Rexroth Indradrive Additional Components and Accessories: Project Planning Manual

Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Rexroth IndraDrive R911306140

Edition 03
Additional Components and

Accessories
Project Planning Manual
Bosch Rexroth AG | Electric Drives Rexroth IndraDrive | Project Planning Manual
and Controls
Title Rexroth IndraDrive

Additional Components and
Accessories
Type of Documentation Project Planning Manual
Document Typecode DOK-INDRV*-ADDCOMP****-PR03-EN
Internal File Reference RS-3aee9eb90a6846ac0139e9630b45f9bf-2-en-US-4
Record of Revision Edition Release Date Notes

DOK-INDRV*-ADDCOMP****-PR01-EN 2004-11 1st edition
DOK-INDRV*-ADDCOMP****-PR02-EN 2006-01 Motor filter HMF01.1 for
HCS03 added; housing
for control sections
(HAC) added
DOK-INDRV*-ADDCOMP****-PR03-EN 2008-02 See chapter "Introduc‐
tion" → "Documenta‐
tion" → "Changes"
Copyright © Bosch Rexroth AG, 2008

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 de‐
rived 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.de
Dept. EDY1 (RR/US/BB)
Note This document has been printed on chlorine-free bleached paper.
Project Planning Manual | Rexroth IndraDrive Electric Drives | Bosch Rexroth AG I/IX
and Controls
Table of Contents
Table of Contents
Page
1 Introduction.................................................................................................................... 1
1.1 Documentation........................................................................................................................................ 1
1.1.1 General Information............................................................................................................................. 1
1.1.2 Changes.............................................................................................................................................. 2
1.1.3 Reference Documentations................................................................................................................. 2
Drive Systems, System Components............................................................................................... 2
Motors............................................................................................................................................... 2
Cables.............................................................................................................................................. 3
Firmware........................................................................................................................................... 3
2 Important Directions for Use ......................................................................................... 5

2.1 Appropriate Use ..................................................................................................................................... 5
2.1.1 Introduction.......................................................................................................................................... 5
2.1.2 Areas of Use and Application.............................................................................................................. 5
2.2 Inappropriate Use................................................................................................................................... 6
3 Safety Instructions for Electric Drives and Controls....................................................... 7

3.1 Safety Instructions - General Information............................................................................................... 7
3.1.1 Using the Safety Instructions and Passing them on to Others............................................................ 7
3.1.2 How to Employ the Safety Instructions................................................................................................ 7
3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness.............................................. 8
3.1.4 Hazards by Improper Use.................................................................................................................... 9
3.2 Instructions with Regard to Specific Dangers....................................................................................... 10
3.2.1 Protection Against Contact with Electrical Parts and Housings......................................................... 10
3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage................................................. 11
3.2.3 Protection Against Dangerous Movements....................................................................................... 11
3.2.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 14
3.2.5 Protection Against Contact with Hot Parts......................................................................................... 14
3.2.6 Protection During Handling and Mounting......................................................................................... 14
3.2.7 Battery Safety.................................................................................................................................... 15
3.2.8 Protection Against Pressurized Systems........................................................................................... 15
4 Brief Description, Usage.............................................................................................. 17

4.1 General Information.............................................................................................................................. 17
4.2 Applications of the Drive System Rexroth IndraDrive........................................................................... 17
4.3 Mains Transformers DST and DLT....................................................................................................... 17
4.4 Mains Filters HNF, HNK, NFE, HNS02 and NFD................................................................................. 17
4.5 Mains Chokes HNL01 and HNL02........................................................................................................ 18
4.6 DC Bus Resistor Unit HLB01................................................................................................................ 19
4.7 Braking Resistor HLR01....................................................................................................................... 19
4.8 DC Bus Capacitor Unit HLC01............................................................................................................. 19
4.9 Motor Filters HMF01............................................................................................................................. 20
4.10 Housing for Control Sections HAC01................................................................................................... 20
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5 General Specifications of the Components.................................................................. 21

5.1 Certifications......................................................................................................................................... 21
5.2 Transport and Storage.......................................................................................................................... 23
5.2.1 Transport of the Components............................................................................................................ 23
5.2.2 Storage of the Components............................................................................................................... 23
5.3 Installation Conditions........................................................................................................................... 24
5.3.1 Ambient and Operating Conditions.................................................................................................... 24
5.3.2 Mounting Position.............................................................................................................................. 25
5.3.3 Compatibility With Foreign Matters.................................................................................................... 27
5.3.4 Prime Coat and Housing Varnish...................................................................................................... 27
5.4 Capacity Utilization............................................................................................................................... 28
5.5 Voltage Test and Insulation Resistance Test....................................................................................... 29
5.6 Control Voltage Specification (24V Supply).......................................................................................... 30
6 Transformers................................................................................................................ 33
6.1 General Information.............................................................................................................................. 33
6.2 Autotransformers for Drive Controllers................................................................................................. 34
6.2.1 Types................................................................................................................................................. 34
6.2.2 Selection............................................................................................................................................ 35
6.2.3 Technical Data................................................................................................................................... 36
7 Mains Filter.................................................................................................................. 37
7.1 Mains Filters NFD / NFE....................................................................................................................... 37
7.1.1 Type Code NFE / NFD...................................................................................................................... 37
NFE01.1 - Mains Filter, Single-Phase............................................................................................ 37
NFE02.1 - Mains Filter, Single-Phase............................................................................................ 38
NFD03.1 - Mains Filter, 3-Phase.................................................................................................... 39
7.1.2 Mechanical Data NFE / NFD............................................................................................................. 40
NFE01.1......................................................................................................................................... 40
NFE02.1......................................................................................................................................... 40
NFD03.1......................................................................................................................................... 41
7.1.3 Electrical Data NFE / NFD................................................................................................................. 42
7.2 HNF01.1 - Mains Filter, 3-Phase.......................................................................................................... 44
7.2.1 Type Code HNF01.1.......................................................................................................................... 44
7.2.2 Mechanical Data HNF01.1................................................................................................................ 45
Dimensions..................................................................................................................................... 45
Drilling Pattern................................................................................................................................ 47
7.2.3 Electrical Data HNF01.1.................................................................................................................... 48
Data HNF01.1A-xxxx-Rxxxx-A-480-NNNN for Infeeding Supply Systems..................................... 48
Data HNF01.1A-xxxx-Rxxxx-A-480-NNNN for Regenerative Supply Systems.............................. 49
7.3 HNK01.1 - Mains Filter, With Mains Choke.......................................................................................... 51
7.3.1 Type Code HNK01.1......................................................................................................................... 51
7.3.2 Type Plate HNK01.1.......................................................................................................................... 51
7.3.3 Mechanical Data HNK01.1................................................................................................................ 53
Dimensions..................................................................................................................................... 53
Project Planning Manual | Rexroth IndraDrive Electric Drives | Bosch Rexroth AG III/IX
and Controls
Table of Contents
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7.3.4 Electrical Data HNK01.1.................................................................................................................... 57
7.3.5 Arrangement of the Components Drive Controller HCS03 and Mains Filter HNK01......................... 58
7.4 HNS02.1 - Mains Filter, With Switch-Disconnector.............................................................................. 62
7.4.1 Identification...................................................................................................................................... 62
Type Code...................................................................................................................................... 62
7.4.2 Mechanical Data HNS02.1................................................................................................................ 63
Dimensions..................................................................................................................................... 63
7.4.3 Electrical Data HNS02.1.................................................................................................................... 64
7.4.4 Connection Points............................................................................................................................. 64
8 HNL - Mains Chokes for Supply Units and Converters................................................ 67

8.1 Identification.......................................................................................................................................... 67
8.1.1 Type Code......................................................................................................................................... 67
8.1.2 Type Plate......................................................................................................................................... 68
8.2 HNL01.1E - Mains Chokes, Infeeding.................................................................................................. 69
8.2.1 Technical Data................................................................................................................................... 69
Mechanical System and Mounting.................................................................................................. 69
Basic Data...................................................................................................................................... 71
8.3 HNL01.1R - Mains Chokes, Regenerative............................................................................................ 72
8.3.1 Safety Instruction............................................................................................................................... 72
8.3.2 Technical Data................................................................................................................................... 73
Basic Data...................................................................................................................................... 73
8.4 HNL01.1*-****-S - Mains Chokes, Current-Compensated.................................................................... 74
8.4.1 Function............................................................................................................................................. 74
8.4.2 Technical Data................................................................................................................................... 75
Basic Data...................................................................................................................................... 76
8.5 HNL02.1 - Mains Choke....................................................................................................................... 77
8.5.1 Identification...................................................................................................................................... 77
Type Code...................................................................................................................................... 77
8.5.2 Technical Data................................................................................................................................... 78
Basic Data...................................................................................................................................... 78
Connection Points.......................................................................................................................... 79
9 HLL01 - DC Bus Choke, Current-Compensated (Preliminary).................................... 83

9.1 Brief Description, Usage and Commissioning...................................................................................... 83
9.1.1 Brief Description................................................................................................................................ 83
9.2 Type Code and Identification................................................................................................................ 83
9.2.1 Type code.......................................................................................................................................... 83
9.2.2 Identification...................................................................................................................................... 84
9.3 Scope of Supply.................................................................................................................................... 85
9.4 Installation and Mounting...................................................................................................................... 86
9.4.1 General Information........................................................................................................................... 86
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9.4.2 Dimensions HLL01............................................................................................................................ 87
9.4.3 Circuit Diagram HLL01...................................................................................................................... 87
9.5 Technical Data...................................................................................................................................... 88
10 HLC01.1 - DC Bus Capacitor Unit............................................................................... 91

10.1 Application Instructions......................................................................................................................... 91
10.2 Identification.......................................................................................................................................... 92
10.3 Mounting............................................................................................................................................... 92
10.3.1 Notes................................................................................................................................................. 92
10.3.2 Mechanical Data................................................................................................................................ 94
Dimensions HLC01.1C................................................................................................................... 94
Dimensions HLC01.1D................................................................................................................... 95
Weight............................................................................................................................................ 95
10.4 Installation............................................................................................................................................. 96
10.4.1 Electrical Data................................................................................................................................... 96
10.4.2 Connection Points............................................................................................................................. 96
General Information........................................................................................................................ 96
Overview......................................................................................................................................... 97
X1, Module Bus.............................................................................................................................. 98
Control Voltage (+24 V, 0 V)........................................................................................................... 98
L+ L-, DC Bus Connection.............................................................................................................. 99
Connection of Equipment Grounding Conductor.......................................................................... 100
Ground Connection...................................................................................................................... 102
10.4.3 Touch Guard at Devices.................................................................................................................. 103
Cutouts......................................................................................................................................... 103
Mounting....................................................................................................................................... 104
11 HLB01.1C and HLB01.1D - DC Bus Resistor Unit..................................................... 105

11.1 Description.......................................................................................................................................... 105
11.2 Identification........................................................................................................................................ 105
11.3 Mounting HLB01.1.............................................................................................................................. 106
11.3.1 Mechanical Data HLB01.1............................................................................................................... 106
Dimensions HLB01.1C................................................................................................................. 106
Dimensions HLB01.1D................................................................................................................. 107
Weight.......................................................................................................................................... 108
11.4 Installation HLB01.1............................................................................................................................ 108
11.4.1 Electrical Data HLB01.1.................................................................................................................. 108
11.4.2 Connection Points........................................................................................................................... 109
Overview HLB01.1C..................................................................................................................... 109
Overview HLB01.1D..................................................................................................................... 110
L+ L-, DC Bus Connection............................................................................................................ 111
Connection of Equipment Grounding Conductor.......................................................................... 112
Ground Connection...................................................................................................................... 114
X13 at HLB01, Control Voltage.................................................................................................... 115
Control Voltage HLB01.1D........................................................................................................... 115
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and Controls
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X1, Module Bus............................................................................................................................ 116
X31 at HLB01, Ready for Operation and Prewarning Contact..................................................... 117
X32 at HLB01, DC Bus Short Circuit Control, Clear Errors, Braking Resistor Threshold............. 118
X2, Serial Interface (RS232)......................................................................................................... 119
X2, RS232 Interface..................................................................................................................... 121
11.4.3 Touch Guard at Devices.................................................................................................................. 121
Cutouts......................................................................................................................................... 121
Mounting....................................................................................................................................... 123
11.5 Commissioning, Operation, Diagnoses.............................................................................................. 123
12 HLR01 - Braking Resistors........................................................................................ 127

12.1 Braking Resistor HLR01..................................................................................................................... 127
12.2 Type Code and Identification.............................................................................................................. 127
12.2.1 Type Code....................................................................................................................................... 127
12.2.2 Identification.................................................................................................................................... 128
12.3 Scope of Supply.................................................................................................................................. 129
12.4 Technical Data.................................................................................................................................... 129
12.4.1 Technical Data HLR01 for HCS02.1................................................................................................ 129
Assignment HLR01 to HCS02.1E................................................................................................. 129
HLR01 for HCS02.1E-W0054....................................................................................................... 130
HLR01 for HCS02.1E-W0070....................................................................................................... 131
12.4.2 Technical Data HLR01 for HCS03.1E............................................................................................. 132
Assignment HLR01 to HCS03.1E................................................................................................. 132
HLR01 for HCS03.1E-W0070....................................................................................................... 133
HLR01 for HCS03.1E-W0100....................................................................................................... 135
HLR01 for HCS03.1E-W0150....................................................................................................... 136
HLR01 for HCS03.1E-W0210....................................................................................................... 137
12.5 Installation and Mounting.................................................................................................................... 138
12.5.1 Notes on Installation and Mounting................................................................................................. 138
12.5.2 Braking Resistors HLR01.1, Type of Construction A (Version for Device Mounting)...................... 140
General Information...................................................................................................................... 140
HCS03.1E-W0070-xNBV With HLR01.1N-0300-N17R-A-007-NNNN.......................................... 141
HCS03.1E-W0100-xNBV With HLR01.1N‑0470‑N11R7‑A‑007‑NNNN........................................ 143
HCS03.1E-W0150-xNBV With HLR01.1N‑0780‑N07R7‑A‑007‑NNNN........................................ 145
HCS03.1E-W0210-xNBV With HLR01.1N‑1K08‑N05R0‑A‑007‑NNNN....................................... 147
12.5.3 Braking Resistors HLR01.1, Type of Construction N (Version for Free Assembly)......................... 149
Fixed Resistor IP 20 Type A......................................................................................................... 149
Steel-Grid Fixed Resistor IP 20 Type B........................................................................................ 150
Steel-Grid Fixed Resistor IP 20 Type C....................................................................................... 151
13 HMF01.1 - Motor Filter............................................................................................... 153

13.1 Type Code.......................................................................................................................................... 153
13.2 Type Plate........................................................................................................................................... 153
13.3 Electrical Data..................................................................................................................................... 154
13.4 Mechanical Data................................................................................................................................. 155
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13.4.1 Dimensions, Mass........................................................................................................................... 155
13.5 Arrangement of the Components HCS03.1 / Motor Filter HMF.......................................................... 159
13.6 Arrangement of the Components HCS03.1 / Motor Filter and Mains Filter........................................ 161
14 HAC01 - Housing for Control Sections...................................................................... 165

14.1 Identification........................................................................................................................................ 165
14.1.1 Type Code HAC01.1....................................................................................................................... 165
14.1.2 Type Plate HAC01........................................................................................................................... 165
14.2 Usage................................................................................................................................................. 166
14.3 Mechanical and Electrical Data.......................................................................................................... 167
14.3.1 Dimensional Drawings HAC01.1..................................................................................................... 167
HAC01.1-001-NNN-NN................................................................................................................ 167
HAC01.1-002-NNN-NN................................................................................................................ 168
14.3.2 Connections at HAC01.................................................................................................................... 168
X13, Control Voltage.................................................................................................................... 168
15 HAT01 - Control Module for Holding Brake............................................................... 171

15.1 Brief Description, Usage and Design.................................................................................................. 171
15.2 Type Code and Identification.............................................................................................................. 171
15.2.1 Type Code....................................................................................................................................... 171
15.2.2 Identification.................................................................................................................................... 172
15.3 Scope of Supply.................................................................................................................................. 172
15.4 Dimensions......................................................................................................................................... 173
15.5 Technical Data.................................................................................................................................... 173
15.6 Connection Points............................................................................................................................... 176
15.6.1 Front View....................................................................................................................................... 176
15.6.2 X1, 24 V Power Supply.................................................................................................................... 176
15.6.3 X2, Output to Brake......................................................................................................................... 177
15.6.4 X3, Signal Exchange With Control Section..................................................................................... 177
16 Accessories................................................................................................................ 179
16.1 HAS01, Basic Accessories................................................................................................................. 179
16.1.1 Type Code....................................................................................................................................... 179
16.1.2 Brief Description.............................................................................................................................. 179
16.1.3 Usage.............................................................................................................................................. 180
16.1.4 Assignment...................................................................................................................................... 180
16.1.5 Scope of Supply.............................................................................................................................. 182
16.1.6 Mounting the Parts "Bar" and "End Piece" of the Accessories HAS01............................................ 207
16.2 HAS02, Shield Connection................................................................................................................. 207
16.2.1 General Information......................................................................................................................... 207
16.2.2 Type Code....................................................................................................................................... 208
16.2.3 Usage.............................................................................................................................................. 208
16.2.4 Assignment of Accessory HAS02.................................................................................................... 208
16.2.5 Scope of Supply.............................................................................................................................. 209
16.2.6 Mounting the HAS02 Accessories................................................................................................... 224
Project Planning Manual | Rexroth IndraDrive Electric Drives | Bosch Rexroth AG VII/IX
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HAS02.1-001 at HMS01.1N-W0054............................................................................................. 225
HAS02.1-002 at HCS02.1E-W0054............................................................................................. 226
HAS02.1-003 at HMS01.1N-W0210............................................................................................. 227
HAS02.1-004 at HCS03.1E-W0070............................................................................................. 228
HAS02.1-005 at HCS03.1E-W0100 / 150.................................................................................... 229
HAS02.1-008 at HCS03.1E-W0210............................................................................................. 230
HAS02.1-010 at HMS02.1N‑W0028 / 54...................................................................................... 230
HAS02.1-014 at HMS01.1N-W0350............................................................................................. 231
16.2.7 Shield Connection of the Motor Cable via Mains Filter ................................................................... 231
HAS02.1-006 With Motor Cable and Mains Filter......................................................................... 232
HAS02.1-007 With Power Supply Cable and Mains Filter............................................................ 233
HAS02.1-009 With Power Supply Cable and Mains Filter............................................................ 234
16.3 HAS03, Control Cabinet Adapter........................................................................................................ 235
16.3.1 Type Code....................................................................................................................................... 235
16.3.2 Usage.............................................................................................................................................. 235
16.3.3 Assignment of Accessory HAS03.................................................................................................... 236
16.3.4 Scope of Supply.............................................................................................................................. 236
16.4 HAS04, Capacitor............................................................................................................................... 239
16.4.1 General Information......................................................................................................................... 239
16.4.2 Type Code....................................................................................................................................... 239
16.4.3 Usage.............................................................................................................................................. 239
16.4.4 Assignment...................................................................................................................................... 240
16.4.5 Scope of Supply.............................................................................................................................. 240
16.4.6 Capacitor......................................................................................................................................... 243
16.4.7 Mounting Dimensions...................................................................................................................... 243
16.4.8 Mounting the HAS04.1-001 Accessories......................................................................................... 244
16.4.9 Mounting the HAS04.1-002 Accessories......................................................................................... 245
16.5 HAS05, Accessories for Connection Points........................................................................................ 247
16.5.1 Overview of Types........................................................................................................................... 247
16.5.2 Type Code....................................................................................................................................... 248
16.5.3 HAS05.1-001, Adapter for Mains and Motor Connection................................................................ 249
Brief Description and Usage......................................................................................................... 249
Technical Data.............................................................................................................................. 250
16.5.4 HAS05.1-002, Extension................................................................................................................. 251
16.5.5 HAS05.1-003, Signal Level Converter Encoder Emulation............................................................. 252
Usage........................................................................................................................................... 252
Scope of Supply........................................................................................................................... 252
Dimensions................................................................................................................................... 252
Parts............................................................................................................................................. 253
16.5.6 HAS05.1-004, Adapter DC Bus Connection.................................................................................... 255
Technical Data.............................................................................................................................. 259
How to Mount HAS05.1-004......................................................................................................... 260
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16.5.7 HAS05.1-005, Signal Level Converter RS232/RS485..................................................................... 264
Usage........................................................................................................................................... 264
Scope of Supply........................................................................................................................... 264
Technical Data.............................................................................................................................. 265
Installation.................................................................................................................................... 267
16.5.8 HAS05.1-006, Adapter for Controlling Motor Holding Brake........................................................... 269
Usage........................................................................................................................................... 269
Technical Data.............................................................................................................................. 270
Usage........................................................................................................................................... 272
Mounting....................................................................................................................................... 273
16.5.9 HAS05.1-007, Adapter From D-Sub to Terminal Connector........................................................... 274
Usage........................................................................................................................................... 274
Technical Data.............................................................................................................................. 276
16.5.10 HAS05.1-008, Adapter for Connecting two Cables......................................................................... 281
Usage........................................................................................................................................... 281
Mounting....................................................................................................................................... 283
16.6 Fiber Optic Cable Connections........................................................................................................... 284
16.6.1 Overview of Types........................................................................................................................... 284
16.6.2 Interconnection of Drive Controllers................................................................................................ 285
Combination of HCS02 and HCS02............................................................................................. 285
Combination of HCS02 to the Right of HMS or HMD................................................................... 286
Combination of HCS02 to the Left of HMS or HMD..................................................................... 286
Combination of HCS03 to the Right of HMS or HMD................................................................... 287
Combination of HCS03 to the Left of HMS or HMD..................................................................... 287
16.7 RKB0001, Extension for Module Bus Connections............................................................................ 288
16.7.1 Usage.............................................................................................................................................. 288
16.7.2 Mounting.......................................................................................................................................... 289
17 Environmental Protection and Disposal..................................................................... 291

17.1 Environmental Protection.................................................................................................................... 291
17.1.1 Production Processes...................................................................................................................... 291
17.1.2 Prohibited Substances..................................................................................................................... 291
17.1.3 No Release of Hazardous Substances............................................................................................ 291
17.1.4 Principal Components..................................................................................................................... 291
17.2 Disposal.............................................................................................................................................. 291
17.2.1 Return of Products........................................................................................................................... 291
17.2.2 Packaging Materials........................................................................................................................ 291
17.2.3 Recycling......................................................................................................................................... 292
18 Service and Support.................................................................................................. 293

18.1 Helpdesk............................................................................................................................................. 293
18.2 Service Hotline.................................................................................................................................... 293
18.3 Addresses........................................................................................................................................... 293
18.4 Helpful Information.............................................................................................................................. 293
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19 Appendix.................................................................................................................... 295
19.1 Discharging of Capacitors................................................................................................................... 295
19.1.1 Discharging of DC Bus Capacitors.................................................................................................. 295
19.1.2 Discharging Device.......................................................................................................................... 295
Operating Principle....................................................................................................................... 295
Dimensioning................................................................................................................................ 296
How to Proceed for Discharging................................................................................................... 296
Index.......................................................................................................................... 297
and Controls
Project Planning Manual | Rexroth IndraDrive Electric Drives | Bosch Rexroth AG 1/300
and Controls
Introduction
1 Introduction
1.1 Documentation
1.1.1 General Information
This Documentation This documentation describes the following additional components and acces‐
sories for Rexroth IndraDrive systems:
● Transformers (DST)
● Mains filters (HNF, HNK, HNS, NFE, NFD)
● Mains chokes (HNL)
● DC bus chokes (HLL)
● DC bus capacitor units (HLC)
● DC bus resistor units (HLB)
● Braking resistors (HLR)
● Motor filters (HMF)
● Housing for control sections (HAC)
● Control module for holding brake (HAT)
● Accessories (HAS)
Personal injury and property damage caused by incorrect project plan‐

ning for applications, machines and installations!
Take the content of the following Project Planning Manual into account: "Re‐
WARNING xroth IndraDrive, Drive System" (DOK-INDRV*-SYSTEM*****-PRxx-EN-P; part
no: R911309636).
Documentation for Project Plan‐
ning of System
For complete project planning of a Rexroth IndraDrive system you need,
in any case, the documentation "Rexroth IndraDrive, Drive System" (Project
Planning Manual; DOK-INDRV*-SYSTEM*****-PRxx-EN-P; part no.:
R911309636). This documentation, among other things, contains:
● General specifications for the components of the drive system
● Configuration of the drive system components
● Arrangement of the components in the control cabinet
● Electromagnetic compatibility (EMC)
● Types of mains connection
● Requirements on the mains connection
● Control circuits for the mains connection
● Connections of the components in the drive system
● Fusing and selection of the mains contactor
● Calculations (determining appropriate drive controller; mains connection;
leakage capacitance; operating data of mains filters; selecting the 24V
supply; braking behavior when using a DC bus resistor unit)
2/300 Bosch Rexroth AG | Electric Drives Rexroth IndraDrive | Project Planning Manual
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Introduction
1.1.2 Changes
Changes in Comparison to Previ‐ Chapter Changes
ous Edition
Introduction Reference documentations updated
DC Bus Choke DC bus choke HLL included
Motor Filter Motor filter for HCS02 included:
● HMF01.1A-N0K2-M0012-A-500-NNNN
● HMF01.1A-N0K2-M0028-A-500-NNNN
Type code updated
Mains Filter Data updated
HNS02.1 (mains filter, with switch-disconnector): Descrip‐
tion of connection points updated
DC Bus Resistor Unit HLB01.1D, interface X32: Pin assignment updated
Accessories New chapter
Fig.1-1: Changes
1.1.3 Reference Documentations

Drive Systems, System Components
Title Kind of documentation Document typecode1) Part number
Rexroth IndraDrive … DOK-INDRV*-… R911…
Drive System Project Planning Manual SYSTEM*****-PRxx-EN-P 309636

Mi Drive Systems Project Planning Manual KCU+KSM****-PRxx-EN-P 320924
Supply Units and Power Sections Project Planning Manual HMV-S-D+HCS-PRxx-EN-P 318790
Drive Controllers Control Sections Project Planning Manual CSH********-PRxx-EN-P 295012
Additional Components and Accesso‐ Project Planning Manual ADDCOMP****-PRxx-EN-P 306140
ries
C Drive Controllers HCS02.1, Operating Instructions FU**********-IBxx-EN-P 314905
HCS03.1
1) In the document typecodes, "xx" is a wild card for the current edition of
the documentation (example: PR01 is the first edition of a Project Plan‐
ning Manual)
Fig.1-2: Documentations – overview
Motors
Rexroth IndraDyn … DOK-MOTOR*-… R911…
A Series Asynchronous Motors Project Planning Manual MAD/MAF****-PRxx-EN-P 295781

H Frameless Synchronous Spindle Project Planning Manual MBS-H******-PRxx-EN-P 297895
Motors
L Synchronous Linear Motors Project Planning Manual MLF********-PRxx-EN-P 293635
and Controls
Introduction

Rexroth IndraDyn … DOK-MOTOR*-… R911…
S Synchronous Motors Project Planning Manual MSK********-PRxx-EN-P 296289

T Synchronous Torque Motors Project Planning Manual MBT********-PRxx-EN-P 298798
the documentation (example: PR01 is the first edition of a Project Plan‐
ning Manual)
Cables
DOK-… R911…
Rexroth Connection Cables Selection Data CONNEC-CABLE*STAND-AUxx- 282688

EN-P
the documentation (example: AU03 is the third edition of the documen‐
tation "Selection Data")
Firmware
Rexroth IndraDrive … DOK-INDRV*-… R911…
Firmware for Drive Controllers Functional Description MP*-05VRS**-FKxx-EN-P 320182

Firmware for Drive Controllers Parameter Description GEN-**VRS**-PAxx-EN-P 297317
Firmware for Drive Controllers Troubleshooting Guide GEN-**VRS**-WAxx-EN-P 297319
Integrated Safety Technology Functional and Application SI*-**VRS**-FKxx-EN-P 297838
Description
Rexroth IndraMotion MLD Application Manual MLD-**VRS**-AWxx-EN-P 306084
Rexroth IndraMotion MLD Library Library Description MLD-SYSLIB*-FKxx-EN-P 309224
the documentation (example: PA02 is the second edition of a Parameter
Description)
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Important Directions for Use
2 Important Directions for Use

2.1 Appropriate Use
2.1.1 Introduction
Rexroth products represent state-of-the-art developments and manufacturing.
They are tested prior to delivery to ensure operating safety and reliability.
Personal injury and property damage caused by incorrect use of the

products!
The products have been designed for use in the industrial environment and may
WARNING only be used in the appropriate way. If they are not used in the appropriate way,
situations resulting in property damage and personal injury can occur.
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 forfei‐
ted. The user alone carries all responsibility of the risks.
Before using Rexroth products, make sure that all the pre-requisites for an ap‐
propriate 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 ap‐
propriate 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.
2.1.2 Areas of Use and Application

Drive controllers made by Rexroth are designed to control electrical motors and
monitor their operation.
Control and monitoring of the Drive controllers may require additional sensors
and actors.
The drive controllers may only used with the accessories and parts
specified in this documentation. If a component has not been spe‐
cifically named, then it may neither be mounted nor connected. The
same applies to cables and lines.
Operation is only permitted in the specified configurations and com‐
binations of components using the software and firmware as speci‐
fied in the relevant Functional Descriptions.
Drive controllers have to be programmed before commissioning, making it pos‐

sible for the motor to execute the specific functions of an application.
Drive controllers of the Rexroth IndraDrive line have been developed for use in
single- and multi-axis drive and control tasks.
To ensure application-specific use of Drive controllers, device types of different
drive power and different interfaces are available.
Typical applications include:
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Important Directions for Use
● handling and mounting systems,

● packaging and food machines,
● printing and paper processing machines and
● machine tools.
Drive controllers may only be operated under the assembly and installation
conditions described in this documentation, in the specified position of normal
use and under the ambient conditions as described (temperature, degree of
protection, humidity, EMC, etc.).
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 tem‐
peratures.
● Furthermore, 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!
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Safety Instructions for Electric Drives and Controls
3 Safety Instructions for Electric Drives and Controls

3.1 Safety Instructions - General Information
3.1.1 Using the Safety Instructions and Passing them on to Others
Do not attempt to install or commission this device without first reading all doc‐
umentation 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 im‐
mediately 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,
these safety instructions must be delivered with the device in the official lan‐
guage of the user's country.
Improper use of these devices, failure to follow the safety instructions in

this document or tampering with the product, including disabling of safe‐
ty devices, may result in material damage, bodily harm, electric shock
WARNING or even death!
Observe the safety instructions!
3.1.2 How to Employ the Safety Instructions

Read these instructions before initial commissioning of the equipment in order
to eliminate the risk of bodily harm and/or material damage. Follow these safety
instructions at all times.
● Bosch Rexroth AG is not liable for damages resulting from failure to ob‐
serve the warnings provided in this documentation.
● Read the operating, maintenance and safety instructions in your language
before commissioning 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 installa‐
tions:
– 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 assem‐
bly, installation and operation of the product, as well as an under‐
standing 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 safe‐
ty equipment and be trained in first aid.
● Only use spare parts and accessories approved by the manufacturer.
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● Follow all safety regulations and requirements for the specific application
as practiced in the country of use.
● The devices have been designed for installation in industrial machinery.
● The ambient conditions given in the product documentation must be ob‐
served.
● Only use safety-relevant applications that are clearly and explicitly ap‐
proved in the Project Planning Manual. If this is not the case, they are
excluded. Safety-relevant are all such applications which can cause dan‐
ger 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 applica‐
tions 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.
● Commissioning 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 appli‐
cation are met.
● The instructions for installation in accordance with EMC requirements can
be found in the section on EMC in the respective documentation (Project
Planning Manuals of components and system).
The machine or installation manufacturer is responsible for compliance
with the limiting values as prescribed in the national regulations.
● Technical data, connection and installation conditions are specified in the
product documentation and must be followed at all times.
National regulations which the user must take into account
● European countries: according to European EN standards
● United States of America (USA):
– National Electrical Code (NEC)
– National Electrical Manufacturers Association (NEMA), as well as
local engineering regulations
– regulations of the National Fire Protection Association (NFPA)
● Canada: Canadian Standards Association (CSA)
● Other countries:
– International Organization for Standardization (ISO)
– International Electrotechnical Commission (IEC)
3.1.3 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:
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Degree of hazard serious‐

Warning symbol Signal word ness acc. to ANSI Z
535.4-2002
Death or severe bodily harm

Danger
will occur.
Death or severe bodily harm

Warning
may occur.
Minor or moderate bodily

Caution harm or material damage
may occur.
Fig.3-1: Hazard classification (according to ANSI Z 535)
3.1.4 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 lines!
CAUTION
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Risk of injury by improper handling of batteries!

CAUTION
3.2 Instructions with Regard to Specific Dangers

3.2.1 Protection Against Contact with Electrical Parts and Housings
This section 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 unavoid‐
able 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 electrical equipment
DANGER are permitted to operate, maintain and repair this equipment.
● Follow general construction and safety regulations when working on pow‐
er installations.
● Before switching on the device, the equipment grounding conductor must
have been non-detachably connected to all electrical equipment in ac‐
cordance with the connection diagram.
● Do not operate electrical equipment at any time, even for brief measure‐
ments 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 electric 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. Do not remove or plug in connectors when the component
has been powered.
● 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.
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For electrical drive and filter components with voltages of more than
50 volts, observe the following additional safety instructions.
High housing voltage and high leakage current! Risk of death or bodily
injury by electric shock!
● Before switching on, the housings of all electrical equipment and motors
DANGER 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
devices 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 section of a minimum of
10 mm2 for this equipment grounding connection!
● Before commissioning, also in trial runs, always attach the equipment
grounding conductor or connect to the ground wire. Otherwise, high vol‐
tages may occur at the housing causing electric shock.
3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage

Protective extra-low voltage is used to allow connecting devices with basic in‐
sulation to extra-low voltage circuits.
All connections and terminals with voltages between 5 and 50 volts at Rexroth
products are PELV systems. 1) It is therefore allowed to connect devices
equipped with basic insulation (such as programming devices, PCs, notebooks,
display units) to these connections and terminals.
High electric voltage by incorrect connection! Risk of death or bodily

injury by electric shock!
If extra-low voltage circuits of devices containing voltages and circuits of more
WARNING than 50 volts (e.g. the mains connection) are connected to Rexroth products,
the connected extra-low voltage circuits must comply with the requirements for
PELV. 2)
3.2.3 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.
1) "Protective Extra-Low Voltage"

2) "Protective Extra-Low Voltage"
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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.
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Dangerous movements! Danger to life, risk of injury, severe bodily harm

or material damage!
● Ensure personal safety by means of qualified and tested higher-level
DANGER monitoring devices or measures integrated in the installation.
These measures 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 possi‐
ble 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 di‐
rectly 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 equip‐
ment near electronics circuits and supply leads. If the use of such devices
cannot be avoided, verify the system and the installation for possible mal‐
functions in all possible positions of normal use before initial startup. If
necessary, perform a special electromagnetic compatibility (EMC) test on
the installation.
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3.2.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐

ation 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!
● Persons with heart pacemakers and metal implants are not permitted to
WARNING 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 noise immunity of pres‐
ent 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. Oth‐
erwise health hazards may occur.
3.2.5 Protection Against Contact with Hot Parts

Hot surfaces at motor housings, on drive controllers or chokes! Danger
of injury! Danger of burns!
● Do not touch surfaces of device housings and chokes in the proximity of
CAUTION heat sources! Danger of burns!
● Do not touch housing surfaces of motors! Danger of burns!
● According to the 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 mi‐
nutes! 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.
3.2.6 Protection During Handling and Mounting

In unfavorable conditions, handling and mounting certain parts and compo‐
nents in an improper way can cause injuries.
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Risk of injury by improper handling! Bodily injury by bruising, shearing,

cutting, hitting!
● Observe the general construction and safety regulations on handling and
CAUTION mounting.
● Use suitable devices for mounting 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 gog‐
gles, safety shoes, safety gloves).
● Do not stand under hanging loads.
● Immediately clean up any spilled liquids because of the danger of skidding.
3.2.7 Battery Safety

Batteries consist of active chemicals enclosed in a solid housing. Therefore,
improper handling can cause injury or material damage.
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.
● When replacing the battery/batteries do not damage electrical parts in‐
stalled in the devices.
● Only use the battery types specified by the manufacturer.
Environmental protection and disposal! The batteries contained in

the product are considered dangerous goods during land, air, and
sea transport (risk of explosion) in the sense of the legal regulations.
Dispose of used batteries separate from other waste. Observe the
local regulations in the country of assembly.
3.2.8 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 par‐
tially supplied with externally fed, pressurized media, such as compressed air,
hydraulics oil, cooling liquids and cooling lubricating agents. Improper handling
of the connected supply systems, supply lines or connections can cause injuries
or material damage.
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Risk of injury by improper handling of pressurized lines!

● Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐
sion).
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.
Environmental protection and disposal! The agents used to operate

the product might not be economically friendly. Dispose of ecolog‐
ically harmful agents separately from other waste. Observe the local
regulations in the country of assembly.
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Brief Description, Usage
4 Brief Description, Usage

4.1 General Information
In terms of "Appropriate Use", cases of operation and applications not men‐
tioned in this chapter are not allowed.
4.2 Applications of the Drive System Rexroth IndraDrive

The digital, intelligent drive system Rexroth IndraDrive is the cost-efficient sol‐
ution with a high degree of functionality for single-axis and multi-axis drive and
control tasks.
The drive system Rexroth IndraDrive fulfills a large number of drive tasks in the
most varied applications.
Typical applications are the industrial sectors:
● printing and paper converting
● packaging and food
● mounting and handling
● wood machining
● machine tools
● metal forming
● general automation
For these applications there are different device types of graduated perform‐
ance.
4.3 Mains Transformers DST and DLT

DST and DLT transformers are used to transform mains voltages to the allowed
nominal voltages of the devices.
DLT transformers are used to
● prevent overvoltage between outer conductor and ground
● protect other loads against leakage currents
Type Usage
DST autotransformer Adjusting voltage range in grounded mains

DLT isolating transformer Adjusting voltage range in ungrounded mains
Fig.4-1: Usage of transformers
As a matter of principle, DLT isolating transformers have to be used

at ungrounded mains.
4.4 Mains Filters HNF, HNK, NFE, HNS02 and NFD

Mains filters reduce radio interference and mains pollution.
When using mains filters HNF01, NFD03, HNS02 and HNK01 at

mains grounded via outer conductor, use an isolating transformer
between mains and mains filter.
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Type Usage
NFE01.1 Interference suppression of power supply units up to 230 V

NFE02.1 Interference suppression of single-phase drive controllers up to 230 V
Interference suppression of three-phase drive controllers up to 480 V
NFD03.1 for 1–6 axes and motor cable lengths up to max. 75 m single-axis / 120
m multi-axis (HCS02.1E)
HNF01.1
for drive systems with a high number of axes and long motor cables
Interference suppression of three-phase drive controllers HCS03.1E up
HNK01.1
to 500 V
for drive systems with a maximum of 12 axes and a maximum of 200
HNS02 m motor cable length
Integrated switch-disconnector
Fig.4-2: Usage of mains filters
Only operate expressly allowed components at the mentioned

mains filters. Operating, for example, blowers, pumps etc. at HNF
mains filters is not allowed.
4.5 Mains Chokes HNL01 and HNL02

(Standard) mains chokes HNL01.1E, HNL01.1R and HNL02.1R
● reduce harmonics in the mains current
● increase the allowed DC bus continuous power of certain converters
● allow operating regenerative supply units at the mains
Current-compensated mains chokes HNL01.1E-****-S and HNL01.1R-****-S

reduce asymmetric currents (leakage currents) in the mains connection phase
of the drive system.
The different types may be used exclusively as follows:
Type Usage
For connection to components with regeneration to the supply

HNL01.1R
mains (HMV01.1R)
For connection to components without regeneration to the supply
HNL01.1E
mains (HMV01.1E, HCS02.1E, HCS03.1E)
Current-compensated chokes for use with HNL01.1 mains
chokes to reduce asymmetric currents (leakage currents) in the
HNL01.1*-****-S
mains connection phase of the drive system (HMV01.1E,
HMV01.1R, HCS02.1E, HCS03.1E)
Mains chokes in housing for control cabinet mounting for con‐
HNL02.1R nection to components with regeneration to the supply mains
(HMV02.1R)
Fig.4-3: Usage of mains chokes

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4.6 DC Bus Resistor Unit HLB01

DC bus resistor units HLB01
● convert generated kinetic energy into thermal energy
● increase the continuous regenerative power in the drive system
● increase the peak regenerative power in the drive system
● allow the DC bus short circuit function ("ZKS") in the drive system
Type Usage
In drive systems of the Rexroth IndraDrive C product range with a device

mounting depth of 265 mm.
HLB01.1C
See also Project Planning Manual "Rexroth IndraDrive, Drive System" →
"Configuration of the Drive System" → "Additional Components".
In drive systems of the Rexroth IndraDrive M product range with a device
mounting depth of 322 mm.
HLB01.1D
See also Project Planning Manual "Rexroth IndraDrive, Drive System" →
"Configuration of the Drive System" → "Additional Components".
Fig.4-4: DC bus resistor units HLB
4.7 Braking Resistor HLR01

HLR01.1N‑xxxx‑Nxxx‑A‑007‑NNNN braking resistors convert generated kinet‐
ic energy into thermal energy. For this purpose, the line covers a wide range of
continuous power and energy absorption capacity.
Type Usage
Type of construction A (version for device mounting): To be mounted to

HLR01.1A drive controllers of the Rexroth IndraDrive C product range. For this pur‐
pose, the drive controllers must be equipped with a brake chopper.
Type of construction N (version for free assembly): For free assembly in
the installation, operated by drive controller of the Rexroth IndraDrive C
HLR01.1N
product range. For this purpose, the drive controllers must be equipped
with a brake chopper.
Fig.4-5: Braking resistors HLR

Designs of type of construction N:
● Fixed resistor IP 20 type A
Cement-coated, wire-wound, tube-type fixed resistors; screwed on side
walls; perforated cover; connections in terminal box with PG gland
● Steel-grid fixed resistor IP 20 type B
Fixed resistor in steel-grid design; connection depending on type
● Steel-grid fixed Resistor IP 20 type C
Fixed resistor in steel-grid design; connection depending on type
4.8 DC Bus Capacitor Unit HLC01

DC bus capacitor units HLC01 store energy in the DC bus of the drive system.
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Type Usage
In drive systems of the product ranges Rexroth IndraDrive C and Rexroth

HLC01.1C
IndraDrive M
In drive systems of the product ranges Rexroth IndraDrive C and Rexroth
HLC01.1D
IndraDrive M
Fig.4-6: DC bus capacitor units HLC
4.9 Motor Filters HMF01

HMF01 motor filters
● reduce the rise of the output voltage of drive controllers
● reduce leakage currents of the motor lines
● reduce interference voltage on the motor lines
Type Usage
HMF01.1 At the motor output of HCS drive controllers
Fig.4-7: HMF01 motor filters
4.10 Housing for Control Sections HAC01

Additional components HAC01 are used to
● insert control sections in them
● supply control sections with 24V control voltage
Type Usage
HAC01.1-002-NNN-NN To insert CDB01 control sections in it
Fig.4-8: HAC01 type

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General Specifications of the Components
5 General Specifications of the Components

5.1 Certifications
Declaration of Conformity For the components, there are declarations of conformity available which con‐
firm that the components have been designed according to the valid EN
standards and EC directives. If required, our sales representative can provide
you with the declarations of conformity.
Description Standard
CE conformity regarding Low-Voltage Di‐ EN61800-5-1 (IEC 61800-5-1:2003)

rective
CE conformity regarding EMC product EN61800-3 (IEC 61800-3:2004)
standard
Fig.5-1: Applied standards

CE Label
Fig.5-2: CE label
C-UL-US Listing The components are labeled:
Fig.5-3: C-UL-US label

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Description Standard
Listing according to UL
UL 508 C
standard (UL)
Listing according to CSA Canadian National Standard C22.2 No. 14-05
standard
UL files (UL) Company Name:
BOSCH REXROTH ELECTRIC DRIVES & CON‐
TROLS GMBH
Category Name:
Power Conversion Equipment
UL ratings
For using the component in the scope of CSA / UL, take the UL
ratings of the individual components into account.
See documentation of the respective component.

In the scope of CSA / UL, it is exclusively the following components
which have been approved to supply the IndraDrive components
HMS, HMD, KCU, KSM:
● HMV01.1E
● HMV01.1R
● HMV02.1R
● HCS02.1E
● HCS03.1E
Make sure that the indicated short circuit current rating SCCR is not
exceeded, e.g. by appropriate fuses in the mains supply of the sup‐
ply unit.
Wiring material UL
In the scope of CSA / UL, use copper 60/75 °C only; class 1 or
equivalent only.
Allowed pollution degree

Comply with the allowed pollution degree of the components (see
chapter "Ambient and Operating Conditions").
UL file number
The components are listed by UL ("Underwriters Laboratories
Inc.®"). You can find the evidence of certification on the internet
under http://www.ul.com under "Certifications" by entering the file
number or the "Company Name: Rexroth".
File numbers of the IndraDrive components:
● E134201
● E227957
The control sections are part of the listed components.
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CCC (China Compulsory Certifica‐ The CCC test symbol comprises a compulsory certification of safety and quality
tion) for certain products mentioned in the product catalog "First Catalogue of Prod‐
ucts Subject to Compulsory Certification" and in the CNCA document "Appli‐
cation Scope for Compulsory Certification of Products acc. first Catalogue" and
put in circulation in China. This compulsory certification has been existing since
2003.
CNCA is the Chinese authority responsible for certification directives. When a
product is imported in China, the certification will be checked at the customs by
means of entries in a database. For the requirement of certification three criteria
are normally relevant:
1. Customs tariff number (HS code) according to CNCA document "Appli‐
cation Scope for Compulsory Certification of Products acc. first Cata‐
logue".
2. Scope of application according to CNCA document "Application Scope for
Compulsory Certification of Products acc. first Catalogue".
3. For the IEC product standard used, the corresponding Chinese GB stand‐
ard must exist.
For the Rexroth drive components described in this documentation, certification
is not required at present, thus they are not CCC certified. Negative certifica‐
tions will not be issued.
5.2 Transport and Storage

5.2.1 Transport of the Components
Ambient and operating conditions - Transport
Description Symbol Unit Value
Temperature range Ta_tran °C -25 … 70
Relative humidity % 5 … 95
Absolute humidity g/m3 1 … 60
Climatic category (IEC721) 2K3
Moisture condensation Not allowed
Icing Not allowed
Fig.5-5: Ambient and operating conditions - Transport
5.2.2 Storage of the Components

Damage to the component caused by long storage periods!
Some components contain electrolytic capacitors which may deteriorate during
storage.
CAUTION When storing these components for a longer period of time, operate them once
a year for at least 1 hour:
● HCS and HMV: Operation with mains voltage ULN
● HMS, HMD, HLC: Operation with DC bus voltage UDC
and Controls
Ambient and operating conditions - Storage
Temperature range Ta_store °C -25 … 55
Moisture condensation Not allowed
Icing Not allowed
Fig.5-6: Ambient and operating conditions - Storage
5.3 Installation Conditions

5.3.1 Ambient and Operating Conditions
The supply units and drive controllers, as well as their additional components,
are designed for control cabinet mounting.
Check that the ambient conditions, in particular the control cabinet

temperature, are complied with by calculating the heat levels in the
control cabinet. Afterwards, make the corresponding measure‐
ments to find out that the ambient conditions have actually been
complied with.
In the Technical Data of the individual components, the power dis‐
sipation is indicated as an important input value for calculating the
heat levels.
Distributed servo drives KSM are designed for use near to the machines and
are not installed in control cabinets.
Ambient and operating conditions
Description Symbol Unit Value Value

(supply units, (distributed servo
drive controllers) drives KSM)
Degree of protection (IEC529) IP20 IP65

Use in the scope of CSA / UL For use in NFPA-79 Applications only.
Temperature during storage See chapter "Storage of the Components"
Temperature during transport See chapter "Transport of the Components"
Allowed mounting position G1 IM B5
Definition of mounting positions: See chapter IM V1

5.3.2 Mounting Position, page 25 IM V3
Allowed ambient temperature range Ta_work °C 0 … 40
Allowed ambient temperature range during oper‐ Ta_work_red °C 0 … 55

ation with reduced nominal data1) See figure "Capacity utilization at higher ambient
temperature" in chapter "Capacity Utilization"
Derating at Ta_work < Ta < Ta_work_red2) fTa %/K See Technical Data of the individual components
and Controls
Description Symbol Unit Value Value

(supply units, (distributed servo
drive controllers) drives KSM)
Nominal data up to installation altitude hnenn m 1000
Maximum installation altitude without additional hmax_ohne m 2000

overvoltage limiter
Maximum installation altitude3) hmax m 4000
See figure "Capacity utilization at higher installa‐
tion altitude" in chapter "Capacity Utilization"
Reduced power data above installation altitude at hred m 1000
Ta < Ta_work_red4)
Allowed pollution degree (EN50178) 2 3 (only with connectors
plugged in)
Allowed dust, steam EN50178 tab. A.2 According to degree of
protection
Vibration sine: amplitude (peak-peak) at 10 … 57 mm 0,15 ±15 % -
Hz5)
Vibration sine: acceleration at 57 … 150 Hz5) g 1 ±15 % -
Vibration noise (random) frequency5) Hz 20 … 150 -

Vibration noise (random) spectral acceleration g2/Hz 0,005 ±3 dB -
density, amplitude5)
Vibration noise (random) rms value of total ac‐ g 1 -
celeration5)
Shock test out of operation (EN60068-2-27), g 10 -
11 ms
Shock test half sine: out of operation (6 ms) 7) g - 15
Vibration sine: acceleration at 10 … 2000 Hz 6), g - 1

axial
Vibration sine: acceleration at 10 … 2000 Hz 6), g - 1
radial
1) Observe derating
2) Data to be derated: PDC_cont; PBD; Iout_cont
3) In the installation, install overvoltage limiter for transient overvoltages to
limit the voltage to 1 kV between the outer conductors and to 2.5 kV
between conductor-ground
4) See following characteristic; observe derating
5) According to EN 60068-2-36
Fig.5-7: Ambient and operating conditions
5.3.2 Mounting Position

Only operate the components in allowed mounting positions.
and Controls
Definition of Mounting Positions for As a matter of principle, only the mounting position G1 is allowed for drive con‐
Drive Controllers trollers.
a Mounting surface
g Direction of gravitational force
G1 Normal mounting position. The natural convection supports the forced
cooling air current. This avoids the generation of pockets of heat in the
component.
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
Fig.5-8: Definition of mounting positions
Definition of Mounting Positions Distributed servo drives KSM can be supplied in type of construction B05. The
KSM allowed types of installation according to EN 60034-7:1993 are contained in the
following table.
and Controls
Type of con‐ Allowed types of installation

struction of
motor Description Drawing Installation
Flange mounting on
IM B5
drive side of flange
Flange mounting on
IM V1 drive side of flange, drive
B05 side bottom
Flange mounting on
IM V3 drive side of flange, drive
side top
Fig.5-9: Mounting positions
Motor damage caused by penetration of fluids!

If motors are attached according to IM V3, fluid present at the output shaft over
a prolonged time may enter into and cause damage to the motors.
CAUTION ⇒ Ensure that fluid cannot be present at the output shaft.
5.3.3 Compatibility With Foreign Matters

All Rexroth controls and drives are developed and tested according to the state-
of-the-art technology.
As it is impossible to follow the continuing development of all materials (e.g.
lubricants in machine tools) which may interact with 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
materials.
5.3.4 Prime Coat and Housing Varnish

The housing varnish of the KSM01 consists of black (RAL9005) 2K epoxy resin
coating on the basis of epoxy polyamide resin in water.
Chemically resistant to In restricted form resistant Nonresistant to

to
● Diluted acids/lyes ● Organic solvents ● Concentrated acids/

● Water, sea water, ● Hydraulic oil lyes
waste water
● Common mineral oils
Fig.5-10: Varnish resistance

and Controls
It is permitted to provide the housing with additional varnish with a maximum

coat thickness of 40 µm. Before varnishing, verify the adhesion and resistance
of the new varnish.
5.4 Capacity Utilization

Where installation conditions differ, the following performance data are reduced
in accordance with the diagrams:
Drive controller:
● Allowed DC bus continuous power PDC_cont
● Braking resistor continuous power PBD
● Continuous current Iout_cont
Motor:
● Power
● Continuous torque at standstill
● S1 continuous torques
● Short-time service torque MKB
If differing ambient temperatures and higher installation altitudes occur simul‐
taneously, 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.
Use outside of the indicated installation conditions is not allowed,

even if the performance data are additionally reduced.
Capacity Utilization vs. Ambient As the ambient temperature increases, the capacity utilization of the devices is
Temperature reduced according to the figure below.
fTa Capacity utilization factor

Ta work Ambient temperature range for operation with nominal data
Ta work red Ambient temperature range for operation with reduced nominal data
Fig.5-11: Capacity utilization at higher ambient temperature
Capacity Utilization vs. Installation As the installation altitude increases, the capacity utilization of the devices is
Altitude reduced according to the figure below.
and Controls
f Capacity utilization factor

hnenn Maximum installation altitude for operation with nominal data
hmax_ohne Maximum installation altitude for operation with reduced nominal data
without using an overvoltage limiter
hmax Maximum installation altitude for operation with reduced nominal data
when using an overvoltage limiter
Fig.5-12: Capacity utilization at higher installation altitude
5.5 Voltage Test and Insulation Resistance Test

According to standard, the components of the Rexroth IndraDrive range are
tested with voltage.
Test Test rate
Voltage test 100% (EN61800-5-1)

Insulation resistance test 100% (EN50178)
Voltage test of the installation

Disconnect all connections to the components or disconnect the
plug-in connections to protect the electronic components, before
making
● a voltage test or
● an insulation resistance test for the installation in which the
components are used.
and Controls
5.6 Control Voltage Specification (24V Supply)

PELV for 24V power supply unit
For the 24V supply of the devices of the Rexroth IndraDrive range,
use a power supply unit or a control-power transformer with pro‐
tection by PELV 1) according to IEC 60204-1 (section 6.4).
In the scope of CSA/UL, the data of the control-power transformer
are limited to:
● Max. output voltage: 42.4 Vpeak or 30 Vac
● Max. output power: 10000 VA
The data in the table below generally apply to the 24V supply of the devices of
the Rexroth IndraDrive range. For other data, such as power consumption and
inrush currents, see the technical data of the respective device.
The specified values apply at the connections (+24V, 0V) to the "24V supply"
of the devices!
Control voltage for drive systems without UN3 V 19,2 … 28,8 (24 ±20%)
operation of motor holding brakes in Re‐ When using supply units HMV01.1E, HMV01.1R,
xroth motors HMV02.1R, HLB01.1D:
22,8 … 27,3 (24 ‑5%, 26 +5%)
Control voltage for drive systems with op‐ UN3 V Depending on the motor cable length, the control volt‐
eration of motor holding brakes in Rexroth age must be within the following voltage ranges:
motors ● Motor cable length < 50 m: 22,8 … 25,2 (24 ±5%)
● Motor cable length > 50 m: 24,7 … 27,3 (26 ±5%)
Take the data of the corresponding motor holding brake
into account.
External control voltage at devices of de‐ UN3 V 26 … 28,8
sign "NNNV" The output voltage of the internal switching power sup‐
(see type code HCS02, HCS03; other de‐ ply unit is 24 ±10% (see control voltage block diagram
sign: "int. SMPS").
DC 24 V power supply from the DC bus and
external)
Max. ripple content w - The amplitudes of the alternating component on UN3
must be within the specified voltage range.
Maximum allowed overvoltage UN3max V 33 (max. 1 ms)
Fig.5-14: Control voltage
1) Protective Extra-Low Voltage

and Controls
Overvoltage
Overvoltage greater than 33 V has to be discharged by means of
the appropriate electrical equipment of the machine or installation.
This includes:
● 24V power supply units that reduce incoming overvoltage to
the allowed value.
● Overvoltage limiters at the control cabinet input that limit ex‐
isting overvoltage to the allowed value. This, too, applies to
long 24V lines that have been run in parallel to power cables
and mains cables and can absorb overvoltage by inductive or
capacitive coupling.
Power supply units with buffer (UPS)

For HMV supply units, use 24 V supplies with buffer times of at least
100 ms (e.g. UPS), if commutation drops and short-time interrup‐
tions in the application exceed the specified values.
For the 24V supply, also take the following chapter into account:
"Project Planning of Mains Connection" in the Project Planning
Manual "Rexroth IndraDrive, Drive System".
Insulation monitoring impossible

The input 0 V is connected in conductive form with the housing po‐
tential. Insulation monitoring at +24 V and 0 V against housing is
impossible.
Control Voltage Block Diagram The control voltage, which is supplied via the connection for 24V supply, takes
HCS, HMS, HMD effect according to the following block diagram.
BR circuit for brake control

LT power section, e.g. HCS02
ST control section, e.g CSB01
ZK DC bus
int. SMPS internal switching power supply unit, for types HCS0x.1E-Wxxxx-NxxV
Fig.5-15: Block diagram of internal control voltage
and Controls
and Controls
Transformers
6 Transformers
6.1 General Information
Transformers are only needed if the mains voltage is outside of the allowed
nominal voltage of the drive controller.
Grounded Mains For grounded mains, the mains voltage is adjusted to the nominal voltage of
the device by means of autotransformers which have been dimensioned for a
specific output voltage range.
Ungrounded Mains For voltage adjustment of ungrounded mains, always connect isolating trans‐
formers to prevent overvoltages between outer conductor and ground.
and Controls
Transformers
6.2 Autotransformers for Drive Controllers

6.2.1 Types
Fig.6-1: Type code DST

and Controls
Transformers
6.2.2 Selection
Select the autotransformer according to the mains voltage and the power re‐
quirements of the installation. For the selection, proceed as follows:
1. By means of the required nominal mains voltage range from the diagram
"Classification of the three-phase current autotransformers in type
groups", determine the type group and read the transformation ratio "i".
2. Calculate the actual transformer output voltage by means of the given
nominal mains voltage and the transformation ratio "i".
3. Check the drive data. The output voltage of the transformer has an effect
on the drive data.
4. Select the three-phase current autotransformer for the determined mains
connected load SLN.
Determining the mains connected load: See Project Planning Manual
"Rexroth IndraDrive, Drive System" → "Calculations" → "Calculations for
the Mains Connection" → "Calculating the Mains-Side Phase Current"
The nominal power of the transformer must at least equal the mains con‐
nected load SLN.
For DST transformers, the nominal power is identical to the throughput
rating.
Fig.6-2: Classification of the three-phase current autotransformers in type

groups
and Controls
Transformers
6.2.3 Technical Data
Fig.6-3: DST autotransformers for drive controllers for mains voltage adjustment
and Controls
Mains Filter
7 Mains Filter
7.1 Mains Filters NFD / NFE
7.1.1 Type Code NFE / NFD
NFE01.1 - Mains Filter, Single-Phase
Fig.7-1: Type code NFE01.1

and Controls
Mains Filter
NFE02.1 - Mains Filter, Single-Phase
Fig.7-2: Type code NFE02.1

and Controls
Mains Filter
NFD03.1 - Mains Filter, 3-Phase
Fig.7-3: Type code NFD03.1

and Controls
Mains Filter
7.1.2 Mechanical Data NFE / NFD

NFE01.1
Fig.7-4: Single-phase filter NFE01.1-250-006 for interference suppression of the

power supply unit NTM
The mains filter is connected by means of tab receptacles

(b = 6.3 mm, d = 1 mm).
NFE02.1
Type NFE02.1-230-008 (with 3 terminal connectors)

Fig.7-5: Single-phase filter NFE02.1 for drives
and Controls
Mains Filter
NFD03.1
Fig.7-6: Three-phase current filter NFD03.1 for drives

Tolerance limits for NFD03.1:
● The dimensions B, C, D, K are maximum values. They can be reduced up
to 15 mm.
● The ground studs M can also be arranged horizontally (protruding from
the mounting flange), instead of vertically (as illustrated above).
Mains filter type A B C D E F G H J K L M MAE MAKl
NFD 03.1-480-007 190 90 50 160 180 20 5,4 – – 190 – M5 2,2 0,8

NFD 03.1-480-016 250 90 55 220 235 25 5,4 – – 250 – M5 2,2 0,8
NFD 03.1-480-030 270 100 60 240 255 30 5,4 – – 270 – M5 2,2 2
NFD 03.1-480-055 250 105 90 220 235 60 5,4 – – 260 – M6 4 2,2
and Controls
Mains Filter
Mains filter type A B C D E F G H J K L M MAE MAKl
NFD 03.1-480-075 270 145 90 240 255 60 6,5 – – 280 – M6 4 4,5

NFD 03.1-480-130 270 160 100 240 255 65 6,5 – – 330 – M10 18 8
NFD 03.1-480-180 380 180 130 350 365 102 6,5 – – 455 – M10 18 20
NFE 02.1-230-008 90 210 60 60 80 40 5,3 40 0,75 – 15 10 0,8 0,8
NFE 01.1-250-006 See drawing
MAE Maximum tightening torque of the ground stud in Nm
MAKl Maximum tightening torque of the terminal in Nm
Fig.7-7: Dimensions of the mains filters NFD/NFE
7.1.3 Electrical Data NFE / NFD

Using mains filters in mains grounded via outer conductor
When using mains filters NFD03 in mains grounded via outer con‐
ductor, use an isolating transformer between mains and mains filter.
Maximum mains con‐ Nominal Number Mains filter type Terminal connectors (3) Power Weig Type of
nection voltage of mains of pha‐ dissipa‐ ht construc‐
mains 50 … 60 Hz current ses tion ap‐ tion
UN Inenn (1) prox.
In V In A Flexible Rigid AWG W kg

[mm2] [mm2]
AC 480V +10% 7 3 NFD 4 (3) 6 (3) AWG 12 3,9 0,7 Vertical
03.1-480-007
AC 480V +10% 16 3 NFD 4 (3) 6 (3) AWG 12 6,4 1,0 Vertical
03.1-480-016
AC 480V +10% 30 3 NFD 10 16 AWG 6 11,9 1,4 Vertical
03.1-480-030
03.1-480-055
03.1-480-075
AC 480V +10% 130 3 NFD 50 50 AWG 38 4,7 Vertical
03.1-480-130 1/0
AC 480V +10% 180 3 NFD 95 95 AWG 61 10 Vertical
03.1-480-180 4/0
AC 230V +10% 7,5 1 NFE 4 (3) 6 (3) AWG 10 7,2 1,1 Vertical
02.1-230-008
AC 230 V +10% 4,7 1 NFE Tab connectors 6.3 × 0.8 mm 4 0,245 Horizontal
01.1-250-006 (2)
NFD Three-phase filter
NFE Single-phase filter
(1) Mains-side maximum continuous current at 45 °C ambient temperature
(2) Only use for interference suppression of the power supply unit NTM
(3) For the equipment grounding conductor, connect a conductor cross
section of 10 mm2 by means of terminal pin or ring cable lug
Fig.7-8: Technical data
and Controls
Mains Filter
Operating frequency From 0–60 Hz at 45 °C

Power dissipation Measured 2 or 3 × RI2 Nenn DC
Temperature range -25 … +85 °C

Overload 1.5 × INenn 1 minute per hour or 4 × INenn for 10 s
Effective attenuation Frequency range 0.15–30 MHz

Saturation behavior Reduction of filter attenuation by 6 dB at 2.5-fold to 3-fold
nominal current
Test voltage L/N → PE or L → PE: DC 2700 V, 2 s at 25 °C
L/ N → L: DC 2100 V, 2 s at 25 °C
Current reduction in See formula for reduction in chapter "Calculations"
the case of overtem‐
perature
Leakage current at Symmetrical three-phase operation: Typ. 30 mA
50 Hz Single-phase operation or in the case of tripped fuses of a
phase: Typ. 175 … 190 mA
Degree of protection IP 20, except for NFE01.1-250-006: IP 10
Fig.7-9: Technical data

and Controls
Mains Filter
7.2 HNF01.1 - Mains Filter, 3-Phase

7.2.1 Type Code HNF01.1
Fig.7-10: Type code

and Controls
Mains Filter
7.2.2 Mechanical Data HNF01.1

Dimensions
Mounting position and distances
Mount HNF01 in the control cabinet in normal mounting position G1
and allow cooling by natural convection. For this purpose, keep at
least 80 mm at the top side and bottom side of HNF free from
mounted parts.
Fig.7-11: Dimensions
and Controls
Mains Filter
Mains filter A B C D E F G H Max. al‐

[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] lowed
tightening
torque
[Nm]
HNF01.1A-F240-R0026-A‑480‑NNNN 480 262 100 440 - - 26 M6×20 8.6

HNF01.1A-F240-E0051-A‑480‑NNNN
480 262 100 440 - - 33 M6×16 2.3
HNF01.1A-M900-E0051-A‑480‑NNNN
HNF01.1A-M900-R0026-A‑480‑NNNN 480 262 150 440 - - 26 M6×20 8.6
HNF01.1A-F240-R0065-A‑480‑NNNN
480 262 150 440 40 110 40 M6×16 4.8
HNF01.1A-M900-R0065-A‑480‑NNNN
HNF01.1A-F240-R0094-A‑480‑NNNN
480 262 150 440 40 110 45 M10×30 25
HNF01.1A-M900-R0094-A‑480‑NNNN
HNF01.1A-F240-E0125-A‑480‑NNNN
480 262 150 440 40 110 45 M10×30 25
HNF01.1A-M900-E0125-A‑480‑NNNN
HNF01.1A-F240-E0202-A‑480‑NNNN 480 262 150 440 40 110 63.5 M10×30 25
HNF01.1A-M900-E0202-A‑480‑NNNN 480 262 250 440 40 110 63.5 M10×30 25
HNF01.1A-H350-R0180-A‑480-NNNN 480 262 250 440 40 110 67 M10×30 25
and Controls
Mains Filter
Drilling Pattern
Fig.7-13: Drilling pattern
Mains filter K [mm] L [mm] M [mm] N [mm] P [mm] R [mm]
HNF01.1A-F240-E0051-A‑480‑NNNN
50 466 25 7 13 6,5
HNF01.1A-M900-E0051-A‑480‑NNNN
HNF01.1A-F240-E0125-A‑480‑NNNN
125 466 12,5 7 13 6,5
HNF01.1A-M900-E0125-A‑480‑NNNN
HNF01.1A-F240-E0202-A‑480‑NNNN 125 466 12,5 7 13 6,5
HNF01.1A-M900-E0202-A‑480‑NNNN
150 466 50 7 13 6,5
HNF01.1A-H350-R0180-A‑480-NNNN
HNF01.1A-F240-R0026-A‑480‑NNNN 50 466 25 7 13 6,5
HNF01.1A-M900-R0026-A‑480‑NNNN 100 466 25 7 13 6,5
HNF01.1A-F240-R0065-A‑480‑NNNN
100 466 25 7 13 6,5
HNF01.1A-M900-R0065-A‑480‑NNNN
HNF01.1A-F240-R0094-A‑480‑NNNN
125 466 12,5 7 13 6,5
HNF01.1A-M900-R0094-A‑480‑NNNN
Fig.7-14: Drilling pattern

and Controls
Mains Filter
7.2.3 Electrical Data HNF01.1

Data HNF01.1A-xxxx-Rxxxx-A-480-NNNN for Infeeding Supply Systems
When using mains filters HNF01 in mains grounded via outer con‐
Technical data - Currents, voltages, power
HNF01.1 HNF01.1 HNF01.1 HNF01.1 HNF01.1 HNF01.1

A-F240- A-F240- A-F240- A-M900- A-M900- A-M900-
Description Symbol Unit E0051- E0125- E0202- E0051- E0125- E0202-
A-480- A-480- A-480- A-480- A-480- A-480-
NNNN NNNN NNNN NNNN NNNN NNNN
Degree of protection according to

IP20
IEC60529
Listing according to UL standard
UL1283
(UL)
Listing according to CSA standard
C22.2 No. 8
(UL)
Mass (weight) m kg 15,00 18,00 29,00 15,00 30,00 37,00
Mains voltage three-phase at TN-
ULN V 380...480
S, TN-C, TT mains
Mains voltage three-phase at Cor‐
ULN V Not allowed
ner-grounded-Delta mains1)
Mains voltage three-phase at IT
ULN V Not allowed
mains2)
Tolerance ULN (UL) % ±10
Input frequency (UL) fLN Hz 50...60
Tolerance input frequency (UL) Hz ±2
Nominal current IL_cont A 51,00 125,00 202,00 51,00 125,00 202,00
Maximum allowed peak current3) IL_max A 77,00 188,00 303,00 77,00 188,00 303,00
Power dissipation at continuous

current and continuous DC bus PDiss_cont W <89 <127 <373 <91 <174 <373
power respectively (UL)4)
Insulation resistance at DC 500 V Ris Mohm 1,18

and Controls
Mains Filter
HNF01.1 HNF01.1 HNF01.1 HNF01.1 HNF01.1 HNF01.1

A-F240- A-F240- A-F240- A-M900- A-M900- A-M900-
Description Symbol Unit E0051- E0125- E0202- E0051- E0125- E0202-
A-480- A-480- A-480- A-480- A-480- A-480-
Required wire size according to
ALN mm2 16 70 185 16 70 185
IEC 60364‑5‑52; at IL_cont5)
Required wire size according to UL

508 A (internal wiring); at IL_cont (UL) ALN AWG 6 1 4/0 6 1 4/0
6)
1) 2) Mains voltage > ULN: Use a transformer with grounded neutral point,
don´t use autotransformers!
3) With R-types: t = 0,3 s; T = 1,42 s; K = 2,5; with E-types: t = 0,3 s;
T = 0,67 s; K = 2,5
4) HMV, HCS: Plus dissipation of braking resistor, control section
5) Copper wire; PVC-insulation (conductor temperature 70 °C); installation
method B2; table B52-4; Ta ≤ 40 °C
6) Copper wire; PVC-insulation (conductor temperature 90 °C); table
13.5.1; Ta ≤ 40 °C
Fig.7-15: HNF - Technical data - Currents, voltages, power
Data HNF01.1A-xxxx-Rxxxx-A-480-NNNN for Regenerative Supply Systems
When using mains filters HNF01 in mains grounded via outer con‐
HNF01. HNF01. HNF01. HNF01. HNF01. HNF01. HNF01.

1A- 1A- 1A- 1A- 1A- 1A- 1A-
F240- F240- F240- H350- M900- M900- M900-
Description Symbol Unit
R0026- R0065- R0094- R0180- R0026- R0065- R0094-
A-480- A-480- A-480- A-480- A-480- A-480- A-480-
NNNN NNNN NNNN NNNN NNNN NNNN NNNN

IP20
IEC60529
UL1283 - UL1283
(UL)
C22.2 No. 8 - C22.2 No. 8
(UL)
Mass (weight) m kg 14,00 25,00 28,00 45,00 17,00 26,00 29,00
ULN V 380...480
S, TN-C, TT mains
ULN V Not allowed
ULN V Not allowed
mains2)

and Controls
Mains Filter
HNF01. HNF01. HNF01. HNF01. HNF01. HNF01. HNF01.

1A- 1A- 1A- 1A- 1A- 1A- 1A-
F240- F240- F240- H350- M900- M900- M900-
R0026- R0065- R0094- R0180- R0026- R0065- R0094-
A-480- A-480- A-480- A-480- A-480- A-480- A-480-
NNNN NNNN NNNN NNNN NNNN NNNN NNNN
Nominal current IL_cont A 26,00 65,00 94,00 180,00 26,00 65,00 94,00
Maximum allowed peak current3) IL_max A 65,00 163,00 235,00 270,00 65,00 163,00 235,00

current and continuous DC bus PDiss_cont W <73 <163 <135 305,00 77,00 157,00 146,00
Insulation resistance at DC 500 V Ris Mohm 0,17 1,18 1,33 0,17

ALN mm2 6 25 50 120 6 25 50
IEC 60364‑5‑52; at IL_cont5)

508 A (internal wiring); at IL_cont (UL) ALN AWG 10 6 3 4/0 10 6 3
6)
3) With R-types: t = 0,3 s; T = 1,42 s; K = 2,5; with E-types: t = 0,3 s;
T = 0,67 s; K = 2,5
13.5.1; Ta ≤ 40 °C
Fig.7-16: HNF - Technical data - Currents, voltages, power
and Controls
Mains Filter
7.3 HNK01.1 - Mains Filter, With Mains Choke

7.3.1 Type Code HNK01.1
Fig.7-17: Type code HNK01.1
7.3.2 Type Plate HNK01.1

Each mains filter is identified by a type designation. There is a type plate at‐
tached to all components.
and Controls
Mains Filter
1 Type designation
2 Part number
3 Serial number
4 Production date
Fig.7-18: Example of type plate HNK01.1
Position of type plate:
1) Type plate
Fig.7-19: Type plate arrangement
and Controls
Mains Filter
7.3.3 Mechanical Data HNK01.1

Dimensions
Fig.7-20: Dimensions mains filter HNK01.1A-A075-E0050

and Controls
Mains Filter
Fig.7-21: Dimensions mains filter HNK01.1A-A075-E0050 with HAS02

and Controls
Mains Filter
Fig.7-22: Dimensions mains filter HNK01.1A-A075-E0080/0106
Fig.7-23: Dimensions mains filter HNK01.1A-A075-E0080/0106 with HAS02

and Controls
Mains Filter
Fig.7-24: Dimensions mains filter HNK01.1A-A075-E0146
Fig.7-25: Dimensions mains filter HNK01.1A-A075-E0146 with HAS02

and Controls
Mains Filter
7.3.4 Electrical Data HNK01.1

Circuit Diagram
C1, C2, C3 Approx. 3.3 µF

C4 Approx. 0.5 µF
Fig.7-26: Block diagram HNK01
HNK01.1A- HNK01.1A- HNK01.1A- HNK01.1A-

Description Symbol Unit A075-E0050- A075-E0080- A075-E0106- A075-E0146-
A-500-NNNN A-500-NNNN A-500-NNNN A-500-NNNN

IP20
IEC60529
Listed as optional part of HCS03
(UL)
-
(UL)
Minimum distance on the bottom of
dbot mm 100
the device1)
Minimum distance on the top of the
dtop mm Mounted to HCS03
device2)
Mass (weight) m kg 15,00 20,00 28,00
ULN V 380...480
S, TN-C, TT mains
ULN V 380...480
ULN V 380...480
mains4)
Continuous current IL_cont A 50 80 106 146
Typical inductance per winding at

Ltyp µH 571 362 240 170
Icont
and Controls
Mains Filter
HNK01.1A- HNK01.1A- HNK01.1A- HNK01.1A-

Description Symbol Unit A075-E0050- A075-E0080- A075-E0106- A075-E0146-
A-500-NNNN A-500-NNNN A-500-NNNN A-500-NNNN
current and continuous DC bus PDiss_cont W 55 90 120 140
Insulation resistance at DC 500 V Ris Mohm >15

ALN mm2 16 35 50 95
IEC 60364‑5‑52; at IL_cont6)

508 A (internal wiring); at IL_cont (UL) ALN AWG 8 4 2 1/0
7)
1) 2) See fig. "Air intake and air outlet at drive controller"

13.5.1; Ta ≤ 40 °C
Fig.7-27: HNK - Technical data - Currents, voltages, power
7.3.5 Arrangement of the Components Drive Controller HCS03 and Mains

Filter HNK01
Lethal electric shock caused by live parts with more than 50 V!
Establish equipment grounding connection between mains filter HNK01 and
drive controller HCS03. Screw joint bars to guide bar.
DANGER
and Controls
Mains Filter
Put mains filter on guide bar. Ensure equipment grounding connection

by screwing the mounting link.
Fig.7-28: Arrangement of device HCS03.1E-…-W0070 and mains filter HNK01.-
*** -E0050
and Controls
Mains Filter
1) Put mains filter on guide bar

2) Ensure equipment grounding connection by screwing the mounting link
Fig.7-29: Arrangement of device HCS03.1E-…-W0100 / …-W0150 and mains fil‐
ter HNK01.-*** -E0080 / …-E0106
and Controls
Mains Filter
Put mains filter on guide bar. Ensure equipment grounding connection

by screwing the mounting link.
Fig.7-30: Arrangement of device HCS03.1E-…-W0210 and mains filter
HNK01.‑***‑E0146
and Controls
Mains Filter
7.4 HNS02.1 - Mains Filter, With Switch-Disconnector

7.4.1 Identification
Type Code
Fig.7-31: Type code

and Controls
Mains Filter
7.4.2 Mechanical Data HNS02.1

Dimensions
Mounting position and distances
Mount HNS02.1 in the control cabinet in normal mounting position
G1 and allow cooling by natural convection. Observe the minimum
mounting clearance of the device.
Data in mm
A) Minimum mounting clearance
B) Rear view!
Fig.7-32: Dimensions HNS02.1
and Controls
Mains Filter
7.4.3 Electrical Data HNS02.1

Description Symbol Value
Power dissipation W 75
Phase current (continuous current) A 23
Phase current (peak current 1)) A 55
Maximum leakage current at filter input (mains side) with
A 0,57
12 drive controllers and 200 m motor cable
Leakage current at filter output (load side) with 12 drive con‐
A 0,7
trollers and 200 m motor cable
Fig.7-33: Data
Description Symbol Value
Allowed THD (Total Harmonic Distortion) %
Reduction of allowed operating data due to harmonics com‐ See Project Planning Manual "Rexroth In‐
-
ponent draDrive, Drive System"
Connecting voltage V 3 × AC 380 … 480 ±10%, 50/60 Hz ±2%
Sum of leakage currents at filter input with supply unit switched
off: A < 0,8
1 phase failed A < 2,0
2 phases failed
Insulation resistance (phase – ground)
kOhm > 730
(discharging resistances of Y-capacitors)
Degree of protection - IP20
Weight kg 14,9
Materials - Free of asbestos and silicone
1) Duration: 300 ms
Duty cycle for infeeding devices: 0.67 s
Duty cycle for regenerative devices: 1.42 s
Basic load: 60% continuous current
Fig.7-34: Data
7.4.4 Connection Points

Before working on the wiring at filter, mains choke or supply unit:
1. Disconnect the device from the mains voltage
WARNING
2. Discharge the device-internal capacitors (short-circuit the power connec‐
tions at filter output or choke input)
and Controls
Mains Filter
View Description Significance
L1, L2, L3 Input for supply with mains voltage

F1, F2, F3 Fuses between mains input (L1, L2, L3) and mains output
(L1.1, L2.1, L3.1)
X41.1, X41.2 Converter (D-Sub ↔ terminal block)
X14 Output to load HMV02 (X14, mains voltage synchronization)
(L1.2, L2.2, L3.2)
F4 Fuses before output X14
Equipment grounding conductor
L1.1, L2.1, L3.1 Output to load HMV02 (X3, mains connection)
Fig.7-35: Connection points and fuses
L1, L2, L3 Unit Min. Max.
Connection cable flexi‐ mm2 4 25

ble
AWG 10 4
Connection cable rigid mm2 4 35
Tightening torque Nm - 4,5
Fig.7-36: Data - connection point L1, L2, L3
L1.1, L2.1, L3.1 Unit Min. Max.
Connection cable flexi‐ mm2 4 10

ble
AWG 10 6
Connection cable rigid mm2 4 16
Tightening torque Nm - 1,8
Fig.7-37: Data - connection point L1.1, L2.1, L3.1

and Controls
and Controls
HNL - Mains Chokes for Supply Units and Converters
8 HNL - Mains Chokes for Supply Units and Converters

8.1 Identification
8.1.1 Type Code
Fig.8-1: Type code

and Controls
8.1.2 Type Plate
1 Word mark
2 Business facility number
3 CE label
4 Type designation (two lines, 20 characters each)
5 Part number
6 Change release
7 Production date (YYWww)
8 Certification label
9 Nominal voltage / frequency
10 Nominal current
11 Number of design specification
12 Nominal inductance
13 Temperature
14 Number and value of additional capacitors
15 Designation of origin
16 Approval number
17 Bar code (39 or 93)
18 Serial number
19 Company address
Fig.8-2: Type plate
and Controls
8.2 HNL01.1E - Mains Chokes, Infeeding

Mechanical System and Mounting
Dimensions Type 1:
Fig.8-3: Dimensions type 1

Dimensions Type 2:

and Controls
Dimensions Type 3:

Dimensions Type 4:
Mains choke Typ Dimensions [mm] Weight

e [kg]
A B C D D1 E F 1) G H S
HNL01.1E-1000-N0012-A-500-NNNN 1 120 61 164 81 - 44 6,4 × 11 - - M5 2,7

HNL01.1E-1000-N0020-A-500-NNNN 1 150 66,5 184 113 - 49,5 6,4 × 11 - - M5 3,9
and Controls
Mains choke Typ Dimensions [mm] Weight

e [kg]
A B C D D1 E F 1) G H S
HNL01.1E-0600-N0032-A-500-NNNN 1 150 66,5 185 113 - 49,5 6,4 × 11 - - M5 4,5

HNL01.1E-0571-N0050-A-500-NNNN 4 153 100 238 127 - 80 8,5 × 12 400 30 - 13
HNL01.1E-0400-N0051-A-480-NNNN 1 180 112 225 125 80 87 7 × 15 - - M6 13,5
Ap‐
HNL01.1E-0362-N0080-A-500-NNNN 3 175 205 180 145 - 185 8,5 × 12 350 prox. M6 13
12
Ap‐
12
HNL01.1E-0200-N0125-A-480-NNNN 1 230 148 295 180 - 122 8 × 12 - - M8 24
Ap‐
12
HNL01.1E-0100-N0202-A-480-NNNN 1 265 152 350 215 - 126 15 × 11 - - M8 33
1) Long hole in "B" direction
Fig.8-7: Dimensions, weight
Mains choke Connection cross section Tightening torque

mm2 / AWG Nm
U1, V1, W1 U1, V1, W1
a, b a, b
U2, V2, W2 U2, V2, W2
HNL01.1E-1000-N0012-A-500-NNNN 4 4 Observe the data imprinted on the com‐

ponent.
HNL01.1E-1000-N0020-A-500-NNNN 6 4
HNL01.1E-0600-N0032-A-500-NNNN 10 4
HNL01.1E-0571-N0050-A-500-NNNN 16 / AWG 8 -
HNL01.1E-0400-N0051-A-480-NNNN 16 2,5
HNL01.1E-0362-N0080-A-500-NNNN 35 / AWG 6 -
HNL01.1E-0240-N0106-A-500-NNNN 35 / AWG 1/0 -
HNL01.1E-0200-N0125-A-480-NNNN 70 2,5
HNL01.1E-0170-N0146-A-500-NNNN 50 / AWG 1/0 -
HNL01.1E-0100-N0202-A-480-NNNN 150 2,5
Fig.8-8: Connection cross section, tightening torque

Basic Data
Mains choke UN IN LN PV Imax Lmin
[V] [A] [µH] [W] [A] At Imax
HNL01.1E-1000-N0012-A-500-NNNN 500 12 3 × 1000 40 25 50% of LN

HNL01.1E-1000-N0020-A-500-NNNN 500 20 3 × 1000 60 50 50% of LN
HNL01.1E-0600-N0032-A-500-NNNN 500 32 3 × 600 75 80 50% of LN
and Controls
Mains choke UN IN LN PV Imax Lmin

[V] [A] [µH] [W] [A] At Imax
HNL01.1E-0571-N0050-A-500-NNNN 500 50 3 × 571 50 100 50% of LN

HNL01.1E-0400-N0051-A-480-NNNN 480 51 3 × 400 165 77 50% of LN
HNL01.1E-0362-N0080-A-500-NNNN 500 80 3 × 362 80 160 50% of LN
HNL01.1E-0240-N0106-A-500-NNNN 500 106 3 × 240 100 212 50% of LN
HNL01.1E-0200-N0125-A-480-NNNN 480 125 3 × 200 170 188 50% of LN
HNL01.1E-0170-N0146-A-500-NNNN 500 146 3 × 170 130 292 50% of LN
HNL01.1E-0100-N0202-A-480-NNNN 480 202 3 × 100 200 303 50% of LN
Fig.8-9: Electrical data
Temperature Contact a, b
Switching capacity Switching temperature
1 A / AC 250 V 125 °C
DC 24 V HNL01.1E mains chokes of type 1 are equipped with a tem‐
perature contact (a, b), types 2, 3 and 4 are not.
Fig.8-10: Temperature contact
8.3 HNL01.1R - Mains Chokes, Regenerative

8.3.1 Safety Instruction
High electrical voltage! Danger to life, electric shock and severe bodily
injury!
● After switch-off, the capacitors in the choke will remain charged for a lon‐
WARNING ger time which can cause electric shock.
● Only operate the choke with connected discharging device or with con‐
nection to "X14, Mains voltage synchronization" at a regenerative HMV
supply unit (HMV01.1R).
● Unless you use a supply unit with connection "X14, Mains voltage syn‐
chronization", operation is only allowed with a connected discharging
device, e.g. with HNF mains filter or additional discharging resistors.
● Before accessing the choke, wait up to 30 minutes after switching off
power to allow the choke to discharge.
● Verify isolation from supply of energized connections before touching the
connections.
● Before switching on, read and observe the notes on project planning.
and Controls

Mains choke Dimensions [mm] Weight

[kg]
A B B1 C D E F 1) S
HNL01.1R-0980-C0026-A‑480‑NNNN 210 108 64 245 175 85 8 × 12 M6 16

HNL01.1R-0590-C0065-A‑480‑NNNN 300 155 50 360 240 123 11 × 15 M8 45
HNL01.1R-0540-C0094-A‑480‑NNNN 340 174 55 385 290 132 11 × 15 M8 65
HNL01.1R-0300-C0180-A‑480‑NNNN 340 191 70 400 290 147 11 × 15 M8 73
1) Long hole in "B" direction
Basic Data
Fig.8-13: Circuit diagram HNL01.1R

Connect the choke inputs U1, V1, W1 to the supply mains and the choke outputs
U2, V2, W2 to the input of the supply unit.
and Controls
Mains choke Connection cross section Tightening torque

mm2 / AWG Nm
U1, V1, W1 a, b U1, V1, W1 a, b
U2, V2, W2 U2, V2, W2
HNL01.1R-0980-C0026-A‑480‑NNNN 16 2,5 Observe the data imprinted on the

component.
HNL01.1R-0590-C0065-A‑480‑NNNN 50 2,5
HNL01.1R-0540-C0094-A‑480‑NNNN 70 2,5
HNL01.1R-0300-C0180-A‑480‑NNNN 95 2,5
Fig.8-14: Connection cross section, tightening torque
Temperature Contact a, b
Switching capacity Switching temperature
1 A / AC 250 V 125 °C
DC 24 V 150 °C (HNL01.1R-0300-C0180-A‑480‑NNNN)
Fig.8-15: Temperature contact a, b
Electrical data
Mains choke UN IN PV LN Imax1) Lmin CΔ

[V] [A] [W] [µH] [A] At Imax [µF]
HNL01.1R-0980-C0026-A‑480‑NNNN 480 26 225 3 × 980 65 80% of LN 3 × 10
HNL01.1R-0590-C0065-A‑480‑NNNN 480 65 310 3 × 590 163 80% of LN 3 × 20
HNL01.1R-0540-C0094-A‑480‑NNNN 480 94 420 3 × 540 235 80% of LN 3 × 20
HNL01.1R-0300-C0180-A‑480‑NNNN 480 180 800 3 × 300 360 80% of LN 3 × 30
1) For 300 ms at 1.42 s duty cycle time and 60 % basic load

8.4 HNL01.1*-****-S - Mains Chokes, Current-Compensated

8.4.1 Function
Current-compensated mains chokes
● reduce asymmetric currents (leakage currents) in the mains connection
phase of the drive system by high asymmetric inductance values
● do not replace the function of conventional mains chokes
and Controls

Dimensions [mm2] Weight

Mains choke
A B C D E F G [kg]
HNL01.1E-5700-S0051-A‑480‑NNNN 230 200 6.5 30 105 600 25 1) 11

HNL01.1E-2800-S0125-A‑480‑NNNN 340 280 8.4 83 150 600 1/0 2) 26
HNL01.1E-3400-S0202-A‑480‑NNNN 340 280 8.4 83 185 600 5/0 2) 30
HNL01.1R-4200-S0026-A‑480‑NNNN 230 200 6.5 30 125 600 16 1) 12
HNL01.1R-6300-S0065-A‑480‑NNNN 250 200 6.5 55 155 600 25 1) 14
HNL01.1R-3000-S0094-A‑480‑NNNN 340 280 8.4 83 170 600 50 1) 24
1) mm2
2) AWG
and Controls
Basic Data
Unit E-5700- E-2800- E-3400- R-4200- R-6300- R-3000-
S0051 S0125 S0202 S0026 S0065 S0094
Degree of protection IP20

Materials Free of asbestos and silicone
Certification Acc. to UL 508 and CSA C22.2 No. 14-M91
Connecting voltage V 3 × AC 380 … 480 ±10%, 50/60 Hz ±2%
Inductance LN mH 3 × 5,7 3 × 2,8 3 × 3,4 3 × 4,2 3 × 6,3 3 × 3,0
Minimum inductance, Lmin 0.8 × LN at Imax
Nominal current A 51 125 202 26 65 94

Peak current 1) A 77 188 303 65 163 235
Total leakage current at power connection A <2 < 2,2 < 2,2 <2 <2 <2
Allowed power dissipation at nominal current and
W 83 179 320 80 138 142
maximum leakage current
1) Duration: 300 ms; duty cycle: for infeeding devices: 0.67 s; for regener‐
ative devices: 1.42 s; basic load: 60%
Fig.8-19: Basic data
1) 3 × 6.3 mH
Fig.8-20: Circuit diagram HNL…S (example HNL01.1R-6300-S0065-
A‑480‑NNNN)
As a matter of principle, the current-compensated mains choke is connected
between the conventional mains choke and the mains input of the supply unit.
and Controls
8.5 HNL02.1 - Mains Choke

Type Code
Fig.8-21: Type code

and Controls

Dimensions
Data in mm
B) Rear view!
Fig.8-22: Dimensions HNL02.1
Weight
HNL02.1R-0980-N0023-A-480-NNNN HNL02.1R-0980-C0023-A-480-NNNN
12.5 kg 13 kg
Fig.8-23: Weight
Basic Data
Unit HNL02.1R-0980-N0023- HNL02.1R-0980-C0023-
A-480-NNNN A-480-NNNN

Operation temperature °C 0 … 55
and Controls
Unit HNL02.1R-0980-N0023- HNL02.1R-0980-C0023-

A-480-NNNN A-480-NNNN
Nominal operating temperature °C 40
UL 506 and CAN/CSA C22.2 Acc. to UL 508 C and CSA
Certification
No. 66 C22.2 No. 14‑M91
Materials Free of asbestos and silicone
Rated voltage ULN V 3 AC 380 … 480 ±10%
Nominal frequency fLN Hz 50/60 Hz ±2%
Inductance LN mH 3 × 0,98
Minimum inductance, Lmin 0.8 × LN at Imax
Capacitors at mains input Cx - 3 × 10 µF
Nominal current A 23
Peak current Imax1) A 55
Total leakage current at power connection with

A < 0,7
12 drive controllers and 200 m motor cable
Power dissipation at nominal current and maxi‐
W 95
mum leakage current
Maximum allowed fusing of blower or tempera‐
A 4
ture contact connection
AC 30
V AC 302)
Switching capacity temperature contact (N/C) DC 24
A 3
Trigger temperature °C 130
1) Duration: 300 ms
Duty cycle for infeeding devices: 0.67 s
Duty cycle for regenerative devices: 1.42 s
Basic load: 60%
2) In the scope of UL, operation with direct voltage is not allowed
Fig.8-24: Specific data
Connection Points
If wiring work is to be carried out at filter, mains choke or supply unit, discharge
the device-internal capacitors after disconnecting the mains voltage. (Short-
WARNING circuit the power connections at filter output or choke input)
and Controls
Fig.8-25: Connection points
Connection Significance
U1, V1, W1 Input from supply mains

U2, V2, W2 Output to supply unit HMV02
Equipment grounding conductor
24VL Supply voltage internal blower
0VL
Temperature contact

and Controls
Cx Capacitors in design HNL02.1E-0980-C0023-A-480-NNNN

Fig.8-27: Circuit diagram
and Controls
and Controls
HLL01 - DC Bus Choke, Current-Compensated (Preliminary)
9 HLL01 - DC Bus Choke, Current-Compensated (Pre‐

liminary)
9.1 Brief Description, Usage and Commissioning
9.1.1 Brief Description
HLL01 DC bus chokes connect Rexroth IndraDrive systems to supply units.
The DC bus choke connects the DC bus of the supply unit to the DC bus of the
drive system.
9.2 Type Code and Identification

9.2.1 Type code
The following figure illustrates the basic structure of the type code.
Our sales representative will help you with the current status of
available versions.
and Controls
Fig.9-1: Type code of DC bus choke HLL01.1
Each DC bus choke is marked by a type designation. There is a type plate
attached to all components.
and Controls
Type Plate Arrangement
1 Type plate
Fig.9-2: Position of type plate
Type Plate
1 Word mark
2 Business facility number
3 CE label
4 Type designation (two lines, 20 characters each)
5 Part number
6 Change release
7 Production date (YYWww)
8 Certification label
9 Nominal voltage / frequency
10 Nominal current
11 Number of design specification
12 Nominal inductance
13 Temperature
14 Number and value of additional capacitors
15 Designation of origin
16 Approval number
17 Bar code (39 or 93)
18 Serial number
19 Company address
Fig.9-3: Type plate
9.3 Scope of Supply

DC bus choke HLL01
and Controls
9.4 Installation and Mounting

Connect the DC bus choke to the equipment grounding system of the control
cabinet.
DANGER Check the continuity of the equipment grounding conductors from the mains
connection to the connected motors.
For the equipment grounding conductor, run stationary lines with the cross
section of the lines of the DC bus choke power connections, but at least
10 mm2.
Mount HLL01 to a bare metal mounting plate which has been connected to the
equipment grounding system of the control cabinet.
and Controls
9.4.2 Dimensions HLL01
Dimensions in mm
Fig.9-4: Dimensions of DC bus choke HLL01.1
9.4.3 Circuit Diagram HLL01

Risk of short circuit, observe correct polarity
Make sure that the positive pole of the DC bus at the supply unit is
connected to the positive pole at the drive system via the HLL01
connections +1, +2.
and Controls
In +1, -1 Input (from supply unit)

Out +2, -2 Output (to drive system)
a, b Temperature contact
PE Equipment grounding conductor
Fig.9-5: Circuit diagram HLL01.1
9.5 Technical Data

HLL01.1N-10M0-S0100-
A-007-05A0-NNNN
Degree of protection according to IEC529 IP20
Allowed ambient temperature range during operation with re‐

Ta_work_red °C 0 … 55
duced nominal data
Reduced nominal current at
fTa %/K 2,0
Ta_work < Ta < Ta_work_red
Horizontally or vertically on mount‐

Allowed mounting position
ing surface
Minimum distance on the bottom of the device dbot mm

All around 80;
Minimum distance on the top of the device dtop mm
allow free convection
Horizontal spacing on the device dhor mm
Mass (weight) m kg 35
Nominal inductance Lnenn mH 10
Nominal voltage ULN V DC 540 … 750
Tolerance ULN ±10%
Nominal current IL_cont 100
Maximum allowed peak current6) IL_max A 250
5 at 70% × IL_cont
Maximum allowed leakage current Iab A
2 at 100% × IL_cont
Power dissipation at continuous current and continuous DC

PDiss_cont W 300
bus power respectively
Required wire size according to IEC 60364‑5‑52; at IL_cont9) ALN mm² 50
and Controls
HLL01.1N-10M0-S0100-
A-007-05A0-NNNN
Required wire size according to UL 508 A (internal wiring); at
ALN AWG 2
IL_cont (UL)10)
Recommended fuse at operation under rated conditions A 125; gL

Allowed range tightening torque M Nm 6,0 … 6,5
Temperature contact
Typical switching temperature of temperature contact Tschalt °C 150
Switching capacity of temperature contact 1 A / 250V AC; 24 V DC

Cross section of connection cable A mm² 1 … 2,5
Cross section of connection cable A AWG 18 … 14
Allowed range tightening torque M Nm 0,5 … 0,6
6) t = 0.3 s; T = 1.42 s; K = 2.5
13.5.1; Ta ≤ 40 °C
Fig.9-6: HLL - Technical data - Currents, voltages, power
and Controls
and Controls
HLC01.1 - DC Bus Capacitor Unit
10 HLC01.1 - DC Bus Capacitor Unit

10.1 Application Instructions
Damage to the drive controller!
In operating cycles of more than 30 cycles per minute, the DC bus capacitors
in the drive controller can be overloaded when the mains connection voltage
CAUTION decreases.
Additionally use DC bus capacitor units.
Using a DC bus capacitor unit you can increase the storable energy in the DC
bus. This makes sense
● for applications with short cycle times (> approx. 30 cycles per minute).
The continuous power of a braking resistor will be reduced and with it the
dissipation heat generated in the control cabinet.
● for applications which need a certain amount of energy, also in case of
mains failure (e.g. for return motions)
● to back up the DC bus for systems with DC bus connections > 2 m between
the drive controllers
and Controls
10.2 Identification
Fig.10-1: Type code
10.3 Mounting
10.3.1 Notes
● Always mount the DC bus capacitor unit directly next to the drive controller
with the highest DC bus continuous power.
● To compensate the different mounting depths of a DC bus capacitor unit
HLC01.1C and IndraDrive M drive controllers, there are suitable distance
bolts (accessory HAS03.1-002-NNN-NN; contains 2 distance bolts). You
and Controls
are only allowed to use the distance bolts when the DC bus capacitor unit
is mounted directly next to the drive controller. In this case you also have
to connect the contact bars for DC bus and control voltage connection to
the DC bus capacitor unit.
● Mount the distance bolts to the bare metal mounting surface of the control
cabinet.
A Distance bolts
B Mounting surface in control cabinet
Fig.10-2: How to use the distance bolts
and Controls
10.3.2 Mechanical Data

Dimensions HLC01.1C

B) Rear view
Fig.10-3: Dimensions HLC01.1C
and Controls
Dimensions HLC01.1D

B) Rear view
Fig.10-4: Dimensions HLC01.1D
Weight
Type Weight [kg]
HLC01.1C-01M0-A-007-NNNN 3,2
HLC01.1C-02M4-A-007-NNNN 4,3
HLC01.1D-05M0-A-007-NNNN 8,6
Fig.10-5: Weight
and Controls
10.4 Installation
10.4.1 Electrical Data
Description Symbol Unit Type
HLC01.1C-01M0 HLC01.1 C-02M4 HLC01.1D-05M0
Allowed input voltage UDC V DC 254 … 750 V
Nominal DC bus capacitance CDC mF 1 2,4 5
Maximum discharging time from

T s 250 280 760
820 V to 50 V
Power dissipation (at 750 V DC bus
Pv W 12 24 13
voltage)
Insulation resistance Ris Mohm > 25
Maximum current (at 55 °C ambient

ICeff A 20 50 60
temperature)
Cooling Natural convection
As the mains connection voltage increases, the storable energy in

the DC bus decreases, because the differential voltage between
braking resistor threshold and DC bus voltage (crest value of con‐
nection voltage) is reduced.

General Information
Before working on live parts: De-energize the installation and secure the power
switch against unintentional or unauthorized re-energization.
WARNING Wait at least 30 minutes after switching off the supply voltages to allow dis‐
charging. To shorten the waiting time until voltage has fallen below 50 V, you
can use a discharging device (see chapter "Appendix").
Check whether voltages have fallen below 50 V before touching live parts!
When using HMV supply units, the discharging time of the DC bus
capacitors can be reduced by activating the function "ZKS".
and Controls
Overview
X1 in, X1 out Module bus

24V, 0V Control voltage
L+, L- DC bus
1) Equipment grounding conductor
2) Ground connection
Fig.10-7: Connections - overview
and Controls
X1, Module Bus

Function, Pin Assignment The module bus is an internal system connection and is used to exchange data
between the devices.
View Identification Function
X1 in To plug in module bus connector

X1 out Passes module bus connection to
neighboring device
Fig.10-8: X1, Module bus

Notes on Installation Keep ribbon cable in parking position, when not connected to neighboring de‐
vice.
When using DC bus capacitor units: Do not establish this connec‐

tion at the DC bus capacitor unit, if the DC bus capacitor unit is the
last device in the drive system.
Control Voltage (+24 V, 0 V)

View Identifica‐ Function

tion
+24V power supply
connection to neighboring devices with contact bars from ac‐
cessory HAS01.1
0V reference potential for power supply
cessory HAS01.1
Screw connection Unit Min. Max.

M6 thread at device (terminal block)
tightening torque Nm 5,5 6,5
power consumption W PN3 (see technical data)
voltage load capacity V UN3 (see technical data)
polarity reversal protection within the allowed voltage range by internal protective diode
Current carrying capacity "looping through" from 24V to 24V, 0V to 0V
(contact bars in scope of supply of accessory HAS01)
with contact bars -072 A 220
Fig.10-9: Function, pin assignment, properties

and Controls
L+ L-, DC Bus Connection

Function, Pin Assignment The DC bus connection connects
● several drive controllers to one another
● a drive controller to additional components
HCS02.1E-W0012 drive controllers do not have a DC bus connec‐

tion.

tion
L+ connection points for connecting DC bus connections
L-

short circuit protection via fusing elements connected in the incoming circuit to the
mains connection
overload protection via fusing elements connected in the incoming circuit to the
mains connection
Current carrying capacity "looping through" from L+ to L+, L- to L-
additionally with contact bars ‑042 and end piece A 245

Notes on Installation If in special cases it is not possible to use the contact bars provided to establish
the connection, the connection must be established using the shortest possible
twisted wires.
and Controls
Risk of damage by reversing the polarity of the DC bus connections L+

and L-
Make sure the polarity is correct.
CAUTION
Length of twisted wire Max. 2 m

Min. 10 mm2, but not smaller than cross section of
Line cross section
supply feeder
Line protection By means of fuses in the mains connection
Dielectric strength of single
≥ 750 V (e.g.: strand type – H07)
strand against ground
Fig.10-11: DC bus line

Connection of Equipment Grounding Conductor
Connect the drive controller to the equipment grounding system of the control
cabinet.
DANGER Supplying device with connection for joint bar:
● Via the joint bar on the front connect the drive controller to the supplying
device.
Supplying device without connection for joint bar:
● Via a separate connection line, connect the drive controller to the equip‐
ment grounding system of the control cabinet.
Via the joint bar on the front connect the drive controller to the neighboring drive
controller.
Connect the equipment grounding conductor connection of the supplying unit
to the equipment grounding system of the control cabinet.
Check the continuity of the equipment grounding conductors from the mains
and Controls
Equipment grounding conductor: material and cross section

For the equipment grounding conductor, use the same metal (e.g.
copper) as for the outer conductors.
For the connections from the equipment grounding conductor con‐
nection of the device to the equipment grounding conductor system
in the control cabinet, make sure the cross sections of the lines are
sufficient.
Cross sections of the equipment grounding connections:
● for HCS03.1E drive controllers and HMV01 supply units, at
least 10 mm2, but not smaller than the cross sections of the
outer conductors of the mains supply feeder
● for HCS02.1E drive controllers, at least 4 mm2, but not smaller
than the cross sections of the outer conductors of the mains
supply feeder
Additionally, mount the housing of HCS02.1E to a bare metal
mounting plate. Connect the mounting plate, too, with at least
the same cross section to the equipment grounding conductor
system in the control cabinet.
For outer conductors with a cross section greater than 16 mm², you
can reduce the cross section of the equipment grounding connec‐
tion according to the table "Cross section of equipment grounding
conductor, excerpt from EN 61800-5-1:2003".
Cross-sectional area A of outer conduc‐ Minimum cross-sectional area APE of

tors equipment grounding connection
A ≤ 16 mm² A
16 mm² < A ≤ 35 mm² 16
35 mm² < A A/2
Fig.10-12: Equipment grounding conductor cross section, excerpt from EN

61800-5-1:2003, table 2
The line for the connection of the equipment grounding conductor

must have at least the cross section of the mains supply feeder.
With cross sections of the mains supply feeder smaller than
10 mm2 (AWG 8), the equipment grounding conductor must have
at least 10 mm2 (AWG 8).
and Controls
1 Joint bar
2 Connection to equipment grounding system
Fig.10-13: Equipment grounding conductor connection for supply via HMV01,
HMV02, HCS03
1 Joint bar
Fig.10-14: Equipment grounding conductor connection for supply via HCS02
Design, Tightening Torque The joint bars are connected by means of screws:
Design Tightening torque
M6 × 25 6 Nm
Fig.10-15: Data of connection point

Ground Connection
The ground connection of the housing is used to provide functional safety of
the drive controllers and protection against contact in conjunction with the
equipment grounding conductor.
Ground the housings of the drive controllers:
1. Connect the bare metal back panel of the drive controller in conductive
form to the mounting surface in the control cabinet. To do this, use the
supplied mounting screws.
2. Connect the mounting surface of the control cabinet in conductive form to
the equipment grounding system.
3. For the ground connection, observe the maximum allowed ground resist‐
ance.
and Controls
See Project Planning Manual "Rexroth IndraDrive – Drive System" chapter

"Dimensioning the Mains Connection"
10.4.3 Touch Guard at Devices

Cutouts
● The appropriate touch guard must be mounted for each device following
connection work.
WARNING ● Never mount a damaged touch guard.
● Immediately replace a damaged touch guard by an undamaged touch
guard.
● Keep the cutouts at the touch guard as small as possible. Only remove
the cutouts if necessary.
Type 1 Type 2
Fig.10-16: Cutouts at the touch guard

● If the DC bus and the control voltage are connected by means of contact
bars, only cutout A may be removed from the touch guard.
● If the DC bus and the control voltage are connected by means of cables
(e.g. in the case of multiple-line arrangement), the cutouts A, B and C may
be removed from the touch guard.
● At the first and last device in a line of interconnected devices, you must
not remove any cutout at the outer side of the touch guard.
and Controls
Mounting
Fig.10-17: Touch guard at device

The touch guard is fixed to the device with screws.
Tightening Torque Max. 2.8 Nm
and Controls
HLB01.1C and HLB01.1D - DC Bus Resistor Unit
11 HLB01.1C and HLB01.1D - DC Bus Resistor Unit

11.1 Description
The DC bus resistor unit can be advantageously used for
● increasing the available continuous regenerative power
● increasing the available peak regenerative power
● DC bus short circuit (ZKS) for quickly discharging the DC bus
11.2 Identification
Fig.11-1: Type code

and Controls
11.3 Mounting HLB01.1

11.3.1 Mechanical Data HLB01.1
Dimensions HLB01.1C

B) Rear view!
Fig.11-2: Dimensions HLB01.1C
and Controls
Dimensions HLB01.1D

B) Rear view!
Fig.11-3: Dimensions HLB01.1D
and Controls
Weight
Type Weight [kg]
HLB01.1C 5,8
HLB01.1D 12,2
Fig.11-4: Weight
11.4 Installation HLB01.1

11.4.1 Electrical Data HLB01.1
Description Symbol Unit HLB01.1C HLB01.1D
Allowed input voltage ULN V DC 254 … 750
Braking resistor threshold UR_DC_on_f V 820 820
Continuous power Pcont kW 1 2
Peak power Ppeak kW 100 100
Max. regenerative power WR_max kWs 100 500
Derating if devices are connected in parallel 1) 0,8 0,8

Control voltage supply
Control voltage UN3 V 19,2 … 28,8 22,8 … 27,3
Power consumption PN3 W 14 14
Max. inrush current IEIN3 A 3 (for 50 ms) 3 (for 50 ms)
1) The factor of derating results from the balancing behavior. The balanc‐
ing behavior is determined by tolerance-afflicted voltage measurements
in the individual devices. Derating applies both to the continuous power
and to the maximum allowed regenerative power.
and Controls

Overview HLB01.1C

Fig.11-6: Connections HLB01.1C
and Controls
Overview HLB01.1D

Fig.11-7: Connections HLB01.1D
and Controls
L+ L-, DC Bus Connection

Function, Pin Assignment The DC bus connection connects
● several drive controllers to one another
● a drive controller to additional components
HCS02.1E-W0012 drive controllers do not have a DC bus connec‐

tion.

tion
L+ connection points for connecting DC bus connections
L-

short circuit protection via fusing elements connected in the incoming circuit to the
mains connection
overload protection via fusing elements connected in the incoming circuit to the
mains connection
Current carrying capacity "looping through" from L+ to L+, L- to L-
additionally with contact bars ‑042 and end piece A 245

Notes on Installation If in special cases it is not possible to use the contact bars provided to establish
the connection, the connection must be established using the shortest possible
twisted wires.
and Controls
Risk of damage by reversing the polarity of the DC bus connections L+

and L-
Make sure the polarity is correct.
CAUTION
Length of twisted wire Max. 2 m

Min. 10 mm2, but not smaller than cross section of
Line cross section
supply feeder
Line protection By means of fuses in the mains connection
Dielectric strength of single
≥ 750 V (e.g.: strand type – H07)
strand against ground
Fig.11-9: DC bus line

Connection of Equipment Grounding Conductor
Connect the drive controller to the equipment grounding system of the control
cabinet.
DANGER Supplying device with connection for joint bar:
● Via the joint bar on the front connect the drive controller to the supplying
device.
Supplying device without connection for joint bar:
● Via a separate connection line, connect the drive controller to the equip‐
ment grounding system of the control cabinet.
Via the joint bar on the front connect the drive controller to the neighboring drive
controller.
Connect the equipment grounding conductor connection of the supplying unit
to the equipment grounding system of the control cabinet.
and Controls

sufficient.
supply feeder

A ≤ 16 mm² A
16 mm² < A ≤ 35 mm² 16
35 mm² < A A/2

61800-5-1:2003, table 2
The line for the connection of the equipment grounding conductor

must have at least the cross section of the mains supply feeder.
With cross sections of the mains supply feeder smaller than
10 mm2 (AWG 8), the equipment grounding conductor must have
at least 10 mm2 (AWG 8).
and Controls
1 Joint bar
Fig.11-11: Equipment grounding conductor connection for supply via HMV01,
HMV02, HCS03
1 Joint bar
Fig.11-12: Equipment grounding conductor connection for supply via HCS02
Design, Tightening Torque The joint bars are connected by means of screws:
Design Tightening torque
M6 × 25 6 Nm
Fig.11-13: Data of connection point

Ground Connection
The ground connection of the housing is used to provide functional safety of
the drive controllers and protection against contact in conjunction with the
equipment grounding conductor.
Ground the housings of the drive controllers:
1. Connect the bare metal back panel of the drive controller in conductive
form to the mounting surface in the control cabinet. To do this, use the
supplied mounting screws.
2. Connect the mounting surface of the control cabinet in conductive form to
the equipment grounding system.
3. For the ground connection, observe the maximum allowed ground resist‐
ance.
and Controls
See Project Planning Manual "Rexroth IndraDrive – Drive System" chapter

"Dimensioning the Mains Connection"
X13 at HLB01, Control Voltage
Assignment Connec‐ Signal name Function
tion
4 +24V Power supply and "looping
through"
3 +24V
2 0V Reference potential for power
supply and "looping through"
1 0V
Spring terminal (connector) Unit Min. Max.

Connection cable solid wire mm2 1 1,5
Connection cable stranded wire mm2 1 1,5
Connection cable AWG 18 16
Power consumption W PN3 (see technical data)
Voltage load capacity V UN3 (see technical data)
Current carrying capacity "looping through" from A 6

+24V to +24V, 0V to 0V
Continuous current PN3/UN3

+24V to +24V, 0V to 0V
Inrush current IEIN3
Polarity reversal protection Within the allowed voltage range by internal protective diode

Notes on Installation Requirements on the connection to the 24V supply:
● Minimum cross section: 1 mm2
● Maximum allowed inductance: 100 µH (2 twisted single strands, 75 m
long)
● Parallel line routing where possible
Control Voltage HLB01.1D
tion
+24V power supply
cessory HAS01.1
0V reference potential for power supply
cessory HAS01.1
and Controls

power consumption W PN3 (see technical data)
voltage load capacity V UN3 (see technical data)
polarity reversal protection within the allowed voltage range by internal protective diode
Current carrying capacity "looping through" from 24V to 24V, 0V to 0V

X1, Module Bus
Function, Pin Assignment The module bus is an internal system connection and is used to exchange data
between the devices.
View Identification Function
X1 in To plug in module bus connector

X1 out Passes module bus connection to
neighboring device
Fig.11-16: X1, Module bus

Notes on Installation Keep ribbon cable in parking position, when not connected to neighboring de‐
vice.

and Controls
X31 at HLB01, Ready for Operation and Prewarning Contact

Assignment Connec‐ Signal name/function
tion
6 Ready for operation contact:
5 Closes, when the following conditions have been fulfilled:
● Control voltage available
● Heat sink temperature OK
● Load resistor temperature OK
● Continuous power is smaller than specified value (see
technical data)
● Maximum regenerative power is smaller than specified
value (see technical data)
4 n. c.
3 n. c.
2 Prewarning contact:
1 Opens, when one of the following conditions have been fulfil‐
led:
● Heat sink temperature too high
● Continuous power > 90%
● Regenerative power > 90%
Shields of control lines Connect to shield connection XS1 of neighboring drive controller

Connection cable solid wire mm2 0,5 1,5
Connection cable stranded wire mm2 0,5 1,5
AWG 20 16
Max. switching voltage V DC 30
Max. switching current A DC 1
Max. continuous current A DC 1
Minimum load of the contacts mA 10

and Controls
X32 at HLB01, DC Bus Short Circuit Control, Clear Errors, Braking Resistor Threshold
Risk of fire caused by the "sacrificing behavior" of the ZKS stage!
The "ZKS" input activates the function "DC bus short circuit", when there hasn't
any voltage been applied and when there isn't any current flowing to the input.
CAUTION This status occurs both in the case of wire break and when the 24V supply fails.
When the 24V supply fails in applications in which energy does not only get to
the DC bus via the mains connection, but also via regeneratively operated mo‐
tors (e.g. following-on rollers), the ZKS stage converts this energy into heat until
it is destroyed ("sacrificing behavior").
Counter measures with such applications:
● Do not use drive controllers with integrated ZKS stage or
● buffer the 24V supply (e.g. by means of a UPS) to evaluate the monitor
and switch off the energy flow in the case of error.
Assignment Connec‐ Signal name/function Signal name/function

tion HLB01.1C HLB01.1D
9 n. c.
8 Input ZKS1 Input ZKS1
Input circuit: See figure " Input circuit: See figure "
HLB01.1C input circuit ZKS" HLB01.1D input circuit ZKS"
7 n. c.
6 n. c.
5 Input clear errors: A negative Input clear errors: A negative
edge at the input against GND edge at the input against
clears all present errors that X32.4 clears all present errors
can be cleared. that can be cleared.
4 GND Reference potential for input
clear errors:
Applies to devices with hard‐
ware index ≥ A17 (see type
plate)
3 n. c.
Applies to devices with hard‐
ware index ≥ A17 (see type
plate)
2 Input braking resistor threshold:
High (n.c.): Load-dependent in the range of DC 820 … 850 V
Low (bridge with 0V): Reserved
1 n. c. Connect ZKS2 (reference po‐
tential for input ZKS1) to 0V
Shields of control lines Connect to shield connection XS1 of neighboring drive controller
DC bus short circuit control Unit Min. Max.
and Controls
High: V 19,2 28,8

ZKS stage not active, i.e. braking resistor switch‐
ed off
Voltage at input ZKS1 against ZKS2 (HLB01.1D)
or against GND (HLB01.1C)
Low: ZKS stage active, i.e. braking resistor V 0 5
switched on
Delay td_on until braking resistor switches on ms Approx. 160
Delay td_off until braking resistor switches off ms Approx. 1
Input resistance kOhm 2 ±10%

Polarity reversal protection Within the allowed input voltage range
Electrical isolation HLB01.1C: Not electrically isolated, input ZKS1 with reference
to GND
HLB01.1D: Inputs ZKS1, ZKS2 are electrically isolated, i.e.
both inputs must be connected!
Input circuit ZKS
HLB01.1C HLB01.1D
Fig.11-18: HLB01.1C input circuit ZKS Fig.11-19: HLB01.1D input circuit ZKS
Connection cross section solid wire mm2 0,5 1,5
Connection cross section stranded wire mm2 0,5 1,5
Connection cross section AWG 28 14

X2, Serial Interface (RS232)
General Information
The serial interface (RS232) is required for programming, parameterization and
diagnosis during commissioning and servicing.
and Controls
Connec‐ Type No. of Stranded Description Figure

tion point poles wire
[mm²]
X2 MiniDin, 8 0,25–0,5 serial interface

female
(device)
Fig.11-21: Connections
Pin Assignment Pin Signal Function
1 RTS request to send

2 CTS clear to send
3 TxD transmit data
4 GND reference potential
5 RxD receive data
6 Vcc supply voltage
7 n. c. n. c.
8 n. c. n. c.
n. c. not connected
Fig.11-22: Pin assignment of serial interface
Features Feature Unit Min. Typ. Max.
number of nodes 1
allowed cable length m 15
transmission rates kBaud 9,6 115
connection galvanically connected to control section
supply
allowed voltage difference be‐ V 1
tween reference potentials of
control section and data end de‐
vice
Fig.11-23: Features
The accessory HAS05.1-005 makes available a converter from

RS232 to RS485 (see Project Planning Manual "Rexroth IndraDrive
- Drive System", chapter "Accessories").
and Controls
Connection Diagrams Serial Interface to PC

Serial Interface to PC With 9-Pin
D‑Sub
Fig.11-24: Connection of serial interface to PC with 9-pin D‑Sub
For direct connection to the serial interface, use our cable

IKB0041.
Serial Interface to PC With 25-Pin

D‑Sub
Fig.11-25: Connection of serial interface to PC with 25-pin D‑Sub

X2, RS232 Interface
For internal use only.
11.4.3 Touch Guard at Devices

Cutouts
● The appropriate touch guard must be mounted for each device following
connection work.
WARNING ● Never mount a damaged touch guard.
● Immediately replace a damaged touch guard by an undamaged touch
guard.
● Keep the cutouts at the touch guard as small as possible. Only remove
the cutouts if necessary.
and Controls
Type 1 Type 2
Fig.11-26: Cutouts at the touch guard

● If the DC bus and the control voltage are connected by means of contact
bars, only cutout A may be removed from the touch guard.
● If the DC bus and the control voltage are connected by means of cables
(e.g. in the case of multiple-line arrangement), the cutouts A, B and C may
be removed from the touch guard.
● At the first and last device in a line of interconnected devices, you must
not remove any cutout at the outer side of the touch guard.
and Controls
Mounting
Fig.11-27: Touch guard at device

The touch guard is fixed to the device with screws.
Tightening Torque Max. 2.8 Nm
11.5 Commissioning, Operation, Diagnoses

Risk of fire caused by the "sacrificing behavior" of the ZKS stage!
The "ZKS" input activates the function "DC bus short circuit", when there hasn't
any voltage been applied and when there isn't any current flowing to the input.
CAUTION This status occurs both in the case of wire break and when the 24V supply fails.
When the 24V supply fails in applications in which energy does not only get to
the DC bus via the mains connection, but also via regeneratively operated mo‐
tors (e.g. following-on rollers), the ZKS stage converts this energy into heat until
it is destroyed ("sacrificing behavior").
Counter measures with such applications:
● Do not use drive controllers with integrated ZKS stage or
● buffer the 24V supply (e.g. by means of a UPS) to evaluate the monitor
and switch off the energy flow in the case of error.
and Controls
At the common DC bus, other braking resistors take effect. For ex‐
ample, converters (HCS02, HCS03) and supply units (HMV) have
integrated braking resistors or operate external HLR braking resis‐
tors.
For operating HLB01 at HCS and HMV, set the following parame‐
ters:
● P-0-0833, Braking resistor threshold
● P-0-0858, Data of external braking resistor
● P-0-0859, Data of internal braking resistor
● P-0-0860, Converter configuration
Fig.11-28: Diagnostic LEDs and reset key

Reset Key S1 Is used for resetting errors.
Diagnostic LED H2 (Green) Status Significance
Device is ready for operation and UZK ≤ 50 V
Flashing
Device is ready for operation and UZK > 50 V
Continuous
light
Fig.11-29: Diagnostic LED H2 (green)

and Controls
Diagnostic LED H3 (Red) Status Significance
● Overload prewarning at 90% load

● Overtemperature prewarning
Flashing
● Overload
● Overtemperature
Continuous ● Internal error
light
Fig.11-30: Diagnostic LED H3 (red)

and Controls
and Controls
HLR01 - Braking Resistors
12 HLR01 - Braking Resistors

12.1 Braking Resistor HLR01
HLR01.1N‑xxxx‑Nxxx‑A‑007‑NNNN braking resistors convert generated kinet‐
ic energy into thermal energy. For this purpose, the line covers a wide range of
continuous power and energy absorption capacity.
Type Usage
Type of construction A (version for device mounting): To be mounted to

HLR01.1A drive controllers of the Rexroth IndraDrive C product range. For this pur‐
pose, the drive controllers must be equipped with a brake chopper.
Type of construction N (version for free assembly): For free assembly in
the installation, operated by drive controller of the Rexroth IndraDrive C
HLR01.1N
product range. For this purpose, the drive controllers must be equipped
with a brake chopper.
Fig.12-1: Usage of DC bus resistor units HLR

Versions of type of construction N:
● fixed resistor IP 20 type A
cement-coated, wire-wound, tube-type fixed resistors; screwed on side
walls; perforated cover; connections in terminal box with PG gland
● steel-grid fixed resistor IP 20 type B
fixed resistor in steel-grid design; connection depending on type
● steel-grid fixed resistor IP 20 type C
fixed resistor in steel-grid design; connection depending on type

12.2.1 Type Code
available versions.
and Controls
Fig.12-2: Type code braking resistor HLR01.1
Each braking resistor is identified by a type designation. There is a type plate
attached to all components.
and Controls
1) Type plate
Fig.12-3: Position of type plate
Type Plate
1) Type designation
2) Part number
3) Serial number
4) Production date
5) Revision index
Fig.12-4: Type plate HLR01.1
12.3 Scope of Supply

The scope of supply of HLR braking resistors provided for mounting to drive
controllers includes the joint bar for the equipment grounding conductor con‐
nection.
12.4 Technical Data

12.4.1 Technical Data HLR01 for HCS02.1
Assignment HLR01 to HCS02.1E
Braking Resistors HLR01 for
HCS02 Converter Braking resistor type1) Type of Type
construc‐ Dimensions 3)
tion 2)
HCS02.1E-W0054- Free as‐

HLR01.1N-01K8-N40R0-… A7
A-03-xNNx sembly N
HLR01.1N-03K8-N40R0-… B1
A-03-xNNx sembly N
and Controls
Converter Braking resistor type1) Type of Type

tion 2)
HLR01.1N-02K4-N28R0-… A8
A-03-xNNx sembly N
HLR01.1N-05K5-N28R0-… B2
A-03-xNNx sembly N
1) Complete type with: A-007-NNNN
2) See Project Planning Manual "Rexroth IndraDrive Additional Compo‐
nents and Accessories", type code HLR
nents and Accessories", dimension tables HLR
Fig.12-5: Assignment braking resistors HLR ↔ HCS02
HLR01 for HCS02.1E-W0054
Description Symbol Unit HLR01.1N-01K8-N40R0 HLR01.1N-03K8-N40R0

IP20
IEC60529
Allowed ambient temperature
range during operation with nomi‐ Ta_work °C 0...40
nal data
Mass (weight) m kg 6,60 9,50
RDC_Bleed‐
Nominal braking resistance ohm 40,00
er
Braking resistor continuous power PBD kW 1,80 3,80
Braking resistor peak power at

PBS kW 18,00
UDC = 850 V
Maximum regenerative power to be

WR_max kWs 72,00 300,00
absorbed
Maximum allowed on-time duty ton_max s 0,13 2,30
Minimum allowed cycle time Tcycl s 4,00 16,67
Cooling type n
Volumetric capacity of forced cool‐
V m3/h -
ing
Temperature rise with minimum
ΔT K 65
distances dbot; dtop; PBD

dtop mm 300 600
device1)
dbot mm 200
the device2)
Horizontal spacing on the device3) dhor mm 200
Allowed range tightening torque M Nm 1,80 2,00

and Controls

AL mm2 4 4,0
IEC 60364‑5‑52;4)
AL AWG 12
508 A (internal wiring); (UL)5)
1) 2) 3) See fig. "Air intake and air outlet at drive controller"
13.5.1; Ta ≤ 40 °C
Fig.12-6: HLR - Technical data - Currents, voltages, power
Property damage due to temperatures higher than 105 °C!

Observe the indicated minimum distances!
Above the devices there may only be such materials which
CAUTION
● are not combustible
● are insensitive to the occurring high temperatures


IP20
IEC60529
nal data
Mass (weight) m kg 7,90 13,00
RDC_Bleed‐
Nominal braking resistance ohm 28,00
er
Braking resistor continuous power PBD kW 2,40 5,50

PBS kW 26,00
UDC = 850 V

WR_max kWs 100,80 420,00
absorbed
Maximum allowed on-time duty ton_max s 0,12 2,10
Minimum allowed cycle time Tcycl s 3,88 16,15
Cooling type n
V m3/h -
ing
ΔT K 65

dtop mm 300 600
device1)
dbot mm 200
the device2)
and Controls
Horizontal spacing on the device3) dhor mm 200
Allowed range tightening torque M Nm 1,80 2,00

AL mm2 4
IEC 60364‑5‑52;4)
AL AWG 12
13.5.1; Ta ≤ 40 °C

CAUTION
12.4.2 Technical Data HLR01 for HCS03.1E

Assignment HLR01 to HCS03.1E
Braking Resistors HLR01 for
HCS03 Converter Braking resistor type1) Type of Type
tion 2)
HCS03.1E-W0070- Device
HLR01.1A‑0300‑N17R5-…
A-05-xNBV mounting A
HCS03.1E-W0100- Device See correspond‐
HLR01.1A‑0470‑N11R7-…
A-05-xNBV mounting A ing dimensional
HCS03.1E-W0150- Device drawing
HLR01.1A‑0780‑N07R0-… HLR01.1N-…
HCS03.1E-W0210- Device
HLR01.1A‑1K08‑N05R0-…
HLR01.1N-01K6-N18R0-… A5
A-05-xNBV sembly N
HLR01.1N-02K0-N15R0-… A6
A-05-xNBV sembly N
HLR01.1N-04K5-N07R4-… B1
A-05-xNBV sembly N
HLR01.1N-06K5-N06R1-… B2
A-05-xNBV sembly N
HLR01.1N-03K5-N19R0-… B1
A-05-xNBV sembly N
HLR01.1N-05K0-N15R0-… B2
A-05-xNBV sembly N
and Controls
Converter Braking resistor type1) Type of Type

tion 2)
HLR01.1N-08K5-N08R0-… B3
A-05-xNBV sembly N
HLR01.1N-12K5-N05R5-… B4
A-05-xNBV sembly N
HLR01.1N-04K5-N18R0-… B2
A-05-xNBV sembly N
HLR01.1N-07K0-N14R0-… B3
A-05-xNBV sembly N
HLR01.1N-11K0-N07R3-… B3
A-05-xNBV sembly N
HLR01.1N-17K0-N05R1-… B5
A-05-xNBV sembly N
HLR01.1N-06K5-N18R0-… B2
A-05-xNBV sembly N
HLR01.1N-09K5-N13R0-… B3
A-05-xNBV sembly N
HLR01.1N-15K0-N08R1-… B4
A-05-xNBV sembly N
HLR01.1N-23K0-N05R5-… C2
A-05-xNBV sembly N
HLR01.1N-10K0-N18R0-… B3
A-05-xNBV sembly N
HLR01.1N-14K5-N13R0-… B4
A-05-xNBV sembly N
HLR01.1N-24K0-N07R2-… C3
A-05-xNBV sembly N
HLR01.1N-36K0-N05R4-… C4
A-05-xNBV sembly N
1) Complete type with: A-007-NNNN
nents and Accessories", type code HLR
nents and Accessories", dimension tables HLR
Fig.12-8: Assignment braking resistors HLR ↔ HCS03
HLR01.1 HLR01.1 HLR01.1 HLR01.1 HLR01.1 HLR01.1

Description Symbol Unit N-01K6- N-0300- N-03K5- N-04K5- N-06K5- N-10K0-
N18R0 N17R5 N19R0 N18R0 N18R0 N18R0

IP20
IEC60529
nal data
and Controls

N18R0 N17R5 N19R0 N18R0 N18R0 N18R0
Mass (weight) m kg 5,20 3,00 9,50 13,00 22,00
RDC_Bleed‐
Nominal braking resistance ohm 18,00 17,50 19,00 18,00
er
Braking resistor continuous power PBD kW 1,60 0,30 3,50 4,50 6,50 10,00

PBS kW 34,00 37,00 31,00 33,00
UDC = 850 V

WR_max kWs 109,00 37,00 252,00 432,00 686,00 1080,00
absorbed
Maximum allowed on-time duty ton_max s 3,30 1,00 8,00 13,00 21,00 32,00
Minimum allowed cycle time Tcycl s 120,00
Cooling type n f n
V m3/h - 200,00 -
ing
ΔT K >40 20 >65 >100

dtop mm 1000 80 1000
device1)
dbot mm 200 80 300
the device2)
Horizontal spacing on the device3) dhor mm 200 0 300
Allowed range tightening torque M Nm 1,80 1,50 2,00

AL mm2 2,5 4,0 6,0 10,0
IEC 60364‑5‑52;4)
AL AWG 14 12 10 8
13.5.1; Ta ≤ 40 °C

CAUTION
and Controls


N15R0 N11R7 N15R0 N14R0 N13R0 N13R0

IP20
IEC60529
nal data
Mass (weight) m kg 6,20 4,50 13,00 22,00 33,00
RDC_Bleed‐
Nominal braking resistance ohm 15,00 11,70 15,00 14,00 13,00
er

PBS kW 40,00 56,00 40,00 43,00 46,00 4,00
UDC = 850 V

WR_max kWs 137,00 56,00 360,00 672,00 1003,00 1566,00
absorbed
Cooling type n f n
V m3/h - 200,00 -
ing
ΔT K >40 23 >65

dtop mm 1000 80 1000
device1)
dbot mm 200 80 300
the device2)
Allowed range tightening torque M Nm 0,50 4,00 2,00 3,00

AL mm2 4,0 6,0 10,0 16,0
IEC 60364‑5‑52;4)
AL AWG 12 10 8 6
13.5.1; Ta ≤ 40 °C
and Controls

CAUTION


N07R4 N07R0 N08R0 N07R3 N08R1 N07R2

IP20
IEC60529
nal data
Mass (weight) m kg 9,50 5,50 22,00 33,00 80,00
RDC_Bleed‐
Nominal braking resistance ohm 7,40 7,00 8,00 7,30 8,10 7,20
er

PBS kW 81,00 93,00 75,00 82,00 74,00 83,00
UDC = 850 V

WR_max kWs 246,00 93,00 612,00 1056,00 1584,00 2592,00
absorbed
Cooling type n f n
V m3/h - 200,00 -
ing
ΔT K >100 20 >65 >100

dtop mm 1000 80 1000
device1)
dbot mm 300 80 300
the device2)
Allowed range tightening torque M Nm 3,00 4,00 3,00 6,00

and Controls

N07R4 N07R0 N08R0 N07R3 N08R1 N07R2
AL mm2 10,0 16,0 25,0 35,0
IEC 60364‑5‑52;4)
AL AWG 8 6 3 2
13.5.1; Ta ≤ 40 °C

CAUTION


Description Symbol Unit N-06K5- N-12K5- N-17K0- N-1K08- N-23K0- N-36K0-
N06R1 N05R5 N05R1 N05R0 N05R5 N05R4

IP20
IEC60529
nal data
Mass (weight) m kg 13,00 33,00 43,00 8,00 56,00 93,00
RDC_Bleed‐
Nominal braking resistance ohm 6,10 5,50 5,10 5,00 5,50 5,40
er

PBS kW 98,00 109,00 117,00 130,00 109,00 111,00
UDC = 850 V

WR_max kWs 356,00 900,00 1632,00 130,00 2429,00 3888,00
absorbed
Cooling type n f n
V m3/h - 200,00 -
ing
ΔT K >100 22 >200
and Controls

Description Symbol Unit N-06K5- N-12K5- N-17K0- N-1K08- N-23K0- N-36K0-
N06R1 N05R5 N05R1 N05R0 N05R5 N05R4
dtop mm 1000 80 1000
device1)
dbot mm 300 80 300
the device2)
Allowed range tightening torque M Nm 6,00

AL mm2 16,0 35,0 16,0 50,0
IEC 60364‑5‑52;4)
AL AWG 6 2 6 1/0
13.5.1; Ta ≤ 40 °C

CAUTION
12.5 Installation and Mounting

12.5.1 Notes on Installation and Mounting
Connect the braking resistor to the equipment grounding system of the control
cabinet.
DANGER ● Braking resistors of type of construction A: For the equipment grounding
connection, mount the joint bar on the front between braking resistor and
drive controller.
● Braking resistors of type of construction N: Connect the equipment
grounding conductor in stationary form to the equipment grounding sys‐
tem of the control cabinet.
connection to the housings of the braking resistors.
and Controls

sufficient.
supply feeder

A ≤ 16 mm² A
16 mm² < A ≤ 35 mm² 16
35 mm² < A A/2

61800-5-1:2003, table 2
Hot surface!
The surface and housing parts of the braking resistor can have a temperature
of more than 250 °C in operation.
CAUTION Do not stress and do not touch surfaces and housing parts of braking resistors.
Before touching the surfaces and housing parts of braking resistors, wait for an
adequate time after switching off power to allow the braking resistors to cool
down.
and Controls
High temperatures in the proximity of braking resistors!

Mount the braking resistors to temperature-resistant mounting surfaces in such
a way that the air can freely enter and escape and heat does not accumulate.
CAUTION Take the minimum distances dtop, dbot and dhor into account.
Take into account that the temperatures in the range of the indicated minimum
distances can be above 250 °C.
Leave sufficient distance to combustible objects and take into account that
braking resistors dissipate a lot of heat.
Make sure there is free cooling air supply at the bottom dbot and cooling air
discharge at the top dtop.
The space must be able to discharge the energy converted by the braking re‐
sistor.
Observe degree of protection!

When mounted outdoor or at the outside of the control cabinet, ob‐
serve the degree of protection IP20 of the braking resistor.
Protect the devices against intrusion of water.
12.5.2 Braking Resistors HLR01.1, Type of Construction A (Version for Device

Mounting)
General Information
Only HLR01 braking resistors of the type of construction A (see type code) are
suited for mounting to HCS03 drive controllers.
The braking resistors provided for mounting above the HCS03 drive
controllers are cooled by the cooling air of the drive controller flow‐
ing off.
For other mounting situations, the HLR braking resistors must be
separately cooled:
Cooling air current of at least 200 m³/h through the braking resistor
and Controls
HCS03.1E-W0070-xNBV With HLR01.1N-0300-N17R-A-007-NNNN

Dimensions for Mounting
Dimensions in mm
dtop, dbot, dhor Distances at top and bottom and on the sides, data see chapter "Tech‐
nical Data"
Fig.12-14: Mounting example device / braking resistor
HLR01.1N‑0300‑N17R5‑A‑007‑NNNN
and Controls
Dimensional Drawing
HLR01.1N-0300-N17R5-A-007-
NNNN
Dimensions in mm
Fig.12-15: Dimensions braking resistor HLR01.1N-0300-N17R5-A-007-NNNN
and Controls
HCS03.1E-W0100-xNBV With HLR01.1N‑0470‑N11R7‑A‑007‑NNNN

Dimensions in mm
nical Data"
HLR01.1N‑0470‑N11R7‑A‑007‑NNNN and
HLR01.1N‑0780‑N07R7‑A‑007‑NNNN
and Controls
Dimensional Drawing
HLR01.1N‑0470‑N11R7‑A‑007‑N
NNN
Dimensions in mm
Fig.12-17: Dimensions braking resistor HLR01.1N‑0470‑N11R7‑A‑007‑NNNN
and Controls
HCS03.1E-W0150-xNBV With HLR01.1N‑0780‑N07R7‑A‑007‑NNNN

Dimensions in mm
nical Data"
HLR01.1N‑0780‑N07R7‑A‑007‑NNNN
and Controls
Dimensional Drawing
HLR01.1N‑0780‑N07R0‑A‑007‑N
NNN
Dimensions in mm
Fig.12-19: Dimensions braking resistor HLR01.1N‑0780‑N07R0‑A‑007‑NNNN
and Controls
HCS03.1E-W0210-xNBV With HLR01.1N‑1K08‑N05R0‑A‑007‑NNNN

Dimensions in mm
nical Data"
HLR01.1N‑1K08‑N05R0‑A‑007‑NNNN
and Controls
Dimensional Drawing
HLR01.1N-1K08-N05R0-A-007-
NNNN
Dimensions in mm
Fig.12-21: Dimensions braking resistor HLR01.1N-1K08-N05R0-A-007-NNNN
and Controls
12.5.3 Braking Resistors HLR01.1, Type of Construction N (Version for Free

Assembly)
Fixed Resistor IP 20 Type A
nical Data"
1) Allowed mounting position (terminals at the bottom; on horizontal sur‐
faces)
2) Inadmissible mounting position (terminals at the top, to the right and to
the left)
Fig.12-22: Type A5 – A6
Type Dimensions in mm Weight in kg
H B T H1 B1 D
A5 586 185 120 526 150 M6 5,2
A6 686 185 120 626 150 M6 6,2
A7 549 275 120 430 240 M6 6,6
A8 649 275 120 530 240 M6 7,9
Fig.12-23: Dimension table braking resistor type A

and Controls
Steel-Grid Fixed Resistor IP 20 Type B
nical Data"
1) Allowed mounting position (terminals at the bottom; perforated sheet at
the top and at the bottom; on horizontal surfaces)
2) Inadmissible mounting position (terminals at the top, to the right and to
the left)
Fig.12-24: Type B1 – B4

B T H B1 T1 D
B1 490 300 270 380 270 M10 9,5

B2 490 400 270 380 370 M10 13
B3 490 600 270 380 570 M10 22
B4 490 800 270 380 770 M10 33
B5 490 1000 270 380 970 M10 44
Fig.12-25: Dimension table braking resistor type B

and Controls
Steel-Grid Fixed Resistor IP 20 Type C
nical Data"
1) Allowed mounting position (vertically on horizontal surfaces)
Fig.12-26: Type C1 – C7

B T H B1 T1 D
C2 595 490 710 570 380 M10 56

C3 795 490 710 770 380 M10 80
C4 995 490 710 970 380 M10 93
Fig.12-27: Dimension table braking resistor type C

and Controls
and Controls
HMF01.1 - Motor Filter
13 HMF01.1 - Motor Filter

13.1 Type Code
Fig.13-1: Type code of motor filter HMF01.1
13.2 Type Plate

Each motor filter is identified by a type designation. There is a type plate at‐
tached to all components.
and Controls
1 Type designation
2 Part number
3 Serial number
4 Production date
Fig.13-2: Type plate
13.3 Electrical Data

HMF01.1 HMF01.1 HMF01.1 HMF01.1 HMF01.1 HMF01.1

A-N0K2- A-N0K2- A-N0K2- A-N0K2- N-N0K2- N-N0K2-
Description Symbol Unit D0045- D0073- D0095- D0145- M0012- M0028-
A-500- A-500- A-500- A-500- A-500- A-500-

IP20
IEC60529
n.s.
(UL)
n.s.
(UL)
Mass (weight) m 15 15,00 20,00 5,10 11,20
Inductance µH 3 × 160 3 × 100 3 × 78 3 × 50 3 × 900 3 × 450
Allowed switching frequencies fs kHz 4 4, 8, 12, 16
Allowed continuous output current

Iout_cont4 A 45,0000 73,0000 95,0000 145,0000 12,0000 28,0000
at fs = 4 kHz
Maximum output current at

Iout_max4 A n.s. 28,0000 70,0000
fs = 4 kHz
Rise of voltage at output with

ULN_nenn and 15 m motor cable dv/dt kV/µs 1,00
length phase-ground (10‑90%)
Rise of voltage at output with
ULN_nenn and 15 m motor cable dv/dt kV/µs 1,00
length phase-phase (10‑90%)
current and continuous DC bus PDiss_cont W 120,00 160,00 190,00 220,00 25,00 50,00
power respectively (UL)
Insulation resistance at DC 500 V Ris kOhm n.s. 600,00

and Controls
HMF01.1 HMF01.1 HMF01.1 HMF01.1 HMF01.1 HMF01.1

A-N0K2- A-N0K2- A-N0K2- A-N0K2- N-N0K2- N-N0K2-
Description Symbol Unit D0045- D0073- D0095- D0145- M0012- M0028-
A-500- A-500- A-500- A-500- A-500- A-500-
ALN mm² 16 35 50 95 1,5 6
IEC 60364‑5‑52; at IL_cont5)

508 A (internal wiring); at IL_cont (UL) ALN AWG 6 2 0 4/0 14 10
6)
n.s. Not specified

13.5.1; Ta ≤ 40 °C
Fig.13-3: HMF - Technical data - Currents, voltages, power
13.4 Mechanical Data

13.4.1 Dimensions, Mass
Fig.13-4: Dimensions motor filter HMF01.1A-N0K2-M0012-A-500-NNNN

and Controls
Fig.13-5: Dimensions motor filter HMF01.1A-N0K2-M0028-A-500-NNNN
Type Dimensions [mm] Weight [kg] Tightening torque electrical

connections
A B C D E
[Nm]
0012 155 91,5 162 130 71,5 5,1 0,6–0,8

0028 210 130 182 175 95 11,2 12
Fig.13-6: Dimensions motor filter

and Controls
Dimensions in mm
Fig.13-7: Dimensions motor filter HMF01.1A-N0K2-D0045-A-500-NNNN
Fig.13-8: Dimensions motor filters HMF01.1A‑N0K2‑D0073‑A‑500‑NNNN,

HMF01.1A‑N0K2‑D0095‑A‑500‑NNNN and
HMF01.1A‑N0K2‑D0145‑A‑500‑NNNN
and Controls
Type Dimensions [mm] Weight [kg] Tightening torque electrical

connections
B H T B H1
[Nm]
See above fig. "Dimensions motor filter HMF01.1A-N0K2-

0045 15 1,5
D0045-A-500-NNNN"
0073 225 315 270 175 257 15 6
0095 225 315 270 175 257 20 6
0145 350 400 260 250 310 20 25
Fig.13-9: Dimensions motor filter

and Controls
13.5 Arrangement of the Components HCS03.1 / Motor Filter HMF
Fig.13-10: Sample mounting HCS03.1E-W0070 / HMF01.1A-D0K2-D0045

and Controls
Fig.13-11: Sample mounting HCS03.1E-W0100, -0150, -0210 / motor filter
HCS03.1E- H B B1
W0100 720 225 175

W0150 720 225 175
W0210 780 350 250
Fig.13-12: Dimension table for sample mounting HCS03.1E-.. / motor filter HMF
and Controls
13.6 Arrangement of the Components HCS03.1 / Motor Filter and

Mains Filter
Fig.13-13: Arrangement HCS03.1E-W0070 / motor filter and mains filter +

HAS05.1‑001 + HAS05.1-002
For information on the HAS accessories, see Project Planning Man‐

ual on the drive system Rexroth IndraDrive.
and Controls
Fig.13-14: Arrangement of device 0100, 0150, 0210 / motor filter and mains filter
and Controls
HCS03.1E- H B1 B
W0100 980 175 225

W0150 980 175 225
W0210 1090 250 350
Fig.13-15: Dimension table for sample mounting HCS03.1E-.. / mains filter / motor
filter
and Controls
and Controls
HAC01 - Housing for Control Sections
14 HAC01 - Housing for Control Sections

14.1 Identification
14.1.1 Type Code HAC01.1
Fig.14-1: Type code HAC01.1
14.1.2 Type Plate HAC01
1 Type
2 Part number
3 Serial number
4 Bar code
5 Hardware index
6 Production week (example: 06W31 meaning year 2006, week 31)
Fig.14-2: Type plate control section (example)
and Controls
14.2 Usage
The additional component HAC01 is a housing in which
control sections are inserted and loops through the control
voltage supply from connection "0V, 24V" to the control sec‐
tions.
The additional component HAC01 can be optionally sup‐
plied. There is no control section contained in the scope of
supply of HAC01.
HAC01
Fig.14-3: Usage
and Controls
14.3 Mechanical and Electrical Data

14.3.1 Dimensional Drawings HAC01.1
HAC01.1-001-NNN-NN
All dimensions in mm
E Minimum mounting clearance
Fig.14-4: Dimensions HAC01.1-001-NNN-NN
and Controls
HAC01.1-002-NNN-NN
E Minimum mounting clearance
Fig.14-5: Dimensions HAC01.1-002-NNN-NN
14.3.2 Connections at HAC01

X13, Control Voltage
tion
4 +24V Power supply and "looping
through"
3 +24V
2 0V Reference potential for power
1 0V

and Controls

Power consumption W PN3 (see technical data of the device)
Voltage load capacity V UN3 (see technical data of the device)

+24V to +24V, 0V to 0V
Continuous current PN3/UN3

+24V to +24V, 0V to 0V
Inrush current IEIN3
Polarity reversal protection Within the allowed voltage range by internal protective diode

Power Consumption at X13 The power consumption at X13 is determined by the control section and op‐
tional modules used.
Overvoltage
Overvoltage greater than 33 V has to be discharged by means of
This includes:
● 24V power supply units that reduce incoming overvoltage to
the allowed value.
and mains cables and can absorb overvoltage by inductive or
capacitive coupling.
Specification of Control Voltage See chapter 5.6 Control Voltage Specification (24V Supply), page 30
and Controls
and Controls
HAT01 - Control Module for Holding Brake
15 HAT01 - Control Module for Holding Brake

15.1 Brief Description, Usage and Design
Brief Description The control module HAT01 belongs to the Rexroth IndraDrive product range
and is used for the "safety related braking and holding system".
HAT01 control modules are mounted on a top-hat rail in the control cabinet.
Usage The types are used as follows:
Type Usage
HAT01.1-002-NNN-NN To control an electrically releasing, redun‐

dant holding brake.
Fig.15-1: Usage

15.2.1 Type Code
available versions.
Fig.15-2: Type code

and Controls
1 Type plate
Fig.15-3: Type plate arrangement
Type Plate
1 Device type
2 Part number
3 Serial number
4 Bar code
5 Country of manufacture
6 Production week, 07W24 meaning year 2007, week 24
7 Hardware index
Fig.15-4: Type plate
15.3 Scope of Supply

The scope of supply of the control module HAT01 contains:
● Connectors X1, X2, X3
and Controls
15.4 Dimensions
A Minimum mounting clearance
dtop, dbot See table "Technical data"
15.5 Technical Data

Technical data
Description Symbol Unit HAT01.1-002-NNN-NN
Weight m kg 0,6
Allowed mounting position Vertical
Minimum distance from the top of the device5) dtop mm 50
Minimum distance from the bottom of the de‐

dbot mm 50
vice6)
Minimum distance on the side of the device dhor mm -

and Controls
Description Symbol Unit HAT01.1-002-NNN-NN
Cooling type3) n
Listing according to UL standard (UL) In preparation
UL files (UL) In preparation
Control voltage supply
Brake cable length < 50 m: 24 ±5%
Rated control voltage input (UL)1) UN3 V
Brake cable length > 50 m: 26 ±5%
Maximum allowed voltage for 1 ms2) UN3_max V 33
Rated power consumption control voltage input

PN3 W 1,5
at UN3 (UL)
Inrush current at 24V supply IEIN3 A 35
Pulse width of IEIN3 tEIN3Lade ms 4
Input capacitance CN3 mF 3,6
Max. 7.5
Power dissipation PDiss W
(brake controlled)
Output current IBr A See "X2, Output to Brake"
1) Observe supply voltage for motor holding brakes

2) See following note regarding overvoltage
3) n: Natural convection; f: Forced cooling
Fig.15-6: HAT01 - Technical data
Overvoltage of more than 33V has to be discharged by means of

This includes:
● 24V power supply units that reduce incoming overvoltages to
the allowed value.
and mains cables and can absorb overvoltages by inductive
or capacitive coupling.
and Controls
Distances
A Air intake
B Air outlet
C Mounting surface in control cabinet
dtop Distance top
dbot Distance bottom
Fig.15-7: Air intake and air outlet at drive controller
and Controls
15.6 Connection Points

15.6.1 Front View
Front view Connection point Description
X1 24 V power supply (24V, 0V)

X2 Output to brake
X3 Signal exchange with control section;
connection with ready-made cable RKS0007
A Strain relief:
Fix connection cable with cable tie
15.6.2 X1, 24 V Power Supply

tion
X1.1 +24V Power supply and "looping
through"
X1.2 +24V
X1.3 0V Reference potential for power
X1.4 0V
X1.5 - Housing potential
Screw connection at connector Unit Min. Max.

Tightening torque Nm 0,5 0,6
Power consumption W See PN3
Voltage load capacity V See UN3

and Controls
Current carrying capacity "looping through" from A 6;

+24V to +24V, 0V to 0V max. 1 other HAT01 for oper‐
ation with HMD01
Polarity reversal protection - Within the allowed voltage range by internal protective diode
15.6.3 X2, Output to Brake

tion
X2.1 Br+ Connection to positive pole of
holding brake
X2.2 Br- Connection to negative pole
of holding brake
X2.3 - Housing potential HAT01
(connection for cable shield)

Output current IBr_cont A 6
Output current IBr_max; t ≤ 1 s; IAV ≤ IBr_cont A 7,5
Output voltage UBr V UN3 ‑ 0.5 V UN3
Output protection - Short-circuit proof and overload-proof within the allowed volt‐
age range
15.6.4 X3, Signal Exchange With Control Section

tion
X3.1 +24V Power supply of isolated in‐
puts/ outputs X3.3 and X3.4
X3.2 +24V
with 24 V / 0.1 A
X3.3 HAT-Steuer Input for brake control via UBr
(X2)
X3.4 HAT-Diagnose Output HAT-Diagnose
X3.5 0V Reference potential for power
supply at X3.1
X3.6 0V
X3.7 - Connection for cable shield

and Controls

Allowed cable length m 3
Input X3.3 controls output Br+/Br- (X2) 250 Hz ±20%, duty cycle ~50% → "H" level at output Br (X2)
(dynamized input)
Output voltage at X3.4 shows status of controlled V Brake applied: 150 Hz ±20%
brake Brake released: "H", (max. X3.1 - 0.5 V)
Brake faulty: "L"
Ready-made connection cable - RKS0007

RKS0007 at HAT01
Fig.15-12: Interconnection diagram RKS0007

and Controls
Accessories
16 Accessories
16.1 HAS01, Basic Accessories
16.1.1 Type Code
available versions.
Fig.16-1: Type code HAS01.1
16.1.2 Brief Description

Accessories for mounting and installing the drive controllers in a group, i.e. next
to each other.
and Controls
Accessories
As adjusted to the device widths, we distinguish 3 types:

● HAS01 without contact bars, (-NNN)
● HAS01 with contact bars (-072-) to connect the DC buses
● HAS01 with contact bars (-072-) to connect the DC buses and joint bars
to connect the equipment grounding conductors of the devices
Observe that the contact bars of the basic accessories HAS01 are
used for connection to the drive controller on the left-hand side.
16.1.3 Usage
The HAS01 accessories are used to
● fix the drive controllers to a mounting surface
● connect the DC bus connections of drive controllers
● connect the 24V supply of drive controllers of the Rexroth IndraDrive M
range
● connect the equipment grounding conductor from drive controller to drive
controller or supply unit
● increase the current carrying capacity of the contact bars in the DC bus
for high-performance devices (by means of the parts "end piece" and
"bar" in HAS01; see chapter "Assignment")
Use of the parts "end piece" and "bar"

For high-performance devices, you have to mount the end pieces
and bars contained in the HAS01 accessory (see chapter "Assign‐
ment").
See sections "DC Bus Connection (L+, L-)" and "Terminal Block, 24V - 0V (24V
Supply)" in the Project Planning Manual "Rexroth IndraDrive, Supply Units and
Power Sections".
16.1.4 Assignment
The accessories are assigned to the individual devices depending on the device
width (see section "Type Code").
Device type Width / mm Accessory HAS01.1-

With"end
piece"
HMS01.1N- W0020 50 050 -

W0036 50 050 -
W0054 75 075 -
W0070 100 100 -
W0110 125 125 -
W0150 150 150 -
W0210 200 200 ■
W0350 350 350 ■
and Controls
Accessories
Device type Width / mm Accessory HAS01.1-

With"end
piece"
HMD01.1N- W0012 50 050 -
W0020 50 050 -
W0036 75 075 -
HMS02.1N- W0028 49.5 050 -
W0054 74.5 075 -
F0028
F0054
F0070
F0110
F0150
F0210
HLB01.1 D 100 100 -
HLC01.1 D 100 100 -
HMV01.1E- W0030 150 150 -
W0075 250 250 ■
W0120 350 350 ■
HMV01.1R- W0018 175 175 -
W0045 250 250 ■
W0065 350 350 ■
W0120 350 350 ■
HMV02.1E- F0025
F0075
HMV02.1R- W0015 150 150 -
F0150
HCS02.1N- W0012 65 065 -
W0028 65 065 -
W0054 105 105 -
W0070 105 105 -
HLB01.1 C 65 065 -
HLC01.1 C 50 050 -
HCS03.1N- W0070 125 125 -
W0100 225 225 -
W0150 225 225 -
W0210 350 350 ■
Fig.16-2: Device width

and Controls
Accessories
16.1.5 Scope of Supply

Components of the accessory: see accompanying notes
and Controls
Accessories
Fig.16-3: Accompanying note

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16.1.6 Mounting the Parts "Bar" and "End Piece" of the Accessories HAS01
The parts "bar" and "end piece" increase the current carrying capacity of the
DC bus connections by reducing the involved contact resistances.
1 Bar
2 End piece (right end)
3 End piece (left end)
Fig.16-27: Mounting bar and end piece of HAS01
● Ad 1: Use the bars (‑042) contained in all HAS01.1-***-072‑** as shown
in the figure at L+ and L‑.
● Ad 2 and 3: Use the end pieces contained in all HAS01.1-350-***-** and
HAS01.1-200‑***‑** at the right and left ends of the DC bus connections
in the drive system.
16.2 HAS02, Shield Connection

Accessories for appropriate connection of the motor cable to the drive control‐
ler, especially the shield connection of the motor cable.
There are appropriate HAS02 accessories for the different drive controllers.
and Controls
Accessories
16.2.2 Type Code
16.2.3 Usage
The HAS02 accessories are used for
● strain relief of the motor cable
● connecting the shield of the motor cable to the drive controller
16.2.4 Assignment of Accessory HAS02

See section "Type Code (Device Assignment)"
and Controls
Accessories

For the scope of supply and the components of HAS02, see the corresponding
accompanying notes.
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16.2.6 Mounting the HAS02 Accessories

General Information
1 Screw in thread XS2

2 Fixing device of shielding plate
3 Shielding plate
4 Shield of motor cable
5 Clip
Fig.16-43: Shield connection of motor cable
● Unscrew bottom or bottom left fixing screw of drive controller.
● Put fixing device 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 12 mm for the thread of the
shield connection XS2.
CAUTION
● Screw second screw (M6 × 12) in thread XS2 at bottom of drive controller.
● Screw shielding plate to sheet metal of accessories according to desired
cable routing of motor cable (45° or horizontal). (The figure below illus‐
trates cable routing with 45°.)
● According to diameter of motor cable, fix motor cable at corresponding
point of shielding plate (12–18 mm or 19–30 mm) with a clip. Make sure
that shield of motor cable has good contact with shielding plate (see figure
below).
and Controls
Accessories
HAS02.1-001 at HMS01.1N-W0054
1 Fixing device
2 Shielding plate
3 Clip
4 Different possibilities of mounting the shielding plate, according to motor
cable routing
Fig.16-44: HAS02.1-001 at bottom of drive controller HMS01.1N‑W0054
Mounting 1. By means of supplied screws, fasten fixing device to bottom of drive con‐
troller.
2. Fix shielding plate to fixing device according to desired motor cable rout‐
ing.
3. Fix shield of cable to shielding plate with appropriate clip.
and Controls
Accessories
HAS02.1-002 at HCS02.1E-W0054
1 Fixing device
2 Shielding plate
3 Clip
cable routing
Fig.16-45: HAS02.1-002 at bottom of drive controller HCS02.1E‑W0054
troller.
ing.
and Controls
Accessories
HAS02.1-003 at HMS01.1N-W0210
1 Fixing device
2 Shielding plate
3 Clip
cable routing
troller.
ing.
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Accessories
HAS02.1-004 at HCS03.1E-W0070
1 Fixing device
2 Shielding plate
3 Clip
cable routing
Fig.16-47: HAS02.1-004 at bottom of drive controller HCS03.1E-W0070
troller.
ing.
and Controls
Accessories
HAS02.1-005 at HCS03.1E-W0100 / 150
1 Fixing device
2 Shielding plate
3 Clip
cable routing
Fig.16-48: HAS02.1-005 at bottom of drive controller HCS03.1E-W0100 / 0150
troller.
ing.
and Controls
Accessories
HAS02.1-008 at HCS03.1E-W0210
1 Fixing device
2 Shielding plate
3 Clip
cable routing
Fig.16-49: HAS02.1-008 at bottom of drive controller HCS03.1E-W0210
troller.
ing.
HAS02.1-010 at HMS02.1N‑W0028 / 54
1 Fixing device
2 Shielding plate
Fig.16-50: HAS02.1-010-NNN-NN at bottom of drive controller
HMS02.1N‑W0028 / 54
and Controls
Accessories
1. Screw fixing device to equipment grounding conductor connection of drive

controller.
2. Fix shield of cable with shielding plate to fixing device.
HAS02.1-014 at HMS01.1N-W0350
1 Fixing device
2 Shielding plate
3 Clip
1. By means of supplied screws, fasten fixing device to front of blower unit.
2. Fix shielding plate to fixing device.
16.2.7 Shield Connection of the Motor Cable via Mains Filter

General Information
There is a special shielding plate for shield connection of the motor cable via
the mains filter at the drive controller:
and Controls
Accessories
Using the shielding plate guarantees optimum shield contact of the

motor cable. You should therefore, where possible, always use the
shielding plate.
The shielding plate is only available as an option.
HAS02.1-006 With Motor Cable and Mains Filter
1 Fixing device
2 Shielding plate
3 Clip
Fig.16-52: HAS02.1-006 at bottom of mains filter (rated current 50 A)
1.Hang up fixing device at bottom of mains filter at threaded bolts and fasten
with supplied nuts.
2. Screw shielding plate to fixing device.
The shield terminals must not be used to provide strain relief.

and Controls
Accessories
HAS02.1-007 With Power Supply Cable and Mains Filter
1 Fixing device
2 Shielding plate
3 Clip
4 Different possibilities of mounting the shielding plate, according to cable
routing
5 Power supply cable
6 Motor cable
Fig.16-53: HAS02.1-007 at bottom of mains filter (rated current 80 A / 106 A)
1.Hang up fixing device at bottom of mains filter and fasten with supplied
screws.
2. Screw shielding plate to fixing device.
According to desired cable routing, the shielding plate can be mounted in dif‐
ferent positions.
3. Fix shield of cable to shielding plate with clip.

and Controls
Accessories
HAS02.1-009 With Power Supply Cable and Mains Filter
1 Fixing device
2 Shielding plate
3 Clip
4 Different possibilities of mounting the shielding plate, according to cable
routing
5 Power supply cable
6 Motor cable
Fig.16-54: Shielding plate HAS02.1-009 at bottom of mains filter (rated current 146
A)
troller.
ing.

and Controls
Accessories
16.3 HAS03, Control Cabinet Adapter

16.3.1 Type Code
16.3.2 Usage
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.
and Controls
Accessories
A Control cabinet adapter

B Mounting surface in control cabinet
Fig.16-56: How to use the control cabinet adapters
Observe the maximum allowed tightening torque of 6 Nm at HAS03.
Mechanical stability of the adapted device requires a rigid connec‐

tion via DC bus rails to a neighboring device without adapter.
● Do not operate HAS03 without neighboring device.
● Mount HAS03 to bare metal mounting plate.
16.3.3 Assignment of Accessory HAS03

See section "Type Code (Device Assignment)".

Scope of Supply For the scope of supply and the parts of HAS03, see the corresponding ac‐
companying note.
and Controls
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and Controls
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and Controls
Accessories
16.4 HAS04, Capacitor

Capacitors from the DC bus connections L+ and L- against housing.
16.4.2 Type Code
Using the HAS04 accessories requires additional mounting clear‐

ance at the drive controller.
Observe the dimensions of HAS04.
16.4.3 Usage
The HAS04 accessories are used to
● operate HCS02 and HCS03 drive controllers at the HNF01.1 mains filter
● operate HMS01 drive controllers at HCS02 and HCS03 drive controllers
HAS04 type Usage
At DC bus connections of HCS02 drive

HAS04.1-001-NNN-NN
controllers
At DC bus connections of HCS03 drive
HAS04.1-002-NNN-NN
controllers
Fig.16-60: HAS04 type

and Controls
Accessories
16.4.4 Assignment
HAS04.1
Device -001 -002
HCS02.1E-W0028 ■ -
HCS02.1E-W0054 ■ -
HCS02.1E-W0070 ■ -
HCS03.1E-W0070 - ■
HCS03.1E-W0100 - ■
HCS03.1E-W0150 - ■
HCS03.1E-W0210 - ■
Fig.16-61: Assignment of accessory HAS04

The HAS04 accessories are available as an option, they are not part of the
standard scope of supply.
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Accessories
Fig.16-62: Accompanying note HAS04.1-001

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Fig.16-63: Accompanying note HAS04.1-002

and Controls
Accessories
16.4.6 Capacitor
Connection HAS04
Fig.16-64: Connection HAS04
16.4.7 Mounting Dimensions
Fig.16-65: Mounting dimensions HAS04
Min. mounting width B Device height H Device depth

Device
[mm] [mm] [mm]
HAS04.1-001 30 75 < 150

HAS04.1-002 40 75 < 150
Fig.16-66: Mounting dimensions

and Controls
Accessories
16.4.8 Mounting the HAS04.1-001 Accessories

Dangerous contact voltage at device housing! Lethal electric shock!
Connect HMx01 drive controllers to the HCS02 drive controller by means of bus
bar 2 (see figure below). Bus bar 2 replaces the equipment grounding connec‐
WARNING tion 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 bus bar
3 Equipment grounding connection at HMx01
Fig.16-67: HAS04.1-001 at drive system HCS02 with HMx01 without touch guard
mounted
and Controls
Accessories
1 Mounted HAS04.1-001 accessories

2 Mounted bus bar
Fig.16-68: HAS04.1-001 at drive system HCS02 with HMx01 with touch guard
mounted
16.4.9 Mounting the HAS04.1-002 Accessories

Dangerous contact voltage at device housing! Lethal electric shock!
Connect the HAS04.1-002 accessories to drive controller HCS03 via the joint
bar (see figure below).
WARNING
and Controls
Accessories

2 Joint bar
Fig.16-69: HAS04.1-002 at drive system HCS03.1E-W0070, -W0100, -W0150 with
HMx01 without touch guard mounted

Fig.16-70: HAS04.1-002 at drive system HCS03.1E-W0210 with HMx01 without
touch guard mounted
and Controls
Accessories
Fig.16-71: HAS04.1-002 at drive system HCS03 with HMx01 with touch guard
mounted
16.5 HAS05, Accessories for Connection Points

16.5.1 Overview of Types
The product line HAS05 includes:
● Cables
● Connectors
● Adapters
HAS05 type Brief description / usage
HAS05.1-001-NNN-NN Adapter for mains and motor connection

Is used for electrical connection between output filter
HMF01.1A-D0K2-D0045 and HCS03.1E-W0070, as well
as between mains filter HNK01.1A-A075-E0050 and
HCS03.1E-W0070
HAS05.1-002-NNN-NN Extension
Is used for electrical connection between mains filter
HNK01.1A-A075-E0050 and HCS03.1E-W0070, if an
output filter has been mounted between HCS03.1 and
mains filter
HAS05.1-003-NNN-NN Signal level converter encoder emulation
Increases voltage level at output of optional module MEM
(encoder emulation) to voltage range 5 … 30 V
and Controls
Accessories
HAS05 type Brief description / usage

HAS05.1-004-NNL-NN Adapter DC bus connection
HAS05.1-004-NNR-NN With this accessory, you can wire several systems of
drive controllers with greater cross sections at DC bus
connections L+ and L-
NNL: Outgoing direction "left"
NNR: Outgoing direction "right"
HAS05.1-005-NNN-NN Signal level converter RS232/RS485
Converts the serial interface of control sections from
RS232 standard to RS485 standard
HAS05.1-006-NNN-NN Adapter for controlling motor holding brake
HAS05.1-007-NNL-NN Adapter from D-Sub to terminal connector
HAS05.1-007-NNR-NN Universal adapter for safety technology for easier X41
wiring of 2nd channel
NNL: For mounting to double-axis control sections
CDB01 at OP ST1
NNR: For mounting to double-axis control sections
CDB01 at OP ST2
HAS05.1-008-NNN-NN Adapter for connecting two cables
With this accessory, you can connect 2 ring cable lugs
each at connections A1, A2 and A3 of X5 (motor connec‐
tion)
Fig.16-72: HAS05 types
16.5.2 Type Code

available versions.
and Controls
Accessories
16.5.3 HAS05.1-001, Adapter for Mains and Motor Connection

Brief Description and Usage
Brief Description The accessory HAS05.1-001 brings the mains and motor connections from the
bottom of the device to the front of an HCS03.1-W0070.
and Controls
Accessories
You need this adapter when additional components are mounted to HCS03.1E-
W0070 in order to connect them to the mains and motor input.
Assignment HAS05.1-001 can be used at the following drive controllers:
Device HAS05.1-001
HCS03.1E-W0070 ■
Fig.16-74: Assignment accessory HAS05.1-001

Scope of Supply Order this accessory as a separate item. It is not part of the scope of supply of
the device.
Parts of the accessory: see accompanying note
Parts of HAS05.1-001
Fig.16-75: Parts of HAS05.1-001

Technical Data
Connection, Mounting Dimensions
Allowed Cross Sections The accessory HAS05.1 has been dimensioned to insert lines with ferrules in
it.
Unit HAS05.1-001
Allowed connection cross section stranded wire mm² 16

Allowed connection cross section stranded wire AWG 6
Fig.16-76: Connection cross section HAS05.1-001

Mounting Dimensions The mounted adapter remains within the outer housing dimensions of the in‐
volved components HMF and HCS03.
Connection ● HMF01
Connect input of output filter HMF01 to X5 at HAS05.1-001 (motor output
of HCS03).
● HNK01
Connect output of mains filter HNK01 to X3 at HAS05.1-001 (mains input
of HCS03).
Examples of Installation Mounted accessory
and Controls
Accessories
Fig.16-77: Arrangement HCS03 / HAS05.1-001 / HMF01
16.5.4 HAS05.1-002, Extension

Brief Description The accessory HAS05.1-002 is an extension which connects the output of the
HNK01 mains filter to the mains input of HCS03 (X3).
This adapter is required when the additional components HNK01 and HMF01
are mounted to HCS03.1E-W0070. The adapter is not required without HMF01.
Assignment HAS05.1-002 can be used at the following drive controllers:
Device HAS05.1-002
HCS03.1E-W0070
■
With HNK01 and HMF01

the device.
Parts of HAS05.1-002
Fig.16-79: Parts of HAS05.1-002

and Controls
Accessories
16.5.5 HAS05.1-003, Signal Level Converter Encoder Emulation

Usage
Accessories Usage
HAS05.1-003-NNN-NN Adjusts voltage level at output of optional

module MEM to voltage range 5–30 V
Fig.16-80: Usage
Scope of Supply
the device.
Dimensions
Fig.16-81: Dimensions HAS05.1-003

and Controls
Accessories
Parts
1 Top shell of connector housing

2 Bottom shell of connector housing
3 Electronics circuit board with internal connection point
Fig.16-82: Parts
and Controls
Accessories
Description
Fig.16-83: Accessory HAS05.1-003
Connection point Type No. of poles Stranded wire

[mm²]
X2 Screw terminal 6 0,14–1,5

block
Fig.16-84: Connection
Pin Assignment Pin Signal Function
1 UB Voltage supply for electronics

2 UL Voltage supply for output driver
3 UA2+ Incremental encoder track A2
4 0Vext Reference potential
5 UA1+ Incremental encoder track A1
6 UA0+ Incremental encoder reference track A0
Shield Connect cable shield to connector housing
Fig.16-85: Assignment
If the required output voltage UL is greater than 7V, it can be used

to supply the electronics (UB), too.
and Controls
Accessories
Electrical Data Data Unit Min. Typ. Max.
Supply voltage UL V 5 30
(output driver)
Supply current UL mA 16
(output driver)
Supply voltage UB V 7 30
(electronics)
Supply current UB mA 17
(electronics)
Output voltage UA0+, UA1+, UA2+ V UL
Allowed output current per output mA 40
UA0+, UA1+, UA2+
Output resistance kOhm
Short circuit protection Present
Overload protection Present, output voltage is reduced
Fig.16-86: Supply and outputs

Example of Connection
SYS Target, e.g. PLC; incremental input, counter or trigger function

Fig.16-87: Example of connection
16.5.6 HAS05.1-004, Adapter DC Bus Connection

Brief Description The accessory HAS05.1-004-NNR and HAS05.1-004‑NNL is an adapter which
allows connecting lines with cross sections of up to 2 × 50 mm² to the DC bus
connections.
It is typically used at the DC bus connections of high-performance supply units
and inverters, when these devices have not been arranged directly side by side
(e.g. with multiple-line arrangement or with decentralized supply concepts be‐
tween several control cabinets).
The types "NNR" and "NNL" allow connections with outgoing directions to the
right and left (view to front of drive controller).
Assignment The use of the HAS05.1-004 accessory is restricted by the width of the drive
controllers:
● NNL: Device width is at least 125 mm
● NNR: Can be used independently of the device width
and Controls
Accessories
At devices with a width of 50 mm, the outgoing direction to the left can also be
used with the type "NNR".
For devices up to a width of 125 mm and for the outgoing direction to the left,
you can fix lines with a maximum cross section of 1 × 35 mm² (1 ring cable lug)
without fixing device (01) and without bar (05) directly at the terminal block (see
picture 4).
The accessory can be used at the following drive controllers:
Device HAS05.1-004-
NNL NNR
HMV01.1E-W0030, -W0075, -W0120 ■ ■

HMV01.1R-W0018, -W0065, -W0120 ■ ■
HMS01.1N: type current < W0110 - ■
HMS01.1N: type current ≥ W0110 ■ ■
HMD01.1N-W0012, -W0020, -W0036 - ■
HCS03.1E: type current ≥ W0070 ■ ■
HLB01.1D - ■
HLC01.1D - ■

the device.
and Controls
Accessories
Accompanying note HAS05.1-004-NNR-NN
Fig.16-89: Accompanying note HAS05.1-004-NNR-NN

and Controls
Accessories
Accompanying note HAS05.1-004-NNL
Fig.16-90: Accompanying note HAS05.1-004-NNL-NN

and Controls
Accessories
Technical Data
Connection, Mounting Dimensions
Allowed Cross Sections, Lengths The accessory HAS05.1-004 is used to connect lines with ring cable lugs. At
each connection point, it is allowed to use 1 or 2 lines of the same cross section.
Unit HAS05.1-004- HAS05.1-004-

NNL NNR
Allowed connection cross section mm² 35 35

stranded wire; 50 50
1 ring cable lug mounted
AWG 2 2
1/0 1/0
Allowed connection cross section mm² 35 35
stranded wire; 50 50
2 ring cable lugs mounted
AWG 2 2
1/0 1/0
Maximum tightening torque Nm 6,6 6,6
Minimum tightening torque Nm 5,4 5,4
Allowed length, required lengths See Project Planning Manual
of lay etc. "Rexroth IndraDrive, Drive Sys‐
tem" → "Connections of the Com‐
ponents in the Drive System" →
"Connection of the DC Bus Con‐
nections"
Fusing Observe requirement on line pro‐
tection!
See Project Planning Manual
"Rexroth IndraDrive, Drive Sys‐
tem" → "Connections of the Com‐
ponents in the Drive System" →
"Connection of the DC Bus Con‐
nections"
Fig.16-91: Connection cross section HAS05.1-004

Mounting Dimensions When mounted, the accessory requires the following mounting clearance to the
left or to the right.
Fig.16-92: Mounting dimensions HAS05.1-004-NNR, -NNL

and Controls
Accessories
Observe the minimum bending radiuses of the lines used. This re‐
quires additional mounting clearance, particularly on the left side.
Dimension Unit HAS05.1-004-NNL HAS05.1-004-NNR
Mounting dimen‐ mm 41 50
sion B
sion H
sion T
Fig.16-93: Mounting dimensions HAS05.1-004

How to Mount HAS05.1-004
Cases to be Distinguished ● Outgoing direction of the lines to the right (HAS05.1-004-NNR)
● Outgoing direction of the lines to the left (HAS05.1-004-NNL)
● Outgoing direction of the lines to both sides (HAS05.1-004-NNR and
HAS05.1-004-NNL)
Outgoing Direction of the Lines to 1. Mount bar
the Right (HAS05.1-004-NNR)
Without DC bus contact bars (see picture 1):
Screw bar (5) and end piece (12) to terminal block (tightening torque:
6 Nm)
With DC bus contact bars (see picture 2):
Screw bar (5), DC bus contact bar (11) and connection piece (13) to ter‐
minal block (tightening torque: 6 Nm)
2. Mount line:
(See picture 1 and picture 2)
Screw ring cable lug (10) to bar (5) (tightening torque: 6 Nm; with 2 ring
cable lugs, observe inverse arrangement)
3. Mount touch guard:
(See picture 3)
Mount touch guard of drive controller (tightening torque: max. 2.8 Nm)
Insert touch guard of bars (2) and touch guard cover (1) and screw them
together (tightening torque: 1.6 Nm)
and Controls
Accessories
Picture 1
Fig.16-94: HAS05.1-004-NNR; outgoing direction of the lines to the right; without

DC bus contact bars
Picture 2
Fig.16-95: HAS05.1-004-NNR; outgoing direction of the lines to the right; with DC

bus contact bars
and Controls
Accessories
Picture 3
Fig.16-96: HAS05.1-004-NNR; mounting the touch guard
Make sure there is strain relief for the lines outgoing backward.
Outgoing Direction of the Lines to 1. Mount bar
the Left (HAS05.1-004-NNL)
Without DC bus contact bars (see picture 4):
Screw bar (05) and end piece (12) to terminal block (tightening torque:
6 Nm)
With DC bus contact bars (see picture 5):
Screw bar (05), DC bus contact bar (11) and connection piece (13) to
terminal block (tightening torque: 6 Nm)
2. Put fixing device (01) on bar (05)
3. Screw cable holder (02) to left equipment grounding connection
4. Mount line:
(See picture 4 and picture 5)
Screw ring cable lug (10) to bar (05) (tightening torque: 6 Nm; with 2 ring
cable lugs, observe inverse arrangement)
Fix lines with cable tie to cable holder (02)
5. Mount touch guard of drive controller (tightening torque: max. 2.8 Nm)
and Controls
Accessories
Picture 4
Fig.16-97: HAS05.1-004-NNL; outgoing direction of the lines to the left; without DC

bus contact bars
Picture 5
Fig.16-98: HAS05.1-004-NNL; outgoing direction of the lines to the left; with DC

bus contact bars
and Controls
Accessories
Beneath the touch guard, run the non-twisted lines in parallel.

Outside of the touch guard (after the strain relief), twist the line pairs.
In the case of four lines at the connections L+ and L-, twist L+ and
L- to form one pair.
Keep the surface between the individual lines of a pair as small as
possible.
Run the line pairs with the smallest possible distance to each other.
Outgoing Direction of the Lines to For mounting with outgoing direction to both sides, observe the descriptions on
Both Sides (HAS05.1-004-NNR " Outgoing Direction of the Lines to the Left (HAS05.1-004-NNL)" and "Outgoing
and HAS05.1-004-NNL) Direction of the Lines to the Right (HAS05.1-004-NNR)".
Fig.16-99: Mounting HAS05.1-004-NNL and -NNR
16.5.7 HAS05.1-005, Signal Level Converter RS232/RS485

Usage
Accessory Usage
HAS05.1-005-NNN-NN Converts serial interface of Rexroth Indra‐

Drive control sections from RS232 stand‐
ard to RS485 standard
Fig.16-100: Usage
Scope of Supply
the device.
Scope of supply
● Converter
● Connector at X2 and X3
● Cable tie
● Accompanying note
and Controls
Accessories
Technical Data
Dimensions
HAS05.1-005 can be mounted on a top-hat rail. For mounting it at

a wall, remove the top-hat rail clip at the back of the housing.
You can also mount HAS05.1-005 on electrically insulating surfa‐
ces.
Electrical Data Characteristic Unit Min. Typ. Max.
Number of nodes 31
Allowed cable length 1) m 500
Transmission rates 2) kBaud 9,6 115

Mode of operation Semi-duplex 2-wire line
Connection between X1 and X2, Galvanically connected
X3
Allowed voltage difference be‐ V 20
tween the reference potentials of
the drive controllers (housing)
Current consumption at X1.1 mA 50
Termination (TERM) Switchable ON, OFF
Short-circuit protection Data+ against Data-
Data+, Data- against GND
Cable length at X1 m 5
Cable length at X2, X3 m Comply with bus length; see allowed ca‐
ble length
and Controls
Accessories
Characteristic Unit Min. Typ. Max.

Connections X2, X3 Spring terminal
Connection cross section stran‐ mm2 / 0.14–1.5 / 28–16; ferrule without insulat‐
ded wire AWG ing sleeve
1) Bus length RS485, corresponds to total length of all connected cables
2) Is set via firmware used
Fig.16-102: Technical characteristics
Position of Connections, Termina‐
tion
Fig.16-103: HAS05.1-005 with connection cables

Pin Assignment X1 Connection Signal Function
1 Vcc Supply voltage (+5V)
2 RxD Receive Data

3 TxD Transmit Data
4 n. c. n. c.
5 GND Reference potential
6 n. c. n. c.
7 n. c. n. c.
8 RTS Request to send
9 n. c. n. c.
Fig.16-104: Pin assignment X1

and Controls
Accessories
1 Data+ Data transmission +

2 Data- Data transmission -
3 Shield Connection overall shield

1 Data+ Data transmission +

2 Data- Data transmission -
3 Shield Connection overall shield
4 GND Connection internal shield (signal shield)

Installation
General Information
Three connections connect the accessory HAS05.1‑005 to form an RS485 bus:
● Connection X1 to serial interface X2 at control section
● Connection X2 to connection X3 at next HAS05
● Connection X2 to bus master (e.g. RS232/485 converter controlled by a
PC)
Terminate the RS485 bus line at the most remote bus ends.
To do this, switch on the termination at the bus master (converter
at PC). At the last node, set the "TERM" switch to "ON".
See also Functional Description of firmware "Communication via RS485

Interface" and Parameter Description, e.g. "P‑0‑4050, Answer delay
RS-232/485"
and Controls
Accessories
Example of Connection
Connect PC and RS485 bus to a so-called bus master converter;

this RS232/485 converter automatically generates the RTS control
signal.
The accessory HAS05.1-005 does not accomplish this function!
Connection at X1
Connection From X1 to Control
Section (X2)
Fig.16-108: Connection cable RKB0010
For direct connection from X1 to the control section, use our cable
RKB0010 and observe its maximum allowed length (see "Electrical
Data" on page 265).
Connection at X2 and X3
Connect X2 and X3 with a cable according to the interconnection diagram be‐
low.
and Controls
Accessories
Connection Between X2 and X3
Fig.16-109: Connection cable at X2 and X3
To assemble connection cables at X2 and X3, use our non-assem‐

bled cable INK0572.
Strain Relief at Connection X2 and

X3
Fig.16-110: Strain relief at connection X2 and X3
Provide sufficient strain relief for the connections at X2 and X3!

Use the supplied cable ties.
16.5.8 HAS05.1-006, Adapter for Controlling Motor Holding Brake

Usage
Assignment The accessory HAS05.1-006 can be used at the following drive controllers:
● HMS02.1N-W0028
● HMS02.1N-W0054
Function The accessory HAS05.1-006 switches the voltage supply of the motor holding
brake (connection point X6, motor temperature monitoring and motor holding
brake) and has a feedback contact to the switching action.
Scope of Supply Connector at X44
(Connector at X6 is not part of the scope of supply. Use the connector of the
power section.)
Identification, Parts The accessory has a type plate for identification.
and Controls
Accessories
1 Type plate
2 Connector at connection point X44
3 HAS05.1-006
Fig.16-111: HAS05.1-006 at connection point X6 at drive controller
Technical Data
Mounting Dimensions
The accessory requires the following mounting clearance at the drive controller.
Data in mm
Fig.16-112: Mounting dimensions
and Controls
Accessories
quires additional mounting clearance at the drive controller, partic‐
ularly downward.
Connection Points
X6
The connection point is described in the Project Planning Manual "Rexroth

IndraDrive Supply Units and Power Sections" → "Functions and Electrical Con‐
nection Points" → "X6, Motor Temperature Monitoring and
Motor Holding Brake".
X44
View Connec‐ Signal name Function
tion
X44.1 +24V Relay control
X44.2
X44.3 0V
X44.4
X44.5 nc_Rel Relay contact "N/C"
X44.6 nc_Rel

Electrical data
Supply d1 (X44.1/2, X44.3/4) V 19,2 28,8
mA 50
Switching capacity K1 (X44.5, X44.6) A - 2
Switching capacity K2 (X6.3, X6.4) V 28,8
Minimum load of the contacts mA 10
Contact resistance at minimum current Ω 1
Pick up delay ms 30
Drop out delay ms 30
Time constant of load ms ohmic
Number of switching actions at maximum time 1× 106
constant of load
Number of mechanical switching cycles 1 × 106
and Controls
Accessories
Short circuit protection See description of connection point "X6, Motor Temperature
Monitoring and Motor Holding Brake" in the Project Planning
Overload protection
Manual "Rexroth IndraDrive Supply Units and Power Sec‐
tions"
Fig.16-113: Function, pin assignment

Usage
Block Diagram
D1 Free-wheeling diode
D2 Polarity reversal protection diode
d1 Relay
K1 N/C contact
K2 N/O contact
Fig.16-114: Block diagram
and Controls
Accessories
Example of Use
1) Safety door monitor

2) Safety door contacts
Mounting
Mount HAS05.1-006
1. Plug HAS05.1-006 in connection point X6 at drive controller
Make sure that HAS05.1-006 snaps in at X6 at the drive con‐

troller.
2. Plug connectors X6 and X44 in HAS05.1-006
Make sure there is sufficient strain relief for the connectors.
Dismount HAS05.1-006
1. Remove connection cable from HAS05.1-006
and Controls
Accessories
2. Loosen snap-in connection with screwdriver and remove HAS05.1-006

from drive controller
16.5.9 HAS05.1-007, Adapter From D-Sub to Terminal Connector

Usage
The adapter HAS05.1-007 exists in the following types of design:
● NNL: Mounting direction left (outgoing direction spring terminal left)
● NNR: Mounting direction right (outgoing direction spring terminal right)
HAS05.1-007-
NNL NNR
Fig.16-116: Types of design

Assignment The accessory HAS05.1-007 can be used at the following control sections:
HAS05.1-007-NNL HAS05.1-007-NNR
CSH01.1C at X41
CSH01.1C at X41
(Condition: option 3 not equipped)
CDB01.1C at X41.1 (option ST1) CSH01.2C at X41
CDB01.1C at X41.2 (option ST2)
Fig.16-117: Assignment HAS05.1-007

At CDB01 control sections, you can use both types of design together. How‐
ever, there is the following restriction:
When using the type of design NNL at HMD01.1N‑W0012 or
HMD01.1N‑W0020 drive controllers of a width of 50 mm, you cannot use the
adapter of type of design NNR at the neighboring control section on the left-
hand side.
and Controls
Accessories
Fig.16-118: HAS05.1-007-NNL and -NNR at HMD drive controller of a width of 50

mm
Function Universal adapter for safety technology
Usage:
1. Converter of D-Sub connection to terminal connection for an axis
2. Connection of additional component HAT01 to control section and optional
module S1
3. Converter of D-Sub connection to terminal connection for bus connection
of optional modules S1 of the axes of one zone (see figure "Wiring Ex‐
ample With HAS05.1-007-NNR" on page 279)
Identification, Parts The accessory has a type plate for identification.
and Controls
Accessories
HAS05.1-007-NNL
1 Adapter
2 Connector (spring terminal)
3 Type plate
Fig.16-119: HAS05.1-007-NNL
HAS05.1-007-NNR
1 Adapter
2 Connector (spring terminal)
3 Type plate
Fig.16-120: HAS05.1-007-NNR
The adapter is plugged in the connection point X41 (resp. X41.1 or X41.2 for
double-axis devices) of the control section and secured with screws.
Technical Data
Mounting Dimensions
The accessory requires the following mounting clearance at the drive controller.
and Controls
Accessories
HAS05.1-007-NNL
Data in mm
Fig.16-121: Mounting dimensions HAS05.1-007-NNL
HAS05.1-007-NNR
Data in mm
Fig.16-122: Mounting dimensions HAS05.1-007-NNR
quires additional mounting clearance at the front of the drive con‐
troller.
and Controls
Accessories
Connection Point X41

View Connec‐ Signal name Function
tion (termi‐
nal)
HAS05.1-007-NNL 1 X41.1 The adapter brings the con‐
Spring terminal / D-Sub female connector nections of the optional mod‐
2 X41.2
ules L1 or S1 to the connec‐
3 X41.3 tions 1–9 of a spring terminal
and a D-Sub female connec‐
4 X41.4 tor.
5 X41.5
6 X41.6 Description of connec‐
7 X41.7 tion point X41: See Project
Planning Manual "Rexroth In‐
8 X41.8 draDrive Control Sections",
9 X41.9 section "Optional Modules for
Control Sections, Safety
Technology".
HAS05.1-007-NNR
D-Sub female connector / spring terminal

Cable cross section stranded wire mm2 0,5 1,5
Cable cross section AWG 20 16
Coding At both types of design, the connection point 5 has been coded, i.e. provi‐
ded with a coding section. The spring terminal was already assembled
accordingly at the factory.
and Controls
Accessories
Electrical data Description of connection point X41: See Project Planning Manual "Re‐
xroth IndraDrive Control Sections", section "Optional Modules for Control
Sections, Safety Technology".
● Mating connector for D-Sub female con‐ ● RBS0017/S05 → D‑Sub connector, 9-pin
nector ● REB0401 → ribbon cable, 9-pin, can be ordered in steps of 0.5 m
● Ribbon cable For professional assembly of the ribbon cable in the D-Sub connector, use
the following Tyco tools:
● Pistol-Grip tool (part number 734155-1)
● Matrix for D-Sub connector (part number 734148-1)
Fig.16-123: Function, pin assignment
Fig.16-124: HAS05.1-007-NNL and HAS05.1-007-NNR at CDB control section

Wiring Example With HAS05.1-007-NNR is the preferred adapter for the bus connection of several
HAS05.1-007-NNR optional modules S1.
and Controls
Accessories
RBS0017/ D-Sub connector with connection for ribbon cable

S05
REB0401 ribbon cable
Fig.16-125: HAS05.1-007-NNR
At CSH01.1C control sections, the adapter HAS05.1-007-NNL can only be used
at the left end of the bus connection, when option 3 has not been equipped.
Fig.16-126: HAS05.1-007-NNR, RBS0017/S05 and REB0401 for bus connection of

optional modules S1 of the axes of one zone
and Controls
Accessories
16.5.10 HAS05.1-008, Adapter for Connecting two Cables

Usage
Assignment The accessory HAS05.1-008 can be used at the following drive controllers:
● HCS03.1E-W0100…0210
● HMS01.1N-W0150…0210
Function With the accessory HAS05.1-008, you can connect two 16 mm2 cables with
ring cable lugs at the mentioned devices at terminal block X5 (motor connec‐
tion), each at A1, A2 and A3.
Scope of Supply The accessory contains:
● 3 × adapter
● 3 × screw M6 × 25
and Controls
Accessories

and Controls
Accessories
Mounting
B-B Transverse profile of connection

Fig.16-128: HAS05.1-008 at an X5 connection point
1. Screw adapter to connection point with supplied screw.
2. Connect cable as shown and screw it on.
3. Repeat steps 1 and 2 for each connection point.
and Controls
Accessories
16.6 Fiber Optic Cable Connections

16.6.1 Overview of Types
1 Fiber optic cable connections outside of control cabinet

2 Control cabinet duct
3 Fiber optic cable connections inside of control cabinet
Fig.16-129: Fiber optic cable connections
Installation location Description Type designation
Outside of control cab‐ Robust fiber optic cable connections

RKO0101
inet from peripherals to control cabinet
Control cabinet duct with plug-in con‐
At control cabinet INS0610
nectors
Inside of control cabi‐ Fiber optic cable connections to and
RKO0100
net between drive controllers
Fig.16-130: Fiber optic cable connection elements
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 see the above table and add the required
length to it.
Determine the length by means of the list of different device ar‐
rangements.
Example of order code for arrangement HCS02 (left 105 mm) next to HCS02
(right 65 mm):
and Controls
Accessories
● Required length: 0.25 m

● Type designation: RKO0100
● Order code RKO0100 / 0,25
16.6.2 Interconnection of Drive Controllers

General Information
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
Fig.16-131: HCS02 with HCS02
For fiber optic cables from CSB01.1N‑SE control sections to other

control section types, take fiber optic cables which are 0.05 m longer
(at the devices, SERCOS connections are at different heights and
sides).
Observe the routing guidelines and technical data (e.g. allowed
bending radiuses) contained in documentation "Rexroth Connec‐
tion Cables", DOK-CONNEC-CABLE*LWL**-AW**-**-*.
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.16-132: Fiber optic cable lengths

and Controls
Accessories
Combination of HCS02 to the Right of HMS or HMD
Fig.16-133: HCS02 to the right of HMS or HMD

Independent of the width of the devices, cable length is 0.15 m.
Combination of HCS02 to the Left of HMS or HMD
Fig.16-134: HCS02 to the left of HMS or HMD

sides).
Cable length = width HCS02 + width HMS/HMD + 10 cm
Width HCS02 [mm] Width HMS / HMD [mm]

50 75 100 125
and Controls
Accessories

65 0,25 0,25 -- --
105 0,25 0,30 0,30 0,30

Combination of HCS03 to the Right of HMS or HMD
Fig.16-136: HCS03 to the right of HMS or HMD

Combination of HCS03 to the Left of HMS or HMD
Fig.16-137: HCS03 to the left of HMS or HMD

sides).
and Controls
Accessories
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
16.7 RKB0001, Extension for Module Bus Connections

16.7.1 Usage
Assignment The extension RKB0001 can be used at:
● HMV01.1E
● HMV01.1R
● HMS01.1N
● HMD01.1N
● HMV02.1R
● HMS02.1N
● HCS03.1E-W0070, -W0100; -W0150
The extension RKB0001 cannot be mounted at HCS02 drive con‐

trollers.
Function With the accessory RKB0001 you can extend the module bus connection be‐
tween devices, when the distance between the drive controllers is greater than
5 mm (e.g. in the case of multiple-line arrangement).
Lengths That can be Ordered, Or‐ Lengths: 0.5 m to 40 m (in steps of 0.5 m)
der Code
Parts:
● Housing with hinged cover
● Cable with strain relief mounted at both ends
Indicate the complete order code for your order.
Example:
● Required length: 2.5 m
● Type designation: RKB0001
● Order code RKB0001 / 02,5
and Controls
Accessories
16.7.2 Mounting
Fig.16-139: Dimensions RKB0001

and Controls
Accessories
Fig.16-140: Extension of module bus

Mounting RKB bus cable
1. Mount housing to point of connection for equipment grounding conductor.
2. Open cover and plug ribbon cable of right device into circuit board.
3. Close cover.
4. Screw strain relief down to point of connection for equipment grounding
conductor.
5. Plug ribbon cable into X1.
Make sure the connection between strain relief and point of con‐
nection for equipment grounding conductor is well conductive.
By means of appropriate wiring, establish equipment grounding
connections of devices that are not directly adjoining.
and Controls
Environmental Protection and Disposal
17 Environmental Protection and Disposal

17.1 Environmental Protection
17.1.1 Production Processes
The products are made with energy- and resource-optimized production pro‐
cesses which allow re-using and recycling the resulting waste. We regularly try
to replace pollutant-loaded raw materials and supplies by more environment-
friendly alternatives.
17.1.2 Prohibited Substances

We guarantee that our products do not contain any of the substances specified
in the German regulation of prohibited chemicals ("Chemikalien-Verbotsver‐
ordnung"). We furthermore declare that our products are free of mercury,
asbestos, PCB and chlorinated hydrocarbons.
17.1.3 No Release of Hazardous Substances

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

The principal components contained in our products are listed below:
Electronic devices Motors
● steel
● steel
● aluminum
● aluminum
● copper
● copper
● brass
● synthetic materials
● magnetic materials
● electronic components and modules
● electronic components and modules
Fig.17-1: Principal components
17.2 Disposal
17.2.1 Return of Products
Our products can be returned to us free of charge for disposal. It is a precon‐
dition, however, that the products are free of oil, grease or other dirt.
Furthermore, the products returned for disposal mustn't contain any undue for‐
eign 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
17.2.2 Packaging Materials

The packaging materials consist of cardboard, wood and polystyrene. These
materials can be recycled anywhere without any problem.
and Controls
Environmental Protection and Disposal
For ecological reasons, please refrain from returning the empty packages to
us.
17.2.3 Recycling
Due to their high content of metal, most of the product components can be
recycled. In order to recycle the metal in the best possible way, the products
must be disassembled into individual modules.
Metals contained in electric and electronic modules can also be recycled by
means of special separation processes. The synthetic materials remaining after
these processes can be thermally recycled.
If the products contain batteries or accumulators, these have to be removed
before recycling and disposed of.
and Controls
Service and Support
18 Service and Support

18.1 Helpdesk
Our service helpdesk at our headquarters in Lohr, Germany, will assist you with
all kinds of inquiries.
Contact us:
● By phone through the Service Call Entry Center
Monday to Friday: 7:00 am - 6:00 pm Central European Time
+49 (0) 9352 40 50 60
● By fax
+49 (0) 9352 40 49 41
● By e-mail: service.svc@boschrexroth.de
18.2 Service Hotline

Out of helpdesk hours please contact our German service department directly:
+49 (0) 171 333 88 26
or
+49 (0) 172 660 04 06
Hotline numbers for other countries can be found in the addresses of each
region on the Internet (see below).
18.3 Addresses
For the current addresses of our sales and service offices, see
http://www.boschrexroth.com
On this website you will find additional notes regarding service, maintenance
(e.g. delivery addresses) and training.
Outside Germany please contact our sales/service office in your area first.
18.4 Helpful Information

For quick and efficient help please have the following information ready:
● Detailed description of the fault and the circumstances
● Information on the type plate of the affected products, especially type co‐
des and serial numbers
● Your phone and fax numbers and e-mail address, so we can contact you
in case of questions
and Controls
and Controls
Appendix
19 Appendix
19.1 Discharging of Capacitors
19.1.1 Discharging of DC Bus Capacitors
In the drive system Rexroth IndraDrive, capacitors are used in the DC bus as
energy stores. In drive controllers and particularly in supply units, such capac‐
itors have already been integrated.
Energy stores maintain their energy even when the supply voltage 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 sys‐
tem Rexroth IndraDrive; within the indicated discharging time these devices
discharge the voltage below the allowed 50 V.
If additional capacitors (such as DC bus capacitor units) are connected, these
capacitors, too, have to be 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 supply voltage was cut off, the voltage value falls
below 50 V within a discharging time of a maximum of 30 minutes.
To shorten the waiting time until voltage has fallen below 50 V, you can take
the following measures:
● When using HMV01 supply units: activate the function "ZKS" (DC bus
short circuit)
● Use the discharging device described below.
19.1.2 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.
R discharging resistor
K contactor contact
Fig.19-1: Operating principle of discharging device
and Controls
Appendix
Dimensioning
The individual components have to be sufficiently dimensioned:
● Value of the discharging resistor: 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 a
minimum of 1000 V.
● The contactor contact has to withstand the occurring discharge current
according to the resistance value that is used, i.e. 1 A with 1000 ohm.
How to Proceed for Discharging
charging.
1. Install discharging device before switching on supply voltage for the first
time.
2. Establish safe electrical connection between discharging device and ob‐
ject to be discharged.
3. On mains side, switch off supply voltages to drive system before activating
discharging device.
4. Activate discharging device.
and Controls
Index
Index
Symbols RKB0010 268
24V supply 30 Capacitors
Internal 31 Discharging 295
Capacity utilization 28
A CCC, China Compulsory Certification 23
Accessories CE label 21
Connection of two cables, adapter 281 Certifications 21
Control of motor holding brake, adapter 269 Commissioning interface 119
D-Sub to terminal connector, adapter 274 Compatibility with foreign matters 27
For drive systems Rexroth IndraDrive 179 Connection
HAS01, basic accessories 179 DC bus 99, 111
HAS02, shield connection 207 Equipment grounding conductor 100, 112
HAS03, control cabinet adapter 235 Ground 102, 114
HAS04, capacitor 239 Connection diagrams
HAS05, accessories for connection points 247 RS232 121
HAS05.1-001, adapter for mains and motor con‐ Serial interface 121
nection 249 Connection points
HAS05.1-002, extension (connection HNK01 to X44 271
HCS03+HMF01) 251 Contained materials
HAS05.1-003, signal level converter encoder See "Principal Components" 291
emulation 252 Control cabinet adapter
HAS05.1-004, adapter DC bus connection 255 HAS03 235
HAS05.1-005, signal level converter RS232/ Control module for holding brake HAT01 171
RS485 264 Control voltage
HAS05.1-006, Adapter for controlling motor hold‐ Specification 30
ing brake 269 Supply 31
HAS05.1-007, adapter from D-Sub to terminal C-UL-US listing 21
connector 274
HAS05.1-008, adapter for connecting two cables D
281 DC bus
Adapter Connection 99, 111
DC bus connection 255 DC bus capacitors
Mains and motor connection 249 Discharging 295
Addresses 293 DC bus capacitor unit
Ambient conditions 24 HLC01 91
Applications DC bus capacitor unit HLC01
Drive system Rexroth IndraDrive 17 Brief description 19
Appropriate use 5 DC bus choke
Applications 5 HLL01 83
Autotransformers 34 DC bus connection
Adapter 255
B DC bus resistor unit
Bar HLB01 105
Use 180 HLB01, brief description 19
Braking resistor HLR01 Declaration of conformity 21
Brief description 19, 127 Discharging
See "HLR01" 127 Of DC bus capacitors 295
Bus cable Discharging device 295
Extension 288 Disposal 291
Bus master 267 DLT
Brief description 17
C Documentation
Cables Overview 2
IKB0041 121 Reference documentations 2
INK0572 269
and Controls
Index
Drive system Rexroth IndraDrive HAS05.1-

Applications 17 001, adapter for mains and motor connection
DST 249
Autotransformers 34 002, extension (connection HNK01 to HCS03
Brief description 17 +HMF01) 251
003, signal level converter encoder emulation
E 252
Encoder emulation 004, adapter DC bus connection 255
Voltage signal level converter 252 005, signal level converter RS232/RS485 264
End piece 006, adapter for controlling motor holding brake
Use 180 269
Environmental protection 291 007, adapter from D-Sub to terminal connector
Equipment grounding conductor 274
Connection 100, 112 008, adapter for connecting two cables 281
Extension HAT01
For mains filter HNK01 and mains input HCS03 Connection points 176
251 Control module for holding brake 171
Dimensions 173
F Technical data 173
Fiber optic cables Type code 171
Accessories 284 Type plate 172
Fields of application Hazardous substances 291
Drive system Rexroth IndraDrive 17 Helpdesk 293
File numbers HLB01
UL 22 Brief description 19
Foreign matters Commissioning, operation, diagnoses 123
Compatibility with 27 Connection points 109
Data, electrical 108
Data, mechanical 106
G
DC bus resistor unit 105
G1, G2, G3, G4, G5
H2, LED 124
Mounting positions 25
H3, LED 125
Ground
S1, Reset key 124
Connection 102, 114
Type code 105
Ground connection 102, 114
HLC01
H Connection points 96
H2 Data, electrical 96
HLB01, LED 124 Data, mechanical 94
H3 DC bus capacitor unit 91
HLB01, LED 125 Type code 92
HAC01 HLL01
Brief description 20 DC bus choke 83
Housing for control sections 165 HLR01
HAS01 Braking resistor 127
Assignment 180 Brief description 19, 127
Basic accessories 179 Dimension table type A 149
Mounting "bar" and "end piece" 207 Dimension table type B 150
HAS02 Dimension table type C 151
Shield connection 207 For HCS02 129
HAS03 For HCS03 132
Control cabinet adapter 235 Installation and mounting 138
HAS04 Scope of supply 129
Capacitor 239 Technical data 129
HAS05 Type code 127
Accessories for connection points 247 Type of construction A (version for device mount‐
ing) 140
and Controls
Index
Type of construction N (version for free assem‐ L

bly) 149 L+, L-
Type plate 129 DC bus 99, 111
HMF01 Listing
Brief description 20 C-UL-US 21
Motor filter 153
HNF M
Brief description 17 Mains and motor connection
Data, electrical 48 Adapter HAS05.1-001 249
Data, mechanical 45 Mains choke
Mains filter 44 Brief description 18
Type code 44 Current-compensated 74
HNK HNL 67
Brief description 17 HNL02 77
Data, electrical 57 Infeeding 69
Data, mechanical 53 Regenerative 72
Mains filter 51 Mains filter
Type code 51 Brief description 17
Type plate 51 HNF 44
With HCS03 58 HNK 51
HNL HNS02 62
Brief description 18 NFD, NFE 37
Mains choke 67 Mains transformers
Type code 67 Brief description 17
Type plate 68 Module bus 98, 116
HNL01.1E 69 Extension 288
Technical data 69 Motor filter
HNL01.1E-****-S 74 HMF01 153
HNL01.1R 72 HMF01, brief description 20
Technical data 73 Mounting position
HNL02 77 Definitions 25
Technical data 78
Type code 77 N
HNS02 NFD
Brief description 17 Brief description 17
Connection points 64 Data, electrical 42
Data, electrical 64 Data, mechanical 40
Data, mechanical 63 Mains filter 37
Fuses 64 NFE
Mains filter 62 Brief description 17
Type code 62 Data, electrical 42
Holding brake Data, mechanical 40
Control module HAT01 171 Mains filter 37
Housing for control sections HAC01, 165
Housing varnish 27 O
Operating conditions 24
I
Inappropriate use, 6 P
Consequences, exclusion of liability 5 Packaging materials 291
Industrial sectors 17 Prime coat 27
INS0610 284 Principal components 291
Installation conditions 24 Production processes 291
Insulation resistance test 29 Prohibited substances 291
R
Recycling 292
Reference documentations 2
and Controls
Index
Return of products 291 Termination

RKB0001 288 HAS05.1-005 265
RKO0100 284 Test
RKO0101 284 Insulation resistance 29
RS232 119 Voltage 29
RS232/485 Touch guard 103, 121
Signal level converter 264 Transformers 33
Transport
S Of the components 23
S1 Types of installation 26
HLB01, Reset key 124
Safety instructions for electric drives 7 U
Serial interface (RS232) UL
X2 119 File numbers 22
Service hotline 293 Listing 21
Service interface 119 Use
Shield connection Appropriate use 5
Accessories HAS02 207 Inappropriate use 6
Signal level converter
Voltage signal level converter (for encoder emu‐ V
lation) 252 Varnish 27
Signal level converter RS232/485 264 Voltage test 29
Specifications Of the installation 29
Of the Components 21
State-of-the-art 5 X
Storage X1
Of the components 23 Module bus 98, 116
X2
T Serial interface (RS232) 119
TERM X44 271
HAS05.1-005 265
Project Planning Manual | Rexroth IndraDrive Electric Drives | Bosch Rexroth AG
and Controls
Notes
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 (0)93 52-40-50 60
Fax +49 (0)93 52-40-49 41
service.svc@boschrexroth.de
www.boschrexroth.com
Printed in Germany
R911306140 DOK-INDRV*-ADDCOMP****-PR03-EN-P

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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Rexroth IndraDrive R911306140

Additional Components and

Title Rexroth IndraDrive

Type of Documentation Project Planning Manual

Document Typecode DOK-INDRV*-ADDCOMP****-PR03-EN

Internal File Reference RS-3aee9eb90a6846ac0139e9630b45f9bf-2-en-US-4

Record of Revision Edition Release Date Notes

Copyright © Bosch Rexroth AG, 2008

2 Important Directions for Use ......................................................................................... 5

3 Safety Instructions for Electric Drives and Controls....................................................... 7

4 Brief Description, Usage.............................................................................................. 17

5 General Specifications of the Components.................................................................. 21

8 HNL - Mains Chokes for Supply Units and Converters................................................ 67

9 HLL01 - DC Bus Choke, Current-Compensated (Preliminary).................................... 83

10 HLC01.1 - DC Bus Capacitor Unit............................................................................... 91

11 HLB01.1C and HLB01.1D - DC Bus Resistor Unit..................................................... 105

12 HLR01 - Braking Resistors........................................................................................ 127

13 HMF01.1 - Motor Filter............................................................................................... 153

14 HAC01 - Housing for Control Sections...................................................................... 165

15 HAT01 - Control Module for Holding Brake............................................................... 171

17 Environmental Protection and Disposal..................................................................... 291

18 Service and Support.................................................................................................. 293

Personal injury and property damage caused by incorrect project plan‐

1.1.3 Reference Documentations

Drive System Project Planning Manual SYSTEM*****-PRxx-EN-P 309636

A Series Asynchronous Motors Project Planning Manual MAD/MAF****-PRxx-EN-P 295781

Title Kind of documentation Document typecode1) Part number

S Synchronous Motors Project Planning Manual MSK********-PRxx-EN-P 296289

Rexroth Connection Cables Selection Data CONNEC-CABLE*STAND-AUxx- 282688

Firmware for Drive Controllers Functional Description MP*-05VRS**-FKxx-EN-P 320182

Important Directions for Use

2 Important Directions for Use

Personal injury and property damage caused by incorrect use of the

Rexroth as manufacturer is not liable for any damages resulting

2.1.2 Areas of Use and Application

Drive controllers have to be programmed before commissioning, making it pos‐

Important Directions for Use

● handling and mounting systems,

2.2 Inappropriate Use

Safety Instructions for Electric Drives and Controls

3 Safety Instructions for Electric Drives and Controls

Improper use of these devices, failure to follow the safety instructions in

3.1.2 How to Employ the Safety Instructions

Safety Instructions for Electric Drives and Controls

3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness

Safety Instructions for Electric Drives and Controls

Degree of hazard serious‐

Death or severe bodily harm

Death or severe bodily harm

Minor or moderate bodily

3.1.4 Hazards by Improper Use

Dangerous movements! Danger to life, severe bodily harm or material

High electric voltage because of incorrect connection! Risk of death or

Hot surfaces on device housing! Danger of injury! Danger of burns!

Risk of injury by improper handling! Risk of bodily injury by bruising,

Current-compensated mains chokes HNL01.1E--S and HNL01.1R--S