessory HASxx.
Routing The connection lines from supply unit to axis systems and between axis
systems
• have to be twisted with a maximum length of lay of 30 mm
• have to be routed with minimum mechanical distance to ground
potential
• have to be routed with a minimum distance of 200 mm to control
voltage lines.
The figures below illustrate the correct DC bus connection for stacked
drive controllers. The illustrated way of connection keeps bare wire
sections from being situated directly vis-à-vis. This avoids voltage arcing.
The cables have to be twisted.
Risk of damage!
⇒ If the total power when using HMV supply units is
more than 60 kW, the DC bus connection has to be
realized to both sides so that the connection
CAUTION
elements are not overloaded.
⇒ Connect the devices both to the left and to the right
screw connection at the terminal block.
⇒ Observe the notes in chapter "Arranging the
Components in the Control Cabinet".
Cable Routing to the Left
Damage caused by voltage arcing!

⇒ Insulate ring terminals and connecting lines with a
heat-shrinkable sleeve. Afterwards only strip the
insulation of the contact surface of the ring terminal.
CAUTION
Realize connections according to figure.
device 1
(DC bus connection)
device 2
(DC bus connection)
device 1
(DC bus connection)
device 2
(DC bus connection)
correct incorrect
DC bus nach links_1f4
Fig. 12-7: DC bus connections for cable routing to the left
Cable Routing to the Right
Damage caused by voltage arcing!

⇒ Insulate ring terminals and connecting lines with a
heat-shrinkable sleeve. Afterwards only strip the
insulation of the contact surface of the ring terminal.
CAUTION
device 1
(DC bus connection)
device 2
(DC bus connection)
device 1
(DC bus connection)
device 2
(DC bus connection)
correct incorrect
DC bus nach rechts_1f4.fh7
Fig. 12-8: DC bus connections for cable routing to the right
Control Voltage Connection (0 V, + 24 V)
Note: The input 0 V is 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.
Single-Line Arrangement The figure below illustrates the connection point and connection of the
control voltage connections for system components HMV01, HMV02,
HMS01, HMS02, HMD01, HLB01.1D and HCS03 in single-line
arrangement..
A B
schienen_steuerspg
A: cable (to source of control voltage supply)

B: contact bars
Fig. 12-9: Connection points and connections of control voltage
Note: Connect the system components HCS02 and HLB01.1C to

the control voltage supply. To do this connect each connection
point X13 to the control voltage supply.
Make use of the loop-through contacts and observe the
allowed load.
Multiple-Line Arrangement The following figures show the correct control voltage connection for
stacked drive controllers. The illustrated way of connection ensures that
the touch guard can be correctly mounted and the required clearances
and creepage distances can be complied with.
The cables have to be twisted. Observe the notes in chapter "Arranging

the Components in the Control Cabinet", section "Installing the 24V
Supply".
Cable Routing to the Left
device 1
(control voltage connection)
device 2
device 1
(control voltage
connection)
device 2
(control voltage
connection)
correct incorrect
steuerspg nach links
Fig. 12-10: Control voltage connections for cable routing to the left
Cable Routing to the Right
device 1
device 2
device 1
(control voltage
connection)
device 2
(control voltage
connection)
correct incorrect
DC bus nach rechts_1f4.fh7
Fig. 12-11: Control voltage connections for cable routing to the right
Module Bus Connection X1

The module bus connection is used for signal exchange within the drive
system and has to be established via the supplied ribbon cables.
Graphic Representation
X1 out X1 in
X1f2.FH7
Fig. 12-12: X1
Note: When extension cables are used for the module bus, they
must be shielded. Their total length mustn't exceed a
maximum of 40 m.
The module bus extension accessory is available to extend
the module bus connection.
Motor Connection
Power Connection, X5
• outputs to motor A1, A2, A3
• equipment grounding conductor connection
Control Contacts Connection, X6

• motor temperature monitoring
• motor holding brake
Fig. 12-13: Motor connection
Cables for Motor Connection
Note: For detailed information, particularly on suitable additional

parts, such as control cabinet ducts and extensions, see
documentation "Rexroth Connection Cables".
12.2 Overall Connection Diagrams of the System

To draw up the overall connection diagrams there are ePlan macros of
the components available.
Please ask our sales representative.
Notes
Rexroth IndraDrive Fusing and Selecting the Mains Contactor 13-1
13 Fusing and Selecting the Mains Contactor
13.1 Fusing and Selecting the Mains Contactor for Mains

Connection
The data below are recommended values applying under the conditions
that
• the listed devices are operated with individual supply.
• the performance data are not exceeded.
• the line cross sections according to EN60204 - installation type B1 (or
E for mains currents higher than 100A) - are to be selected without
taking correction factors into account.
• easily separable contact-welded connections at the contactor are
allowed after a short-circuit which corresponds to assignment type "2"
according to DIN IEC 60947-4.
Applications deviating from these conditions require detailed calculation of
the mains connection values.
If several drive controllers are to be operated at one fuse and one mains
contactor, the mains-side phase currents and inrush currents calculated
for the individual drives have to be added.
Damage to the drive controller caused by

overload!
⇒ Make sure the specified performance data - peak
CAUTION power and continuous power - are complied with by
correct drive dimensioning and selective fusing in the
mains connection.
Note: Fuses of characteristic gR protect the involved

semiconductors against further damage in the case of short
circuit.
Fuses of characteristic gL protect the lines.
For the switch-off delay of the mains contactor see the
technical data of the selected type. Take into account that
additional components at the operating coil cause changes in
the switch-off delay.
By way of example, the selection table shows types of certain

manufacturers. Equivalent products by other manufacturers may be used
as well.
Note: In order to prevent the mains contactor from being overloaded

by the load current in the case of frequent cut-off, it is first
necessary to switch off the drive, e.g. via the drive enable in
the master communication, and then to switch off the mains
contactor.
13-2 Fusing and Selecting the Mains Contactor Rexroth IndraDrive
Fusing and Selecting the Mains Contactor

Mains voltage 3 AC 400 V
Device Mains Mains Min. nominal fuse Autom. Power Min. line Recom- Max.
choke input current of circuit- circuit- cross mended allowed
contin. characteristic breaker breaker section@ mains switch-
current Ta40° contactor off
IL,cont delay
[A] eff [A] [A] [A] [A] [mm²] Type [ms]

(setting ([AWG])
@ PDC value)
cont
Properties
gR gL tripping
charact. C
HCS03.1E HNK01.1
W0070 without 32,6 3NE1817-0 3NA6820- - - 16 3RT1036 180
4 (6)
W0070 with 50 3NE1817-0 3NA6820- - - 16 3RT1036 180
4 (6)
W0100 without 58,2 3NE1820-0 3NA6824- - - 35 3RT1044 350
4 (4)
W0100 with 80 3NE1820-0 3NA6824- - - 35 3RT1044 350
4 (4)
W0150 without 77,9 3NE1022-0 3NA6832- - - 2x25/50 3RT1046 350
4 (2)
W0150 with 106 3NE1022-0 3NA6832- - - 2x25/50 3RT1046 350
4 (2)
W0210 without 109,7 3NE1224-0 3NA6836- - - 2x50/95 3RT1055 350
4 (1/0)
W0210 with 146 3NE1224-0 3NA6836- - - 2x50/95 3RT1055 350
4 (1/0)
HCS02.1E HNL01.1
W0012 without 6 -- 10 10 8 1,0 (16) 3RT1016 80
W0012 with 6 -- 10 10 8 1,0 (16) 3RT1016 80
W0028 without 13 -- 20 20 17 2,5 (13) 3RT1025 110
W0028 with 13 -- 20 20 17 2,5 (13) 3RT1025 110
W0054 without 19 -- 25 25 25 4,0 (11) 3RT1026 190
W0054 with 19 -- 25 25 25 4,0 (11) 3RT1026 190
W0070 without 30 -- 35 32 35 6,0 (9) 3RT1034 120
W0070 with 30 -- 35 32 35 6,0 (9) 3RT1034 120
choke input current of circuit- circuit- cross mended allowed
contin. characteristic breaker breaker section@ mains switch-
IL,cont delay
[A] eff [A] [A] [A] [A] [mm²] Type [ms]

(setting ([AWG])
@ PDC value)
cont
Properties
gR gL tripping
charact. C
HMV01.1 HNL01.1
E
W0030 without 45 -- 63 63 51 16 (6) integrated -
W0030 with 51 -- 63 63 51 16 (6) integrated -
W0075 without 98 -- 100 -- 77 25 (2) integrated -
W0075 with 125 -- 160 -- 128 70 (1/0) integrated -
W0120 without 156 -- 160 -- 123 50 (1/0) integrated -
W0120 with 200 -- 250 -- 204 120 integrated -
(0000)
HMV01.1 HNL01.1
R
W0045 with 65 -- 80 -- 65 25 (4) integrated -
HMV02.1 HNL02.1
R
W0015 with 23 50 35 32 integrated 6 (10) integrated
integrated in HNS02
in HNS02 (23)
tbd: in preparation
Fig. 13-1: Fusing and selection of mains contactor 3AC400V
choke input current of characteristic circuit- circuit- cross mended allowed
contin. breaker breaker section@ mains switch-
IL,cont delay
[A] eff [A] [A] [A] [A] [mm²] Typ [ms]

(setting ([AWG])
@ PDC value)
cont
Properties
gR gL tripping
charact.
C
HCS03.1E HNK01.1
W0070 without 27,2 Littelfuse 3NA6..820 - - 16 (6) 3RT10 44 180
L50S50*
Cooper-
Bussmann
FWH-50B*
W0070 with 42 Littelfuse 3NA6..820 - - 16 (6) 3RT10 44 180
L50S50*
Cooper-
Bussmann
FWH-50B*
W0100 without 48,5 Littelfuse 3NA6..824 - - 35 (4) 3RT10 44 350
L50S70*
Cooper-
Bussmann
FWH-70B*
L50S70*
Cooper-
Bussmann
FWH-70B*
W0150 without 65 Littelfuse 3NA6..830 - - 50 (2) 3RT10 46 350
L50S100*
2x25 (2)
Cooper-
Bussmann
FWH-100B*
L50S100*
2x25 (2)
Cooper-
Bussmann
FWH-100B*
W0210 without 91,4 Littelfuse 3NA6..832 - - 95 (1/0) 3RT10 55 350
L50S125*
2x50 (1/0)
Cooper-
Bussmann
FWH-125B*
W0210 with 122 Littelfuse 3NA6..832 - - 95 (1/0) 3RT10 55 350
L50S125*
2x50 (1/0)
Cooper-
Bussmann
IL,cont delay

(setting ([AWG])
@ PDC value)
cont
Properties
gR gL tripping
charact.
C
FWH-125B*
HCS02.1E HNL01.1
W0012 without 6 -- 10 10 8 1,0 (16) 3RT1016 80
W0012 with 6 -- 10 10 8 1,0 (16) 3RT1016 80
W0028 without 13 -- 20 20 17 2,5 (13) 3RT1025 110
W0028 with 13 -- 20 20 17 2,5 (13) 3RT1025 110
W0054 without 19 -- 25 25 25 4,0 (11) 3RT1026 190
W0054 with 19 -- 25 25 25 4,0 (11) 3RT1026 190
W0070 without 30 -- 35 32 35 6,0 (9) 3RT1034 120
W0070 with 30 -- 35 32 35 6,0 (9) 3RT1034 120
HMV01.1 HNL01.1
E
W0030 without 26 -- 35 32 26 6 (10) integrated -
HMV01.1 HNL01.1
R
HMV02.1 HNL02.1
R
W0015 with 20 50 35 32 integrated 4 (10) integrated
integrate in HNS02
d in (20)
HNS02
tbd: in preparation
IL,cont delay

(setting ([AWG])
@ PDC value)
cont
Properties
gR gL tripping
charact.
C
HCS03.1E HNK01.1
W0070 without 26,1 3NE1802-0 3NA6817 - - 16 3RT1044 180
(6)
W0070 with 40 3NE1802-0 3NA6817 - - 16 3RT1044 180
(6)
W0100 without 46,5 3NE1820-0 3NA6824 - - 25 3RT1044 350
(4)
W0100 with 64 3NE1820-0 3NA6824 - - 25 3RT1044 350
(4)
W0150 without 62,4 3NE1021-0 3NA6830 - - 2x25/50 3RT1046 350
(2)
W0150 with 85 3NE1021-0 3NA6830 - - 2x25/50 3RT1046 350
(2)
W0210 without 87,8 3NE1022-0 3NA6832 - - 2x50/95 3RT1055 350
(1/0)
W0210 with 117 3NE1022-0 3NA6832 - - 2x50/95 3RT1055 350
(1/0)
HCS02.1E HNL01.1
W0012 without 6 -- 10 10 8 1,0 (16) 3RT1016 80
W0012 with 6 -- 10 10 8 1,0 (16) 3RT1016 80
W0028 without 13 -- 20 20 17 2,5 (13) 3RT1025 110
W0028 with 13 -- 20 20 17 2,5 (13) 3RT1025 110
W0054 without 19 -- 25 25 25 4,0 (11) 3RT1026 190
W0054 with 19 -- 25 25 25 4,0 (11) 3RT1026 190
W0070 without 30 -- 35 32 35 6,0 (9) 3RT1034 120
W0070 with 30 -- 35 32 35 6,0 (9) 3RT1034 120
tbd: in preparation
Fusing Branches within the Control Cabinet

In the wiring of the drive system components there are branches run from
main lines to short circuit protection devices.
Branch to Synchronization Input For example, a branch from the supply feeder has to be run from the
HMV01.1R output of the mains filters to the synchronization input of HMV01.1R
mains supply modules.
According to EN 60 204 part 1, 5.2.4, such supply lines to short circuit
protection devices branching off main lines do not need to be especially
protected against short circuit, when the following requirements have
been fulfilled:
• the supply lines to the short circuit protection device have at least the
cross section of the conductors at the output of the short circuit
protection device (line cross sections from and to motor circuit breaker
have the same size),
• no supply line to the short circuit protection device is longer than 3 m,
• the lines are protected against external influence by a housing or a
wiring duct,
• they are not run close to combustible material.
Notes
Rexroth IndraDrive Accessories in the Drive System Rexroth IndraDrive 14-1
14 Accessories in the Drive System

Rexroth IndraDrive
14.1 Overview of HAS Accessories
Allocation HAS01 Accessories
Fig. 14-1: Allocation HAS01 accessories
14-2 Accessories in the Drive System Rexroth IndraDrive Rexroth IndraDrive
Allocation HAS02, HAS03, HAS04, HAS05 Accessories
Fig. 14-2: Allocation HAS02, HAS03, HAS04, HAS05 accessories
14.2 Basic Accessories HAS01

Accessories for mounting and installation of drive controllers in
combination, i.e. next to each other.
Type Code
Fig. 14-3: Type code HAS01.1
As adjusted to the device widths, the basic accessories are supplied with
or without contact bars.
HAS01 without contact bars and HAS01 with contact bars.
• Example 1: Without contact bars (-NNN).
• Example 2: With contact bars to interconnect the DC buses (e.g. -048
or -072); the bars are adjusted to the device width.
• Example 3: With contact bars to interconnect the DC buses (e.g. -048
or -072); the bars are adjusted to the device width. In addition, the joint
bars for connecting the equipment grounding conductors are
contained in this case.
Note: Please observe that the contact bars of the basic accessories
HAS01 are used for connection to the drive controller to the
left side.
Applications
The HAS01 accessories are used to
• fasten the drive controllers on a mounting surface,
• interconnect the DC bus connections of drive controllers,
• connect the 24V supply of drive controllers of the
Rexroth IndraDrive M range,
• establish the connection of the equipment grounding conductors from
drive controller to drive controller or supply module,
• increase the current carrying capacity of the contact bars in the DC
bus.
Scope of Supply
The basic accessories HAS01 with contact bars is contained in the
standard scope of supply of the HMS and HMD drive controllers.
The basic accessories HAS01 without contact bars is contained in the
standard scope of supply of the HCS02 drive controllers.
Fig. 14-4: Accompanying note
Abb. 14-26: Accompanying note
Mounting the Parts "Bar" and "End Piece" from the

HAS01 Accessories
The parts "bar" and "end piece" increase the current carrying capacity of
the DC bus connection by reducing the involved contact resistances.
1: bar
2: end pieces (right end)
3: end pieces (left end)
Fig. 14-27: Mounting bar and end piece from HAS01
• Ad 1: Use the bars contained in all HAS01.1-***-072-** at L+ and L- as

illustrated above.
• Ad 2 and 3: Use the end pieces contained in all HAS01.1-350-***-**
and HAS01.1-200-***-** at the right and left ends of the DC bus
connections in the drive system.
14.3 Shield Connection HAS02

Accessories for appropriate connection of the motor cable to the drive
controller, especially the shield connection of the motor cable.
There are appropriate HAS02 available for the different connection cross
sections of the drive controllers.
Type Code
Applications
• provide the motor connection cables with a strain relief,
• connect the shield of the motor connection cables to the drive
controller.
Scope of Supply
The HAS02 accessories are available as an option, they are not part of
the standard scope of supply.
Abb. 14-38: Accompanying note
Mounting the HAS02 Accessories

The sheet metal of the accessories is screwed to the bottom of the drive
controller (see also figure below):
• Unscrew bottom or bottom left fixing screw of drive controller.
• Put sheet metal of accessories to bottom of drive controller and screw
down fixing screw of drive controller again.
Risk of damage to the drive controller caused

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

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

2: sheet metal of accessories
3: fixing device
4: shield of motor cable
5: clip
Fig. 14-39: Shield connection of motor cable
Mounting Shield Connection HAS02.1-004-NNN-NN to

Drive Controller HCS03.1E-W0070
1. By means of supplied screws, fasten shield angle steel to bottom of
drive controller.
2. Fix support to shield angle steel as required.
PE
shield angle steel

hrau
support
clip
methode of installation,
for the motor cable selectable
MZZU0012EN00.FH9
Fig. 14-40: Shielding plate HAS02.1-004-NNN-NN at the bottom of the drive

controller HCS03.1E-W0070
3. Fix shield of motor cable to shielding plate with a clip.
Note: Adapt the size of the clip to the motor cable cross section.

Drive Controller HCS03.1E-W0100 / 150
1. Hang up support at guide section at bottom of drive controller and
fasten it by means of supplied screws.
2. Screw shielding plate to shield angle steel.
According to required motor cable routing, it is possible to mount angle
plate for shield connection in different positions:
• motor cable routed in parallel or
• 45° to bottom of drive controller.
PE PE
install the support on guide rail

with 2 screws
angle plate
Installation 2 clip
Installation 1 MZZU0009EN00.FH9

controller HCS03.1E-W0100 / 0150
Note: Adapt the size of the clip to the motor cable cross section.

Drive Controller HCS03.1E-W0210
1. By means of supplied screws (from the accessories kit SCHR-LIN-
M6,0 x 12,0), fasten support to bottom of drive controller.
2. By means of supplied screws (from the accessories kit
SCREW...M6 x 12), fasten shielding plate between the supports.
According to required power supply cable and motor cable routing, it is
possible to mount shielding plate for shield connection in different
positions.
3. Fix shield of power supply cable and motor cable to shielding plate
with a clip.

controller HCS03.1E-W0210
Note: Adapt the size of the clip to the power supply cable and motor
cable cross sections.
Shield Connection of Motor Cable via Mains Filter

For shield connection of the motor cable at the drive controller via the
mains filter, a special shielding plate is available:
Note: Using the shielding plate guarantees optimum shield contact

of the motor cable. You should therefore always use the
shielding plate, where possible.
The shielding plate is only available as an option.
Shield Connection of Motor Cable HAS02.1-006-NNN-NN

with Mains Filter Mounted
1. Hang up shielding plate at bottom of mains filter at threaded bolts and
fasten with supplied nuts.
2. Screw support to shielding plate.
Clips can be mounted depending on motor cable cross section.
PE
PE
L1 L2 L3 PE
X3 L3
L2
L1
PE
shielding plate
support
clip MBZU0013EN01.FH9
Fig. 14-43: Shielding plate HAS02.1-006-NNN-NN at the bottom of the mains

filter (nominal current 50 A)
Note: The shield terminals must not be used to provide strain relief.
Shield Connection of Power Supply Cable HAS02.1-007-

NNN-NN with Mains Filter Mounted
1. Hang up support at bottom of mains filter and fasten it by means of
supplied screws.
2. Screw shielding plate of power supply cable to support.
According to required power supply cable routing, it is possible to mount
shielding plate in different positions:
• power supply cable routed in parallel or,
• 45° to bottom of mains filter or,
• 90° to bottom of mains filter.

filter (nominal current 80 A / 106 A)
3. Fix shield of power supply cable to front side of mains filter with a clip.
For shield connection of the power supply cable at the mains filter, clips of
various sizes are available according to cross sections and number of
cables, which are hung up to the punched holes.
Shield Connection of Power Supply Cable HAS02.1-009-

NNN-NN with Mains Filter Mounted
1. Hang up support at bottom of mains filter and fasten it by means of
supplied screws.
2. Screw shielding plate of power supply cable to support.
According to required power supply cable routing, it is possible to mount
shield for shield connection in different positions:
• power supply cable routed in parallel or
• 45° to bottom of mains filter.
PE
L1 L2 L3
PE 1
motor cable
power supply cable

MZZU0014EN00.FH9

filter (nominal current 146 A)
3. Fix shield of power supply cable to front side of mains filter with a clip.
For shield connection of the motor cable at the mains filter, clips of
various sizes are available according to cross sections and number of
cables, which are hung up to the punched holes.
14.4 Control Cabinet Adapter HAS03
Type Code
Abbrev. 1
Column 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
Example: H A S 0 3 . 1 - 0 0 2 - N N N - N N
1. Product
1.1 Accessories
IndraDrive . . . = HAS
2. Line
2.1 Control cabinet adapter = 03
3. Design
3.1 1......................=1
4. Device assignment (Number of bolt)

4.1 HCS02.1E-W0012 . . . . . . . . . . . = 002
4.2 HCS02.1E-W0028 . . . . . . . . . . . = 002
4.3 HLB01.1C-01K0-N06R0-A-007-NNNN = 002
4.4 HLC01.1C-01M0-A-007-NNNN = 002
4.5 HLC01.1C-02M4-A-007-NNNN = 002
4.6 HCS02.1E-W0054 . . . . . . . . . . . = 004
4.7 HCS02.1E-W0070 . . . . . . . . . . . = 004
5. Other feature
5.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNN
6. Other design
6.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NN
DT000005v01_en.fh
Applications
The control cabinet adapter is used to
• compensate different mounting depths of drive controllers HCS02.1E
and HLC01.1C and HMS01 / HMD01 when mounted to a common
mounting surface.
has03_verwendung.FH7
A: control cabinet adapter

B: mounting surface in control cabinet
Fig. 14-47: How to use the control cabinet adapters
Note: Observe the maximum allowed tightening torque of 6 Nm at

HAS03.
Scope of Supply
Note: Mechanical stability of the adapted device requires a rigid

connection via DC bus rails to a neighboring device without
adapter.
• Do not operate HAS03 without neighboring device.
• Mount HAS03 to bare metal mounting plate.
14.5 Capacitor HAS04

Capacitors from the DC bus connections L+ and L- against housing.
Type Code
Fig. 14-50: Type code HAS04
Note: Using the HAS04 accessories requires additional mounting

clearance at the drive controller.
Observe the dimensions of HAS04.
Applications
• operate HCS02 and HCS03 drive controllers at the HNF01.1 mains
filter
• operate HMS01 drive controllers at HCS02 and HCS03 drive
controllers
HAS04 type Application

HAS04.1-001-NNN-NN at DC bus connections of HCS02 drive controllers
HAS04.1-002-NNN-NN at DC bus connections of HCS03 drive controllers
Fig. 14-51: HAS04 type
Scope of Supply
Capacitor
Connecting HAS04
Fig. 14-54: Connecting HAS04
Dimensions
Fig. 14-55: Dimensions HAS04
min. Width B Height H Depth

Type
[mm] [mm] [mm]
HAS04.1-001 30 75 <150
HAS04.1-002 40 75 <150
Fig. 14-56: Dimensions
Mounting the HAS04.1-001 Accessories

⇒ Connect HMx01 drive controllers to the HCS02 drive
WARNING controller by means of joint bar 2 (see figure below).
Joint bar 2 replaces the equipment grounding
connection 3 at HMx01 (see figure below) to the
equipment grounding system.
1 mounted HAS04.1-001 accessories with connection to L+ and L-

2 mounted joint bar
3 equipment grounding connection at HMx01
Fig. 14-57: HAS04.1-001 at drive system HCS02 with HMx01 without touch
guard mounted
1 mounted HAS04.1-001 accessories

2 mounted joint bar
Fig. 14-58: HAS04.1-001 at drive system HCS02 with HMx01 with touch guard
mounted
Mounting the HAS04.1-002 Accessories

⇒ Connect the HAS04.1-002 accessories to drive
WARNING controller HCS03 via the joint bar (see figure below).

2: joint bar
Fig. 14-59: HAS04.1-002 at drive system HCS03.1E-W0070, -W0100, -W0150
with HMx01 without touch guard mounted

Fig. 14-60: HAS04.1-002 at drive system HCS03.1E-W0210 with HMx01 without
touch guard mounted
Fig. 14-61: HAS04.1-002 at drive system HCS03 with HMx01 with touch guard
mounted
14.6 Accessories HAS05.1
Type Code HAS05.1
Applications
The HAS05 accessories are used to:
HAS05 type Application

HAS05.1-001-NNN-NN is used for electrical connection between motor filter
HMF01.1A-D0K2-D0045 and HCS03.1E-W0070, as
well as between mains filter HNK01.1A-A075-E0050
and HCS03.1E-W0070
HAS05.1-002-NNN-NN is used for electrical connection between mains filter
HNK01.1A-A075-E0050 and HCS03.1E-W0070, if a
motor filter has been mounted between HCS03.1
and mains filter
HAS05.1-003-NNN-NN is used to increase voltage levels at output of
optional module MEM to voltage range 5…30V
HAS05.1-004-NNN-NN is used to increase the effective cross section of the
DC bus contact bars at the connections L+ and L-
HAS05.1-005-NNN-NN converts the serial interface of control sections from
RS232 standard to RS485 standard
Fig. 14-63: HAS05 type
Scope of Supply
The HAS05.1 accessories have to be ordered separately.
Accessories HAS05.1-001-NNN-NN
EKZU0001EN00.FH9
Fig. 14-64: Accessories HAS05.1-001
HCS03.1E-W0070
HAS05.1-001
HMF01.1A-D0K2-D0045
MZZU0016EN00.FH9
Fig. 14-65: Arrangement HCS / HAS / HMF
When mounting the motor filter HMF01.1 to HCS03.1, connection from

filter to drive controller is established via connector X5 of HAS05.1-001.
When mounting the mains filter HNK01.1 to HCS03.1, connection from
filter to drive controller is established via connector X3 of HAS05.1-001.
Accessories HAS05.1-002-NNN-NN
HNK01.1 HMF01.1 HCS03.1
X3 cable tie HAS05.1-002 HAS05.1-002

(HAS05.1-001)
MBZU0070EN00.FH9
Fig. 14-66: Sample mounting HCS03.1 / HMF01.1 / HNK01.1 with accessories

HAS05.1
Accessories HAS05.1-003-NNN-NN and HAS05.1-005-NNN-NN

For the description of the accessories HAS05.1-003 and HAS05.1-005-
NNN-NN see documentation "Rexroth IndraDrive, Drive Controllers,
Control Sections, Project Planning Manual".
14.7 Accessories for Connection Technique
Fiber Optic Cable Connections
There are accessories available to connect drive controllers to the

peripherals via fiber optic cables.
CNC
SERCOS
1
interface
X10 TX
X10 TX
X10 TX
X10 TX
fiber optic cable ring
ERROR ERROR ERROR ERROR

H3 H3 H3 H3
3 3 3 3
2 2 2 2
1 1 1 1
2 3 AP5127F1.FH7
1: fiber optic cable connections outside of control cabinet

2: control cabinet duct
3: fiber optic cable connections inside of control cabinet
Fig. 14-67: Fiber optic cable connections
Installation location Description Type designation

outside of control robust fiber optic cable RKO 0101
cabinet connections from peripherals to
control cabinet
at control cabinet control cabinet duct with plug-in INS 0610
connector
inside of control fiber optic cable connections to RKO 0100
cabinet and between drive controllers
Fig. 14-68: Fiber optic cable connection elements
Note: For ordering the fiber optic cable connection you have to
generate the complete order code containing details on type
and length.
For the type designation please see the above table and add
the required length to it.
Determine the length by means of the list of different device
arrangements.
Example: Order code for arrangement HCS02 (left 105 mm) next to
HCS02 (right 65 mm):
• required length: 0.25 m
• type designation: RKO 0100
• order code RKO 0101 / 0,25
Interconnection of Drive Controllers

For selecting the fiber optic cable connection of drive controllers take
different possible combinations and different device widths into account.
Combination of HCS02 and HCS02
HCS02 HCS02
ERROR ERROR
H3 H3
3 3
2 2
1 1
lwl_hcs02_hcs02
lwl_hcs02_hcs02.EPS
Fig. 14-69: HCS02 with HCS02
Required fiber optic cable length [m]

Width left HCS02 [mm] Width right HCS02 [mm]
65 105
65 0,15 0,15
105 0,25 0,25
Fig. 14-70: Fiber optic cable lengths
Combination of HCS02 to the Right of HMS or HMD
HMS
HMD HCS02
ERROR ERROR
H3 H3
3 3
2 2
1 1
lwl_hcs02_hms_l
Fig. 14-71: HCS02 to the right of HMS or HMD
Independent of the width of the devices, cable length is 0.15 m.
Combination of HCS02 to the Left of HMS or HMD
HMS
HCS02 HMD
ERROR ERROR
H3 H3
3 3
2 2
1 1
lwl_hcs02_hms_r
Fig. 14-72: HCS02 to the left of HMS or HMD
cable length = width HCS02 + width HMS/HMD + 10 cm

Width Width HMS / HMD [mm]
HCS02 [mm]
50 75 100 125
65 0,25 0,25 -- --
105 0,25 0,30 0,30 0,30
Combination of HCS03 to the Right of HMS or HMD
HMS
HMD HCS03
ERROR ERROR
H3 H3
3 3
2 2
1 1
lwl_hcs03_hms_l
Fig. 14-74: HCS03 to the right of HMS or HMD
Combination of HCS03 to the Left of HMS or HMD
HMS
HCS03 HMD
ERROR ERROR
H3 H3
3 3
2 2
1 1
lwl_hcs03_hms_r
Fig. 14-75: HCS03 to the left of HMS or HMD

Width left
Width right device [mm]
device [mm]
50 75 100 125 150 200 225 350
50 0,15 0,25 0,25 0,25 0,30 0,50 0,50 0,50
75 0,15 0,25 0,25 0,25 0,30 0,50 0,50 0,50
100 0,15 0,25 0,25 0,25 0,30 0,50 0,50 0,50
125 0,15 0,25 0,25 0,25 0,30 0,50 0,50 0,50
150 0,15 0,25 0,25 0,25 0,30 0,50 0,50 0,50
200 0,15 0,25 0,25 0,25 0,30 0,50 0,50 0,50
225 0,15 0,25 0,25 0,25 0,30 0,50 0,50 0,50
350 0,15 0,25 0,25 0,25 0,30 0,50 0,50 0,50
Extension for Module Bus Connections

Application
The bus cable RKB0001 is used to extend module bus connections of
HMV01.1E and HMV01.1R devices with HMS01 / HMD01 drive
controllers as well as HMV02.1R with HMS02.
The extension is required, if the distance between the drive controllers is
more than 5 mm.
The bus cable can be ordered with lengths of 0.5 m to 40 m in steps of
0.5 m.
The cable consists of
• housing with hinged cover
• cable with strain relief mounted at both ends
For ordering generate the complete order code:

Example for required length 2.5 m:
• required length: 2.5 m
• type designation: RKB 0001
• order code RKB 0001 / 02,5
Scope of Supply
The RKB bus cable is available as an option, it is not part of the standard
scope of supply.
Montage_Modulbus_verlaengerung_HMV_HMS.jpg
Fig. 14-77: Extension of module bus
How to Mount RKB Bus Cable Mounting RKB bus cable:

1. Mount housing to ground strap.
2. Unscrew cover and plug ribbon cable of right device into circuit board.
3. Close cover.
4. Screw strain relief down to ground strap.
5. Plug ribbon cable into X1.
Note: Make sure the connection between strain relief and ground
strap is well conductive.
By means of appropriate wiring establish equipment grounding
connections of devices that are not directly adjoining.
Notes
Rexroth IndraDrive Calculations 15-1
15 Calculations
15.1 Determining the Appropriate Drive Controller
Introduction
Supply for the drive system Rexroth IndraDrive takes place by means of
compact converters HCS or mains supply modules HMV. According to
drive task, design of drive controller and operating conditions, you can in
addition use chokes, additional capacitors, braking resistors, transformers
etc.
The drive controller or supply module has to make available the DC bus
continuous power and for acceleration the DC bus peak power. With
regenerative operation, they must be able to absorb the continuous
recovery power and peak recovery power.
Before the drive controller or mains supply module and the additional
components can be selected, the motors and drive controllers to be used
must be defined.
To ensure correct dimensioning of the drive system, we recommend to do
the calculations as described in the following sections.
DC Bus Continuous Power

DC bus continuous power is calculated from the mechanical power,
taking into consideration the motor and controller efficiency, as well as
simultaneity factors.
Mechanical Power
M * n * 2π
Pm [W ] = M ∗ ω = or
60
M *n
Pm [kW ] ≈
9550
Pm: mechanical power
M: torque [Nm]
-1
ω: angular velocity [min ]
-1
n: motor speed [min ]
Fig. 15-1: Mechanical power
Mechanical Continuous Power To calculate the mechanical continuous power of a servo drive, you need
for Servo Drives the effective motor torque and the average motor speed.
The effective motor torque can be taken over from the servo drive
calculation. The average motor speed is determined as follows.
Average Motor Speed For servo drive tasks at common NC machine tools, the average motor
speed is approx. 25% of the rapid traverse speed. In some cases,
however, this rough estimation is not sufficient. An exact calculation of the
average motor speed is required.
15-2 Calculations Rexroth IndraDrive
If the period during which the motor is run at constant speed is

significantly greater than the run-up and braking time, the following
applies:
Average Speed with Run-Up and
Braking Times not Taken into n1 * t1 + n2 * t 2 + ... + nn * t n
Account nav =
t1 + t 2 ... + t n
-1
nav: average motor speed [min ]
-1
n1 ... nn: motor speed [min ]
t1 ... tn: duty cycle [s]
Fig. 15-2: Average speed, effects of run-up and braking times not taken into
account
n1
n2
n3
t1 t2 t3 t4
DGoE.fh7
Fig. 15-3: Speed characteristic; effects of run-up and braking times not taken
into account
In dynamic applications with short cycle times, e.g. roll feeds and nibbling
machines, run-up and braking times must be taken into account.

The DC bus capacitors in the drive controller have been
dimensioned for loading with continuous power.
CAUTION If loaded with cyclic charging and discharging processes
of high energy content, the DC bus capacitors can be
overloaded, especially with decreasing mains connection
voltage.
⇒ Operate additional capacitors at the DC bus.
Average Speed with Run-Up and

Braking Times Taken into n n
Account * t H + n * t1 + * t B
nav = 2 2
t H + t1 + t B + t 2
-1
-1
n: motor speed [min ]
t: time [s]
tH: run-up time [s]
tB: braking time [s]
Fig. 15-4: Average speed; effects of run-up and braking times taken into
account
t
tH t1 tB t2
DGmE.fh7
Fig. 15-5: Average speed; effects of run-up and braking times taken into account
Mechanical Power for Servo

Drives Meff * nav
PmSe =
9550
PmSe: mechanical continuous power for servo drives [kW]
Meff: effective motor torque [Nm]
-1
Fig. 15-6: Mechanical power for servo drives
Mechanical Power for Main Main drives are drives which are mainly used in the constant power speed
Drives range. Thus, nominal power is decisive for dimensioning the mains
supply. The mechanical nominal power of the main drives can be taken
from the operation characteristic or calculated from nominal speed and
nominal torque.
Mn * nn
PmHa =
9550
PmHa: mechanical nominal power for main drives (shaft output) [kW]
Mn: nominal motor torque [Nm]
-1
n n: nominal motor speed [min ]
Fig. 15-7: Mechanical power for main drives
DC bus Continuous Power for The drive controller or the combination of drive controllers has to make
Servo Drives available the DC bus power. However, in most applications, simultaneous
loading of all drives will not occur; thus, only the simultaneous load must
be considered for calculating the DC bus continuous power to be made
available for servo drives. To calculate the DC bus continuous power to
be made available for typical NC feed axes at machine tools, inclusion of
a so-called simultaneity factor has proved to be favorable in practical
application:
Number of axes 1 2 3 4 5 6 n=7 n=n+1

Simultaneity 1 1,15 1,32 1,75 2,0 2,25 FG=2,5 FGn=FG+0,25
factor (FG)
Fig. 15-8: Simultaneity factors
(PmSe1 + PmSe 2 + ... + PmSen ) * 1,25

PZWDSe =
FG
PZWDSe: DC bus continuous power for servo drives [kW]
PmSe1 ...PmSen: mechanical continuous power for servo drives [kW]
F G: simultaneity factor
1,25: constant for motor and controller efficiency
Fig. 15-9: DC bus continuous power for servo drives
DC Bus Continuous Power for If several main drives are operated at one DC bus, the simultaneously
Main Drives required DC bus continuous powers must be added:
PZWHa = (PmHa1 + PmHa 2 + ... + PmHan ) * 1,25

PZWHa: DC bus continuous power for main drives [kW]
PmHa1 ... PmHan: mechanical continuous power for main drives [kW]
Fig. 15-10: DC bus continuous power for main drives
Chokes and additional capacitors have to be selected according to the

actually required DC bus continuous power. It is determined by the
nominal power of the mains drives.
Note: When selecting the drive controllers, make sure that their
maximum DC bus continuous power will not restrict the short-
time operation power of the main drives.
CD Bus Continuous Power for When main and servo drives are operated at a drive controller, the
Main and Servo Drives required DC bus continuous powers must be added.
At a typical NC machine tool, the required DC bus continuous power will
be primarily defined by the main drive. Accordingly, the following equation
is to be used for such applications:
PZWD = [PmHa + 0,3 * (PmSe1 + PmSe 2 + ... PmSen )] * 1,25

0,3: experimental value for standard machine tools
PZWD: DC bus continuous power [kW]
PmSe1 ...PmSen: mechanical continuous power for servo drives [kW]
PmHa: nominal power for main drive (shaft output) [kW]
Fig. 15-11: DC bus continuous power for main and servo drives at NC machine
tools
∑P ZWD, installati on ≤ ∑ PZWD, devices

PZWD,installation: generated DC bus continuous power of the installation
PZWD,devices: allowed DC bus continuous power of the devices
Fig. 15-12: Supply condition: DC bus continuous power
DC Bus Peak Power

The drive controller or combination of drive controllers has to produce DC
bus peak power for example when several axes of a machine tool
simultaneously accelerate to rapid traverse rate after a tool change,
approaching the workpiece.
Damage due to supply unit overload!

⇒ To avoid damage to the drive controller the sum of
peak powers of all drives mustn't exceed the DC bus
peak power of the supplying drive controller (central
CAUTION
supply).
(MNC ± MG ) * neil * 1,25

PZWS =
9550
MNC: acceleration torque in the drive [Nm]
MG: torque due to weight for vertical axes [Nm]
-1
neil: speed at rapid traverse rate [min ]
PZWS: DC bus peak power [kW]
Fig. 15-13: DC bus peak power per drive
∑P ZWS, installati on ≤ ∑ PZWS, devices

PZWS,installation: generated DC bus peak power of the installation
PZWS,devices: allowed DC bus peak power of the devices
Fig. 15-14: Supply condition: DC bus peak power
Regenerative Power
When all main and servo drives connected to a drive controller or
combination of drive controllers brake simultaneously, the generated
regenerative power must not be greater than the maximum regenerative
power of the drive controller or combination of drive controllers. If this is
not taken into consideration in dimensioning the system, thermal
destruction of the braking resistors in the drive controllers may occur.
Risk of damages due to braking resistor

overload!
⇒ Only use a drive controller or combination of drive
CAUTION controllers that can absorb the resulting regenerative
power generated when all main and servo drives
connected to the drive controller or combination of
drive controllers brake simultaneously.
2
JG  2π 
Wrot = *  neil * 
2  60 
W rot: rotary energy [Ws]
-1
2
J G: motor inertia and load inertia reduced to the motor shaft [kgm ]
Fig. 15-15: Regenerative power per drive
∑W R, installati on ≤ ∑ WR, devices

W R,installation: generated regenerative power of the installation
W R,devices: allowed regenerative power of the devices
Fig. 15-16: Supply condition: regenerative power
Calculation to Reduce Generated Power Dissipation - Additional

External Capacitances at DC Bus
When the drive brakes, the rotary energy present in the mechanical
system is released as regenerative power in the DC bus of the drive
controller or combination of drive controllers. It can
• be converted into dissipation heat via the braking resistor integrated in
the drive controller or the additional braking resistor
- or -
• be stored as energy in the drive controllers and possibly available
additional capacitors and reused for following acceleration processes.
This reduces the power dissipation generated in the control cabinet
and lowers the energy consumption.
The following applies to successful use of additional capacitors to avoid

unnecessary power dissipation in the control cabinet:
∑W R, installati on ≤ ∑WZW , devices

W R,installation: generated regenerative power of the installation
W ZW,devices: storable energy of the DC bus capacitors
Fig. 15-17: Condition to avoid power dissipation from the regenerative power
Additional Capacitors as Energy Many acceleration and deceleration processes are typical for applications
Store with servo drives (e.g. nibbling machines or roll feeds). This is why it can
be useful for such applications to connect additional capacitors to the DC
bus of the drive controllers. This provides the following advantages:
• For drive controllers without mains regeneration function this prevents
the braking resistor in the drive controller from being switched on when
the drives brake: The dissipation heat in the control cabinet is
considerably reduced.
• The energy stored in the DC bus capacitors can be used for
acceleration. The energy demand of the drive is reduced.
Storable Energy in DC Bus The specific energy absorption capacity of the drive controllers can be
determined with the formula below.
(C DC + C DCext )
WDC =
2
(
* U R2 _ DC _ On − U DC
2
)
W DC: storable energy in DC bus
CDC: DC bus capacitance in device [F]
CDCext: external DC bus capacitance [F]
UR_DC On: braking resistor switch-on threshold
UDC: DC bus voltage
Fig. 15-18: Storable energy in DC bus
The additional capacitor has to be dimensioned in such a way that it can

store the rotary drive energy:
2Wrot
C DCext ≥ − C DC
(U 2
− U DC
R_DC On
2
)
UR_DC On: braking resistor switch-on threshold
UDC: DC bus voltage
CDC: internal capacitance [F]
CDCext: required external DC bus capacitance [F]
Fig. 15-19: Required additional capacitance [F]
Property damage caused by overload of HMV

and HCS devices!
⇒ Comply with max. allowed external DC bus
CAUTION capacitance! See electrical data of the HMV and
HCS components.
Property damage caused by overload of the

additional external capacitors!
⇒ Use allowed components for drive system
Rexroth IndraDrive.
⇒
CAUTION
The properties of the additional capacitors have to
comply with minimum requirements:
min. dielectric strength: DC900V
min. current load capacity: 15Aeff / mF
min. heat resistance: 105 °C
max. discharge time: 30 min
Take measures against flammability in case of
overload, e.g. by housing the capacitors.
⇒ Connect correct polarity: Connect L+ to positive
pole and L- to negative pole of the additional
capacitors.
Note: When using additional external capacitors, observe that the

series connection of these units can require a balancing
device.
Note: We recommend that you dimension the additional capacitors

at the DC bus for 10% overvoltage at the mains connection.
Note: As the supply voltage increases the storable energy in the DC

bus decreases, as the differential voltage between braking
resistor threshold UB and DC bus voltage UZW (crest value of
supply voltage) is reduced.
The figure below illustrates the characteristic of the storable energy in the
DC bus versus mains voltage with fixed switch-on threshold UB by the
example of HCS02.1E devices.
180
160
140
120
100
WZW [Ws]
80
60
W0070
40
W0054
20 W0028
W0012
0
200 250 300 350 400 450 500
UN1 [V]
Fig. 15-20: Storable energy in DC bus
Continuous Regenerative Power

In terms of average period of time, the sum of the continuous
regenerative power of all drives must not exceed the allowed continuous
power of the braking resistor(s).
In applications with servo drives at typical NC machine tools, machining
time is relatively long relative to the cycle time. Accordingly, the
continuous regenerative powers are only small. For this type of
applications, exact calculation is not required. It is sufficient to make sure
that the regenerative peak power is not exceeded.
Exact calculation is required, for example, for one of the following
applications:
• Applications with servo drives which are characterized by many
acceleration and deceleration processes (e.g. nibbling machines or roll
feeds).
• Machine tools with modular main drive.
• Applications which involve lowering of large masses, e.g. loading
bridges, warehousing and transport systems.
Before the continuous regenerative power can be calculated, the rotary
energy of the drives and the potential energy of non-balanced masses
must be calculated.
2
Jg  2π 
Wrot = *  neil *  *z
2  60 
-1
2
JG: inertia (motor + load) [kgm ]
z: number of braking processes per cycle
Fig. 15-21: Rotary energy of the drives
Wpot = m * g * h * z
W pot: potential energy [Ws]
m: load mass [kg]
g: gravitational acceleration = 9,81 m/s²
h: lowering height [m]
z: number of lowering processes per cycle
Fig. 15-22: Potential energy of non-balances masses
W potg + Wrotg
PRD ,installation =
tz
; ∑P RD ,installati on ≤ ∑ PBD ,devices
PRD,installation: generated continuous regenerative power [kW]

PBD,devices: allowed braking resistor continuous power [kW]
tz: cycle time [s]
W potg: sum of potential energies [kWs]
W rotg: sum of rotary energies [kWs]
Fig. 15-23: Continuous regenerative power
Peak Regenerative Power

Usually, peak regenerative power will occur when an E-Stop signal is
triggered and all axes brake simultaneously.
Risk of damage due to extended braking times

and distances!
⇒ Select the device such that the sum of peak
CAUTION regenerative powers of all drives does not exceed
braking resistor peak power of the supply unit.
See the respective motor selection documentation for the peak

regenerative powers.
Peak regenerative power can be roughly estimated by the following
equation:
∑P ≤ ∑ PBS ,devices
Mmax * nmax
PRS = RS ,installati on
9550 * 1,25
PRS,installation: generated peak regenerated power [kW]
PBS,devices: allowed braking resistor peak power [kW]
Mmax: maximum drive torque [Nm]
-1
nmax: maximum NC useful speed [min ]
Fig. 15-24: Peak regenerative power
Calculating Control Factor

The control factor of an inverter is the ratio of its output voltage to a
reference output voltage.
The reference output voltage is the output voltage of the inverter at mains
input voltage without overload.
U out U
a= = out
U out _ ref U LN
Uout output voltage of inverter
Uref reference output voltage
ULN mains voltage
Fig. 15-25: Control factor
If several inverters have effect on one supply unit at the same time, you
have to consider the so-called mean control factor.
1 n
a= * ∑ ai
n i =1
ai : several control factors
Fig. 15-26: Mean control factor
15.2 Calculations for Mains Connection
Calculating Mains-Side Phase Current

To select an appropriate mains contactor and the appropriate fusing of
the power connection, the mains-side phase current IN has to be
calculated before.
The mains-side phase current IN is determined from the mains connected
load SLN.
For max. mains connected load see technical data of the drive controllers
or calculate according to formula below and formulas contained in
appendix. For several drive controllers add the individual mains
connected loads.
MEFF ⋅ n MITTEL ⋅ 2 ⋅ π
PDC = ⋅k
60
PDC: required DC bus continuous power [W]
MEFF: effective torque [Nm]
nMITTEL: average speed [min-1]
k: factor for motor and controller efficiency = 1,25 (MKD, MHD)
Fig. 15-27: Calculating the DC bus power
PDC
SLN =
TPF
SLN: mains connected load [VA]
PDC: DC bus continuous power [W]
TPF: Total Power Factor λ
Fig. 15-28: Calculating the mains connected load
SLN
single-phase connection: I LN =
U LN
SLN
three-phase connection: I LN =
U LN ⋅ 3
IN1: mains-side phase current [A]
SN1: mains connected load [VA]
UN1: voltage between phases of mains [V]
Fig. 15-29: Calculating the mains-side phase current
Calculating the Inrush Current

ULN * 2
IEIN =
R DC(Start)
IEinGesamt = ∑I EIN
IEin: inrush current of respective device [A]

IEinGesamt: total inrush current in A (relevant value for fusing)
ULN: mains input voltage
RDC(Start): softstart resistor of the device (see respective technical data)
Fig. 15-30: Calculating the inrush current
Note: For calculating the inrush current take all devices connected to
mains voltage into account.
Mains Contactor and Fusing

To facilitate the selection of an appropriate mains contactor and fusing
device for power connection there are selection tables available in chapter
"Fusing and Selecting the Mains Contactor".
Calculating the Mains Harmonics

Harmonic Load THD
The harmonic load of the mains is described by the THD (total harmonic
distortion):
2
I  40
THD = ∑  n 
n=2  I1 
I n: harmonic current of the n-th harmonic

st
I 1: rms value of the 1 harmonic (fundamental wave)
nd
I 2: rms value of the 2 harmonic
I n: rms value of the n-th harmonic
Fig. 15-31: THD (total harmonic distortion)
Harmonic Content / Distortion Factor k

The harmonic content of, for example, the mains current is described by
the distortion factor k. The distortion factor contains all alternating
components, both those of the fundamental wave (I1) and of the
harmonics (Ik). Direct components (I0) are not contained.
∑I
k =2
2
k
I 22 + I 23+...
k= =
n
I 12 + I 22+ I 23...
∑I
k =1
2
k
k: distortion factor or harmonic content

Ik: harmonic current of the k-th harmonic
st
I 1: rms value of the 1 harmonic (fundamental wave)
nd
I 2: rms value of the 2 harmonic
I n: rms value of the n-th harmonic
Fig. 15-32: Distortion factor k or harmonic content
Power Factor cosϕ1 or DPF for Calculating the Reactive

Power Load of the Mains
The power factor cosϕ1 or DPF (Distortion Power Factor) is used to
calculate the reactive power load of the mains:
Pnetz
DPF = cos ϕ1 =
S1LN
Pnetz: effective mains power
S1LN: apparent mains power of fundamental wave
Fig. 15-33: Power factor cos ϕ1 / DPF
Power Factor cosϕ or TPF (λ)

The power factor cosϕ or TPF is used for rating mains components
(transformer, fuse etc.):
Pnetz
TPF = λ = cos ϕ =
SLN
Pnetz: effective mains power
SLN: apparent mains power
Fig. 15-34: Power Factor cos ϕ / TPF/ λ
Note: Only for sinusoidal values does the power factor cosϕ equal
the total power factor TPF (λ).
Calculating Allowed Continuous Powers in Common DC Bus

By interconnecting the DC bus connections of several HCS02 and HLB01
drive controllers the regenerative power and continuous power generated
in the common DC bus is equally distributed to all IndraDrive C
components with braking resistor.
Distribution to the involved components takes place with high balancing
factor.
For Central Supply and Group

Supply with DC Bus Connection ∑P BD , devices = ∑ ( PBD , HCS + PBD , HLB ) * f
PBD, devices : braking resistor continuous power that all devices at common
DC bus can process in continuous operation, in kW
PBD, HCS02: braking resistor continuous power that the drive controller can
process in continuous operation, in kW
PBD, HLB01: braking resistor continuous power that the additional braking
resistor module can process in continuous operation, in kW
f: balancing factor for parallel operation (see electrical data)
Fig. 15-35: Available braking resistor continuous power at common DC bus
∑P ZW , devices = ∑ PZW * f
PZW, devices: available DC bus continuous power at common DC bus, in kW
PZW : DC bus continuous power of the individual devices, in kW
f: balancing factor for parallel operation (see electrical data)
Fig. 15-36: Available DC bus continuous power at common DC bus
For Individual Supply and Group See chapters "Electrical Data" and "Mains Connection" in the respective
Supply without DC Bus Project Planning Manuals of the components.
Connection
15.3 Determining Appropriate Mains Connection Components
Mains Choke HNL

When using mains chokes, take their effect on the connected drive
controllers into account. Due to their inductance, mains chokes have a
smoothing effect on the current and thereby reduce harmonics.
To have the inductance available, comply with the nominal current of the
mains choke.
Depending on the type of mains connection, we distinguish two cases.
Case 1: Only one drive controller or mains supply unit is connected to the
mains choke (individual supply and central supply).
Selection criteria:
• Use of assigned mains choke acc. to Project Planning Manual of drive
controller or mains supply unit.
Case 2: Several drive controllers or mains supply units are connected to

the mains choke (group supply with and without DC bus connection).
Selection criteria:
• Nominal current:
IN ≥ ∑I LN
ILN: mains-side phase current in A

IN: nominal current of mains choke in A
Fig. 15-37: Mains choke conditions
• Nominal inductance:
The nominal inductance of the individual mains choke has to be at
least as high as the inductance of the greatest assigned mains choke
of the connected drives or mains supply.
15.4 Using the Loop-Through Contacts for Control Voltage

Supply
X13 X13 X13
steuerspg_durchschleif.fh7
Fig. 15-38: Looping through the control voltage
Calculation for 3 drive controllers:
PN 3
ID = 3 x
UN 3
Fig. 15-39: Continuous current ID
IE = 3 x IEIN3
Fig. 15-40: Inrush current IE
The inrush current peak is present for the specified duration tEIN3Lade.
15.5 Determining the Leakage Capacitance

The leakage capacitance consists of the values of motor cable and motor
of all individual drives operated at the mains filter. It is calculated as
follows:
C _ab_ G = C _ab_MG + C _ab_KG

C_ab_G: total value of leakage capacitance
C_ab_MG: total value of leakage capacitance of motor
C_ab_KG: total value of leakage capacitance of cable
Fig. 15-41: Total leakage capacitance
The total capacitance C_ab_MG consists of the sum of capacitances of

the individual motors. For these individual capacitances see Project
Planning Manual for motor (a list of selected values is contained in the
appendix of this drive system documentation).
C _ab_MG = C _ab ( Motor _ 1) + C _ab ( Motor _ 2) + ... + C _ab ( Motor _ n)

C_ab: leakage capacitance of a motor
Fig. 15-42: Total leakage capacitance of motor
C _ab_KG = C Belag_K1 * l K1 + C Belag_K2 * l K2 + ... + C Belag_Kn * l Kn

CBelag_K1: capacitance of cables
C_ab_KG: total leakage capacitance of cables
Fig. 15-43: Total leakage capacitance of cables
The total capacitance C_ab_KG consists of the sum of capacitances of

the individual motor cables. For the individual capacitances see the
technical data of motor cables (a list of selected values is contained in the
appendix of this drive system documentation).
15.6 Calculations for Determining the Allowed Operating Data

of Mains Filters
Reducing Allowed Operating Voltage Depending on Actual Temperature

Rise due to Harmonics
The mains filters may only be operated in the allowed mains voltage
range. Harmonics (fn) at the system voltage cause additional temperature
rise of the dielectric of the capacitors used in the filter. Temperature rise
can be calculated according to the following formula:
10 x (UMn )
2
∆Tn = [K ]
(UGn )2
UMn: measured voltage value at frequency fn (harmonic)
UGn: voltage limit value for frequency fn
∆Tn: calculated temperature rise of the dielectric for frequency fn
Fig. 15-44: Calculating the temperature rise of the dielectric
The temperature rises have to be added up for all frequencies fn ≥ fk (fk:

frequency at which the voltage derating of the filter starts; see Fig. 15-46):
10 x (UMv )
m m 2
∆Tges = ∑
v =1
∆Tv = ∑
v =1 (UGv )2
[K ] ≤ 10 [K ]
UMv: voltage value at frequency fv
UGv: voltage limit value for frequency fv
∆Tges: calculated temperature rise of the dielectric for all frequencies
Fig. 15-45: Calculating the temperature rise of the dielectric for all frequencies
By means of the above formulas and the measured voltages it is possible

to determine the real load of a filter with voltages of higher frequencies.
To this end, the rms value of the voltage on the mains side of the filter
with all occurring frequencies (higher than fk) must be measured by
means of a Fourier analysis for all combinations of line/line and line/PE.
You always have to measure the voltages under conditions of operation at
the nominal working point, the filter having been installed. By means of
the measured values it is then possible to calculate the temperature rise.
To do this, the limit values of the following diagram are read at the
respective frequency and used in the formula together with the measured
value.
fk fk
Dg5027f1.fh7
Fig. 15-46: Derating
If the total of the temperature values is greater than 10 K, the harmonics

have to be reduced by means of appropriate measures.
Current Reduction in the Case of Overtemperature

The mains filters recommended by Rexroth have been dimensioned for
an ambient temperature of 45 °C.
For higher temperatures reduce the mains current according to the
following formula:
85 - Tamb
I = INetz •
40
INetz: nominal current of filter at 45 °C
Tamb: ambient temperature
Fig. 15-47: Current reduction in the case of overtemperature
15.7 Determining the Data for Selecting the 24V Supply

At HCS02 and HLB01.1C devices the external 24V supply takes place via
the connection X13, at the devices HCS03, HMS01, HMS02, HMD01,
HLB01.1D, HMV02 and HMV01 via the connections 24V and 0V at the
terminal block.
Via these connections the devices are supplied with 24V for
• the power section of the drive controller
• brake control via X6 and
• the control section of the drive controller.
The following performance data are required for selecting the control
voltage supply:
• nominal voltage of supply
• continuous current capacity of supply
• peak current capacity of supply
Nominal Voltage of 24V Supply

The nominal voltage results from the intersection of the allowed voltage
ranges of the components used.
Continuous Current Capacity of 24V Supply

The continuous current capacity of the control voltage supply has to
correspond at least to the sum of continuous currents of the connected
components. The continuous current results from the power PN3 of the
components and the nominal voltage of the selected 24V supply.
Note: The continuous current of a drive controller consists of

• the continuous current of the control section
• the continuous currents of the optional modules of the
control section that are used
• the continuous current of the power section
• the continuous current of motor brakes to be operated.
Peak Current Capacity of 24V supply

The peak current capacity of the control voltage supply has to correspond
at least to the sum of peak currents of the connected components for the
duration of the inrush current.
Note: The peak current of a drive controller consists of

• the peak current of the control section
• the peak currents of the optional modules of the control
section that are used
• the peak current of the power section
• the peak current of motor brakes to be operated.
To determine the required peak current capacity of the 24V supply the
following approximate calculation is allowed:
I peak ≥ 1,2 × I cont

Ipeak: required peak current capacity
Fig. 15-48: Approximate calculation Ipeak from Icont for 24V supply
The 24V supply has to be able to supply the current Ipeak for at least
100 ms.
15.8 Determining the Braking Behavior when Using DC Bus

Resistor Unit HLB01 (DC Bus Short Circuit)
in preparation
15.9 Other Calculations
Loading the DC Bus

To estimate the delay time td which a supply unit or a converter needs to
load the DC bus, consider the following aspects:
• delay time td from connecting the mains voltage to the device (from
status "ready for operation") to status "drive ready".
See also parameter "P-0-0115, Device control: status word"
Delay Time td
td = Rlade *1, 2*CDC *3 + 200ms
td delay time
Rlade effective loading resistance
CDC effective DC bus capacitance
Fig. 15-49: Delay time for three-phase operation
Note: For single-phase operation take the time twice as much.
Effective Load Resistance with Effective load resistance of several drive controllers at common DC bus
Several Mains Inputs connected to mains voltage:
1 1 1 1
= + + ..... +
Rlade Rlade_1 Rlade_2 Rlade_n
Fig. 15-50: Several loading resistances
Effective Load Resistance with Effective load resistance of one drive controller at common DC bus
One Mains Connection connected to mains voltage:
ULNmax
Rlade ≈
IL trans max (on)
ULNmax see technical data of drive controllers
Iltrans max (on) see technical data of drive controllers
Fig. 15-51: Loading resistance
Resulting DC bus Capacitance C Resulting DC bus capacitance of all drive controllers at common DC bus:
C DC = CDC1 + C DC2 + ... + C DCn + C DCext

CDC see technical data of drive controllers
Fig. 15-52: DC bus capacitance
Notes
Rexroth IndraDrive Replacing Devices 16-1
16 Replacing Devices

The diagnostic display enables aimed and effective troubleshooting in
order to:
• avoid production downtimes due to extensive searches in individual
devices and repairs of devices in the installation.
• start operating the installation again without extensive assembly and
adjustments.
• quickly eliminate the problem and easily replace defective drive
components.
When returning a defective device to our Customer Service, please

enclose the completed Fault Report. The Fault Report is included in this
chapter and may be copied for your convenience.
Note: The new drive component must have the same type
designation as the faulty device. To ensure this, indicate the
entire type designation when requesting replacement parts.
16.2 How to Proceed When Replacing Devices
Note: For replacing devices you absolutely have to observe the

safety instructions contained in chapter 3!
Replacing the Drive Controller

• save parameter set
• open main switch
• make sure main switch cannot be switched on again
• make sure drive controller is completely de-energized
Lethal electric shock caused by contact to live

parts!
⇒ Before touching live parts allow the capacitors to
DANGER discharge! Only then start working on the connection
cables!
• remove touch guard and separate connecting lines from drive

controller
• unscrew screws on top and bottom of housing
• take drive controller out of drive system
• mount new drive controller
• connect new drive controller as specified in machine circuit diagram
• mount touch guard
• copy firmware and parameter set to new drive controller (see firmware
documentation)
16-2 Replacing Devices Rexroth IndraDrive
Replacing the Motor

• disconnect plug-in connectors
Note: When replacing the motor, cover the open mating sites of
power lines with protective caps if sprinkling with cooling
liquid/lubricant or soiling may occur (allowed degree of soiling
according to EN50178: 2).
• replace motor
Note: To mechanically replace the AC servo motor, observe the

instructions of the machine manufacturer.
• connect plug-in connectors
Risk of accident due to accidental axis

movement.
⇒ Servo axes with indirect distance measuring system
WARNING via the motor encoder will loose the position data
reference when the motor is replaced!
This position data reference to the machine
coordinate system must therefore be reestablished
after replacement.
• for servo axes with absolute motor encoder, reestablish the position
data reference
Replacing Cables
Lethal electric shock caused by live parts with

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

machine manufacturer.
If you do not use ready-made Rexroth cables, check to ensure
that the cables match the terminal diagram of the machine
manufacturer!

• disconnect plug-in connectors
Note: When replacing cables, cover the open mating sites of power
lines with protective caps if sprinkling with cooling
liquid/lubricant or soiling may occur (allowed degree of soiling
according to EN50178: 2).
• replace cable
Property damage caused by bad power

connectors!
⇒ Only separate or connect clean and dry power
CAUTION connectors.
• connect plug-in connectors
16.3 Fault Report
Fault Report Date:

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

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

Name of dialog in which fault occurred:
Drive connection:
Note: In order to resolve your DriveTop problem quickly, we would like to ask you to send us the file
"debug.log". You can find it in the DriveTop directory.
Fig. 16-1: Fault report
Notes
Rexroth IndraDrive Disposal and Environmental Protection 17-1
17 Disposal and Environmental Protection
17.1 Disposal
Products
Our products can be returned to us free of charge for disposal. It is a
precondition, however, that the products are free of oil, grease or other
dirt.
In addition, when returned the products mustn't contain any undue foreign
matter or foreign component.
Please send the products free domicile to the following address:

Bosch Rexroth AG
Electric Drives and Controls
Bürgermeister-Dr.-Nebel-Straße 2
D-97816 Lohr am Main
Packaging Materials
The packaging materials consist of cardboard, wood and polystyrene.
They can be easily recycled. For ecological reasons you should not return
the empty packages to us.
17-2 Disposal and Environmental Protection Rexroth IndraDrive
17.2 Environmental Protection
No Release of Hazardous Substances

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

Electronic Devices
Electronic devices mainly contain:
• steel
• aluminum
• copper
• synthetic materials
• electronic components and modules
Motors
Motors mainly contain:
• steel
• aluminum
• copper
• brass
• magnetic materials
• electronic components and modules
Recycling
Due to their high content of metal most of the product components can be
recycled. In order to recycle the metal in the best possible way it is
necessary to disassemble the products into individual modules.
The metals contained in the electric and electronic modules can also be
recycled by means of specific separation processes.
The synthetic materials remaining after these processes can be thermally
recycled.
Rexroth IndraDrive Service & Support 18-1
18 Service & Support
18.1 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: [email protected]
18.2 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
18.3 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.
18.4 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.
18-2 Service & Support Rexroth IndraDrive
18.5 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
[email protected]
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 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 87 11 90 61
[email protected]
[email protected]
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
[email protected] Hotline: +33 (0)608 33 43 28
[email protected]
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
[email protected]
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 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 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 [email protected]
Hotline: +47 64 86 94 82 - service: +34 9 43 31 84 60
[email protected] [email protected]
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) 4 238 88 -50 Tel. +41 (0) 55 46 46 111 Tel.: +41 (0)21 632 84 20
Fax: +46 (0) 4 238 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 (0) 22 738 18 00
Fax: +420 (0)5 48 126 112 Fax: +420 566 62 1657 Fax: +36 (1) 422 3201 – service: +48 (0) 22 738 18 46
Fax: +48 (0) 22 758 87 35
– service: +48 (0) 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
[email protected] [email protected]
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
[email protected] www.boschrexroth.com.tr [email protected] [email protected]
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 [email protected] [email protected]
+61 4 19 369 195 [email protected]
[email protected]
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
[email protected] +91 80 83 97 374 Fax: +91 22 28 56 32 93 Fax: +91 11 26 56 68 87
[email protected] [email protected] [email protected]
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
[email protected] +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
[email protected] [email protected] sanjay.nemade Hotline: +27 82 903 29 23
[email protected] @boschrexroth.com.sg [email protected]
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
[email protected] Fax: +886 - 6 –253 4754 +66 2 943 71 21
[email protected] [email protected] Fax: +66 2 509 23 62
Hotline +66 1 984 61 52
[email protected]
Nordamerika – North America

USA USA Central Region - Mitte USA Southeast Region - Südost 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 1701 Harmon Road 2810 Premiere Parkway, Suite 500
5150 Prairie Stone Parkway Auburn Hills, MI 48326 Duluth, GA 30097
Hoffman Estates, IL 60192-3707
+1-800-REXROTH
Tel.: +1 847 645-3600 Tel.: +1 248 393-3330 Tel.: +1 678 957-4050 +1 800 739-7684
Fax: +1 847 645-6201 Fax: +1 248 393-2906 Fax: +1 678 417-6637
[email protected]
[email protected]
USA Northeast Region – Nordost USA West Region – West
Bosch Rexroth Corporation Bosch Rexroth Corporation

Electric Drives & Controls Electric Drives & Controls
99 Rainbow Road 7901 Stoneridge Drive, Suite 220
East Granby, CT 06026 Pleasanton, CA 94588
Tel.: +1 860 844-8377 Tel.: +1 925 227-1084
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
[email protected] +52 81 83 49 80 91
[email protected] [email protected] 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 [email protected]
+54 11 4756 04 40 [email protected] Fax serv.: +55 11 4414 56 86
Fax: +54 11 4756 01 36 [email protected] [email protected]
+54 11 4721 91 53 [email protected] (Service)
[email protected]
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
[email protected]
Rexroth IndraDrive Appendix 19-1
19 Appendix
19.1 Technical Data "Capacitances Against Ground"

The indicated capacitance values help selecting appropriate mains filters
of the HNF01 and NFD03 lines.
Capacitance Data for Motors

The Rexroth motors have the typical capacitance values listed below. The
data refer to the total capacitance of the power connections U, V, W
against the motor housing.
Motor types Frame length Symbol Unit Typ.

value
MKD025, A C_ab nF
MKE037 B C_ab nF 1,0
MKD, MHD, MHP041, A C_ab nF

MKE047 B C_ab nF 1,6
A C_ab nF 1,2
MKD, MHD, MHP071
B C_ab nF 2,5
MKD, MHD, MHP090,
B C_ab nF 6,7
MKE098
A C_ab nF 4,8
MHD, MHP093 B C_ab nF 7,8
C C_ab nF 9,5
A C_ab nF 3,7
MHD, MHP095 B C_ab nF 5,3
C C_ab nF 6,7
A C_ab nF 5,3
MKD, MHD, MHP112, B C_ab nF 10,3

MKE118 C C_ab nF 14,1
D C_ab nF 20,2
A C_ab nF 6,9
MKD, MHD, MHP115 B C_ab nF 13,2
C C_ab nF 18,2
B C_ab nF 13,9
MHD131
D C_ab nF 25,7
B C_ab nF 2,1
MSK050
C C_ab nF 2,6
B C_ab nF 2,1
MSK060
C C_ab nF
C C_ab nF 3,1
MSK070 D C_ab nF
E C_ab nF
Fig. 19-1: Leakage capacitance of selected motors
19-2 Appendix Rexroth IndraDrive
The scope of available motors is continuously extended; please ask for

data of motors not contained in this list.
Capacitance Data for Power Cables

The Rexroth motor cables of the RKL line have the capacitances listed
below. The values refer to the sum of the single capacitances of power
strands 1, 2 and 3 against the overall shield.
Cable type of non- Nom. cross section Symbol Unit Value

assembled cable in [mm²]
INK 653 1,0 CY_K typ nF/m 0,6
INK 603 4 CY_K typ nF/m tbd
INK 604 6 CY_K typ nF/m 0,8
Fig. 19-2: Capacitance values of power cables
Note: Approximate calculation is allowed with the following values:

• 1 nF/m for cross sections of 1 mm² to 6 mm²
• 1.2 nF/m for cross sections of 10 mm² to 50 mm²
19.2 Short Designations of Products
Short designation Type Description
CZ 1.2 additional capacitor

DLT isolating transformer
DST matching transformer
HCS02.1 drive controller
HCS03.1 drive controller
HLB01.1C DC bus resistor unit
HLB01.1D DC bus resistor unit
HLC01.1C DC bus capacitor unit
HLC01.1D DC bus capacitor unit
HMD01.1 drive controller
HMS01.1 drive controller
HMS02.1 drive controller
HMV01.1E supply unit
HMV01.1R supply unit
HMV02.1R supply unit
HNF01.1 mains filter
HNL01.1 mains choke
HNL02.1 mains choke mains choke with housing to be mounted in control cabinet
HNS02.1 mains filter mains filter with integrated switch-disconnector and motor
circuit breaker
HNK01.1 mains filter mains filter with integrated mains choke, variant for assembly
MSK040 synchronous motor
NFD03.1 mains filter
RKL ready-made motor power cable
RKS ready-made control cable
RKG ready-made encoder cable
VCP01 small operator terminal variant for assembly
Fig. 19-3: Short designations of products
19.3 Discharging of Capacitors
Discharging of DC Bus Capacitors

In the drive system Rexroth IndraDrive capacitors are used in the DC bus
as energy stores. In the drive controllers and particularly in the supply
units such capacitors have already been integrated.
Energy stores maintain their energy even when energy supply has been
cut off and have to be discharged before somebody gets in contact with
them.
Discharging devices have been integrated in the components of the drive
system Rexroth IndraDrive; within the indicated discharging time these
devices discharge the voltage below the allowed 50 V.
If additional capacitances in the form of
• DC bus capacitor units or
• additional capacitors
are connected, make sure that these capacitors, too, are discharged
before somebody gets in contact with them.
Due to the operating principle, the discharging time is the longer
• the bigger the energy store (the capacitance value)
• the higher the voltage to which the energy store has been charged
• the greater the resistance for discharging the capacitors.
Components of the drive system Rexroth IndraDrive have been

dimensioned in such a way that after the energy supply was cut off the
voltage value falls below 50 V within a discharging time of a maximum of
30 minutes.

more than 50 V!
⇒ Wait at least 30 minutes after switching off power to
allow discharging.
⇒
WARNING
Check whether voltage has fallen below 50 V before
touching live parts!
To shorten the waiting time until voltage has fallen below 50 V you can
take the following measures:
• Activate the function "ZKS" (DC bus short circuit) when using HMV01
supply units.

more than 50 V!
⇒ Before touching live parts check whether the voltage
WARNING has fallen below 50 V!
• Use the discharging device described below.
Discharging Device
Operating Principle A contactor is installed to switch a resistor to the terminals L+ and L- of
the DC bus connection to discharge the capacitors. The contactor is
activated via a control input which is supplied with appropriate control
voltage.
L+
L-
DA000010v01_en.fh7
R: discharging resistor
K: contactor contact
Fig. 19-4: Operating principle of discharging device
Dimensioning The individual components have to be sufficiently dimensioned:

• The value of the discharging resistor has to be dimensioned with
1000 ohm and at least 1000 W.
• The discharging resistor and the contactor contact have to withstand
the loads of practical operation (for example in the case of frequent
use of the discharging device of the occurring continuous power).
• The contactor contact has to withstand the occurring direct voltage of
min. 1000 V.
• The contactor contact has to withstand the occurring discharging
current according to the resistance value that is used, i.e. 1 A with
1000 ohm.
How to Proceed for Discharging Observe the proceeding when using the discharging device:
1. Install discharging device before switching energy supply on for the
first time and establish safe electrical connection between discharging
device and object to be discharged.
2. On mains side switch off energy supply to drive system before
activating discharging device.
3. Activate discharging device.

more than 50 V!
⇒ Before touching live parts check in any case whether
WARNING the voltage between the DC bus terminals L+ and L-
has fallen below 50 V!
Notes
Rexroth IndraDrive Index 20-1
20 Index
2
24V supply
determining the data for selecting 15-19
installation 7-34
A
accessories
brief description 4-7
for connection technique 14-62
HAS01 14-3
HAS02 14-29
HAS03 14-48
HAS04 14-52
HAS05 14-59
overview 14-1
additional capacitors as energy store 15-6
ambient conditions 5-5
ANAX 6-23
applications
drive system 4-1
appropriate use 2-1
areas (zones)
of control cabint 7-22
arranging the components in the control cabinet 7-1
B
basic design of the devices 1-12
Bb contact 11-3, 11-5
boring dimensions
for the mounting plate 7-9
braking behavior 15-20
braking resistor
braking resistor and DC bus continuous power
calculate 15-14
branch
synchronization input HMV01.1R 13-7
branches 13-7
brief description
of the devices 4-1
bus cable
RKB 0001 14-66
C
cable
replace 16-3
RKB 0001 14-66
calculations 15-1
capacitance
against ground 19-1
minimum capacitance against ground 6-3
capacitance data
motors 19-1
power cables 19-2
capacitor pack 14-52
capacity utilization 5-6
CCC 5-2
CE label 5-1
central supply 9-7
HCS 9-7
HCS02 with HCS02 6-7
HCS02 with HMS / HMD 6-10
20-2 Index Rexroth IndraDrive
HCS03 6-9
HCS03 with HMS / HMD 6-12
HMV01, HMV02 6-5
certifications 5-1
chapters
main focuses 1-2
combination
allowed combination of individual components 6-1
allowed combinations with motor filter 6-20
in mains connection phase with mains chokes HNL, mains filters HNF and mains chokes
HNK 6-14
not allowed combinations 6-13
of firmware, control section and drive controller 6-21
with other Rexroth components 6-23
commutation drops 10-10
compact converters 1-10
compatibility with foreign matters 5-6
components
arrangement from electrical point of view 7-20
arrangement from mechanical point of view 7-1
arrangement from thermal point of view 7-17
arranging the components in the control cabinet 7-1
main dimensions 7-3
performance-dependent arrangement 7-20
conditions
ambient 5-5
for installation 5-5
storage 5-4
transport 5-4
configuration Rel 1 as Bb contact 11-5
connection
mains choke 12-5
connections
accessories 14-62
connection point of equipment grounding conductor 12-3
contact-welded 13-1
control voltage connection 12-10
DC bus connection 12-5
fiber optic cable 14-62
ground connection of housing 12-2
module bus 14-66
module bus connection X1 12-12
motor connection 12-13
overall connection diagrams of the system 12-13
position of system connections 12-2
continuous regenerative power
calculate 15-8
control 11-2
control cabinet
adapter 14-48
arranging the components 7-1
grounding 7-21
mounting 7-1
with multiple-line structure 7-17
control circuits 11-1
HMV 11-2
control factor
calculating 15-10
control section 1-13
control voltage
connection 12-10
specification 5-8
control voltage supply
determining the data for selecting 15-19
loop-through 15-16
cooling units 7-18
corner grounded delta mains 10-4
cosϕ 10-14
cosϕ1 10-14
C-UL-US listing 5-1
current reduction
in the case of overtemperature 15-19
D
data
ambient 5-5
DC bus
loading 15-21
DC bus capacitors
discharging 19-4
DC bus connection 12-5
DC bus continuous power
calculate 15-1
main drives 15-4
servo drives 15-3
DC bus peak power
calculate 15-4
DC bus resistor unit
DC bus short circuit 15-20
DC capacitor unit
deceleration 11-9
declaration of conformity 5-1
degree of protection 5-5
derating 5-6
devices
depths 7-4
heights 7-4
materials 17-2
replacing 16-1
widths 7-4
dimensions
components 7-3
HAS04 14-55
discharging device 19-5
discharging of DC bus capacitors 19-4
disposal 17-1
dissipation heat
reduce 15-6
distances
for drive controllers 7-5
minimum 7-5
distortion factor 15-12
distortion Factor k 10-15
docu house 1-6
documentation
docu house 1-6
IndraDrive 1-3
overview 1-3
purpose 1-1
your feedback 1-4
DPF 10-14, 15-12
dripping or sprayed water 7-18
drive controller
basic design 1-12
determining appropriate drive controller 15-1
distances 7-5
replace 16-1
selecting 1-14
drive controller HCS03
with HMF01 6-20
drive controllers
drive system
allowed combination of individual components 6-1
applications 4-1
components 1-8
configuration 6-1
IndraDrive C 1-7
IndraDrive M 1-8
introducing the system 1-7
noise immunity 8-1
not allowed combinations 6-13
specifications 5-1
dust, steam 5-5
E
electromagnetic compatibility (EMC) 8-1
EMC
ensuring the requirements 8-6
EU directive 89/336/EWG 8-6
explanations and terms 8-1
optimal arrangement 7-22
rules for design of installations 7-21
standards and laws 8-6
EMI 8-1
environmental protection 17-2
ePlan macros 12-13
equipment grounding conductor
connection 10-22
equipment grounding connections 12-3
E-Stop relay 11-9
F
F8091 Power section defective 6-23
fault report 16-4
fiber optic cable
connections 14-62
first environment 8-5
fuse
characteristic gL 13-1
characteristic gR 13-1
fusing 13-1
branches within the control cabinet 13-7
G
ground connection
of housing 12-2
ground connections 7-32
grounded outer conductor 10-4
group supply 9-3
HCS without DC bus connection of the groups 9-4
HMV without DC bus connection of the groups 9-4
with DC bus connection 9-5
with DC bus connection HCS02 6-6
with DC bus connection HCS03 6-9
with DC bus connection HMV01, HMV02 6-4
without DC bus connection of the groups 9-3
H
harmonic content 15-12
harmonic load THD 15-12
harmonics 10-11
harmonics factors 10-15
HAS
accessories 14-1
HAS01 14-3
HAS02 14-29
HAS03 14-48
HAS04 14-52
HAS05 14-59
HCS02
limit value classes 8-12
with HNF01.1 6-16
HCS02.1E
parallel operation 9-6

HCS03
limit value classes for HCS03 drive controllers with HMS, HMD and HNF01 drive
controllers 8-15
limit value classes for HCS03 drive controllers with HNK01 8-14
with HNF01.1 6-17
with HNK01.1 6-17
HCS03.1E
HLB01.1D 11-16
HMV
with HLB01.1D 11-16
HMV01.1E
housing HAC01 for control sections
I
inappropriate use 2-2
individual supply
with HCS 9-2
with HMV 9-2
IndraDrive
documentations 1-3
hierarchical levels 1-5
industrial area 8-5
industrial sectors 4-1
inrush current
calculate 15-11
installation
24V supply 7-34
EMC-optimal 7-22
in interference-free area of control cabinet (area A) 7-24
in strongly interference-susceptible area of control cabinet (area C) 7-26
type B1 13-1
installation altitude 5-5
installation conditions 5-5
insulation monitoring devices 10-25
interference suppression elements 7-21
interference-susceptible area 7-22
inverter 1-11
IT system 10-3
L
leakage capacitance
determining 15-17
leakage currents
cause 10-23
limit value classes
to be achieved with mains filters 8-10
line routing 7-21
line-based disturbances
limit values 8-3
Loading
DC bus 15-21
loop-through contacts 15-16
M
macros
ePlan 12-13
main dimensions
components 7-3
main drives
DC bus continuous power 15-4
mains
classes 10-6
commutation drops 10-10
emitted mains harmonics of the device 10-14

frequency tolerance 10-9
harmonics 10-11
IT system 10-3
limit values for interference-free operation at mains 10-9
maximum allowed mains overvoltages 10-11
maximum connected load 10-7
power factors 10-14
protective grounding 10-18
selecting connection components 10-8
short-circuit power 10-5
short-time interruptions 10-10
TN-C system 10-2
TN-S system 10-1
TT system 10-3
types 10-1
ungrounded 8-9
voltage tolerances and voltage changes 10-9
voltage unbalance 10-9
with grounded outer conductor 10-4
mains choke
connection 12-5
mains choke HNL
determining 15-15
mains connection
calculations 15-11
control circuits 11-1
fusing 13-1
mains contactor 13-1
protection systems 10-18
requirements 10-1
types 9-1
mains connection phase
allowed combinations 6-14
mains contactor 13-1
control by control unit 11-14
control with E-Stop relay 11-9
selecting 13-1
mains contactor and fusing 15-12
mains filter
allowed operating data 15-18
for drive controllers HCS02 8-12
for drive controllers HCS03 8-14
limit value classes to be achieved 8-10
protecting against overload 8-9
selection 8-8
mains harmonics
calculate 15-12
mains transformer
mains voltage harmonics 10-17
mains-side phase current
calculate 15-11
master-slave
control circuit 11-2
materials
of products 17-2
modular inverters 1-11
module bus
connections 14-66
module bus connection X1 12-12
moisture condensation 7-19
motor
capacitance data 19-1
motor inductance 6-27
replace 16-2
requirements on third-party motors 6-26
temperature evaluation of third-party motor 6-28
third-party, encoder of third-party motor 6-29
third-party, notes on commissioning 6-29
third-party, notes on selection 6-29

third-party, selecting connection technique 6-29
third-party, selecting controller 6-29
voltage load 6-26
motor connection 12-13
motor encoder system 6-22
motor filter
allowed combinations 6-20
motor filter HMF 6-27
motor filter HMF01
assignment to HCS03 6-20
motor power cable
connection to drive controller 7-28, 7-32
limited length 6-24
selecting 6-24
shield connection 14-45
third-party cables 6-25
motors
third-party 6-25
third-party motors 6-25
mounting depth 7-3
mounting depth adapter 14-48
mounting plate
boring dimensions 7-9
mounting position 7-1
N
noise emission
causes 8-2
measures to reduce 8-7
noise immunity
in drive system 8-1
O
operating conditions 5-5
operating voltage
reducing allowed operating voltage 15-18
operator terminal
VCP 6-23
overall connection diagrams of the system 12-13
overtemperature
current reduction 15-19
overvoltages
maximum allowed mains overvoltages 10-11
P
P-0-0860, Converter configuration 6-23
packaging
materials 17-1
parallel operation
HCS 9-6
HMV01.1E 9-6
peak regenerative power
calculate 15-9
PFC 10-7
power cables
capacitance data 19-2
power dissipation
calculation to reduce generated power dissipation 15-6
power factor correction 10-7
power factor cosϕ1 15-12
power factors 10-14
power reduction 5-6
power section 1-12
power voltage supply 5-10
product
line 1-5
platform 1-5
range 1-5
type 1-5
products
materials 17-2
short designations 19-3
project planning manual for system
contents 1-1
project planning manuals
box 1-4
contents 1-6
protective grounding 10-18
R
radio interference suppression
general measures 7-35
RCCB 10-22
RCD 10-22
ready for operation Bb 11-3
Recycling 17-2
regenerative power
calculate 15-5
relay
E-Stop 11-9
replace
cable 16-3
drive controller 16-1
motor 16-2
residual-current-operated circuit-breakers 10-22
restricted distribution 8-5
Rexroth IndraDrive
platform 1-5
RKB 0001 14-66
S
safety instructions for electric drives and controls 3-1
second environment 8-5
sensitive to power pulse current 10-23
sensitive to universal current 10-24
SERCOS analog converter 6-23
servo drives
DC bus continuous power 15-3
shield connection
accessories HAS02 14-29
motor cable 14-45
with accessory HAS02 7-28
without accessory HAS02 7-29
shielding plate 14-45
motor cable 14-45
short designations
of products 19-3
short-time interruptions 10-10
signal lines 7-21
specifications
for the components of the drive system 5-1
standards 1-4
storable energy in DC bus 15-6
storage 5-4
extended storage 5-4
strongly interference-susceptible area 7-22
supply
central supply 9-7
group supply 9-3
individual supply 9-2
selecting the component 1-15
supply mains
nominal current 8-5
supply unit

limit value classes for HMV01.1E 8-10
limit value classes for HMV01.1R 8-11
supply voltages 5-8
synchronization input HMV01.1R 13-7
system connections
position of system connections 12-2
system impedance 10-5
T
temperature
ambient 5-5
storage 5-4
transport 5-4
tests 5-3
applied-overvoltage withstand 5-3
THD 10-15, 15-12
third-party motors 6-25
directives 6-25
third-party motors to be controlled 6-26
TN-C system 10-2
TN-S system 10-1
TPF 10-14
transport 5-4
TT system 10-3
U
UL 5-1
unrestricted distribution 8-5
use
appropriate 2-1
inappropriate 2-2
V
VCP 6-23
vibration
noise 5-5
sine 5-5
vibrations 5-5
voltage load of the motor 6-26
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
[email protected]
www.boschrexroth.com
Printed in Germany
R911309636 DOK-INDRV*-SYSTEM*****-PR03-EN-P

CSH01.1C SE EN2 NNN NNN NN S NN FW REXROTH IndraDrive Manual

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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Rexroth IndraDrive R911309636

Project Planning Manual

Title Rexroth IndraDrive

Document Typecode DOK-INDRV*-SYSTEM*****-PR03-EN-P

Internal File Reference 120-2400-B321-03/EN

Record of Revisions Description Release Date 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

Battery Safety ........................................................................................................................ 3-11

4 Brief Description, Applications 4-1

5 Specifications for the Components of the Drive System 5-1

Power Voltage Supply ........................................................................................................... 5-10

6 Configuration of the Drive System Rexroth IndraDrive 6-1

7 Arranging the Components in the Control Cabinet 7-1

Installing Signal Lines and Cables......................................................................................... 7-33

8 Electromagnetic Compatibility (EMC) 8-1

9 Types of Mains Connection 9-1

10 Requirements to the Mains Connection 10-1

Maximum Allowed Mains Overvoltages .............................................................................. 10-11

11 Control Circuits for the Mains Connection 11-1

12 Connections of the Components in the Drive System 12-1

13 Fusing and Selecting the Mains Contactor 13-1

14 Accessories in the Drive System Rexroth IndraDrive 14-1

Allocation HAS01 Accessories .............................................................................................. 14-1

15.2 Calculations for Mains Connection ........................................................................................... 15-11

16 Replacing Devices 16-1

17 Disposal and Environmental Protection 17-1

18 Service & Support 18-1

1.1 About this Documentation

Personal injury and property damage caused by

Purpose of Documentation This documentation provides…

Note: For detailed technical data of the individual components see

This documentation contains safety regulations, technical data and

18 Service & Support general information

Reference Documentations - Overview

Box with Project Planning Manuals on Rexroth IndraDrive

Order data of the box:

1.2 Overview and Contents of the Documentations on the

control sections power sections supply additional motors firmware

Rexroth IndraDrive platform

Fig. 1-3: IndraDrive products

line HCS02 HCS03 HMV01 HMS01 HMD01 CSB CDB CSH

range Rexroth IndraDrive C Rexroth IndraDrive M Basic Advanced

type Rexroth IndraDrive power sections Rexroth IndraDrive control sections

platform Rexroth IndraDrive platform

Fig. 1-4: Hierarchical levels

specific Application Manuals (safety technology...)

control sections power sections supply additional motors firmware

Rexroth IndraDrive platform

Fig. 1-5: "House" of documentations

1.3 Introducing the System

Drive System Rexroth IndraDrive C

DC bus braking resistor unit

DC bus capacitor unit