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Rexroth IndraDriveDrive ControllersHCS04.2E

Project Planning Manual

DOK-INDRV*-HCS04.2****-PR02-EN-P

RS-ecb76e47905c0d720a6846a001251ef6-1-en-US-4

Edition Release Date Notes

DOK-INDRV*-HCS04.2****-PR02-EN-P 02.2010 First edition

Copyright © Bosch Rexroth AG 2010Copying this document, giving it to others and the use or communication of thecontents thereof without express authority, are forbidden. Offenders are liablefor the payment of damages. All rights are reserved in the event of the grant ofa patent or the registration of a utility model or design (DIN 34-1).

Validity The specified data is for product description purposes only and may not bedeemed to be guaranteed unless expressly confirmed in the contract. All rightsare reserved with respect to the content of this documentation and the availa‐bility of the product.

Published by Bosch Rexroth AGBgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr a. Main, GermanyTelephone +49 (0)93 52/ 40-0 http://www.boschrexroth.com/Dept. DCC/EDY1 (HP, BB)

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

Title

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Record of Revision

Bosch Rexroth AG DOK-INDRV*-HCS04.2****-PR02-EN-P Rexroth IndraDrive Drive Controllers HCS04.2E

Table of ContentsPage

1 Important Directions for Use ......................................................................................... 51.1 Appropriate Use ..................................................................................................................................... 51.1.1 Introduction.......................................................................................................................................... 51.1.2 Areas of Use and Application.............................................................................................................. 51.2 Inappropriate Use................................................................................................................................... 6

2 Safety Instructions for Electric Drives and Controls ...................................................... 72.1 Definitions of Terms................................................................................................................................ 72.2 General Information................................................................................................................................ 82.2.1 Using the Safety Instructions and Passing Them on to Others........................................................... 82.2.2 Requirements for Safe Use................................................................................................................. 82.2.3 Hazards by Improper Use.................................................................................................................... 92.3 Instructions with Regard to Specific Dangers....................................................................................... 102.3.1 Protection Against Contact with Electrical Parts and Housings......................................................... 102.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 112.3.3 Protection Against Dangerous Movements....................................................................................... 112.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 132.3.5 Protection Against Contact With Hot Parts........................................................................................ 132.3.6 Protection During Handling and Mounting......................................................................................... 132.3.7 Battery Safety.................................................................................................................................... 142.3.8 Protection Against Pressurized Systems........................................................................................... 142.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 15

3 IndraDrive HCS04.2E.................................................................................................. 173.1 Device Line IndraDrive HCS04.2E....................................................................................................... 173.1.1 For all Drives in Industry, Mechanical Engineering and Automation................................................. 173.2 General Specification............................................................................................................................ 203.3 Quality................................................................................................................................................... 213.3.1 CE Label............................................................................................................................................ 213.3.2 Installation Instructions...................................................................................................................... 213.4 Mains Conditions.................................................................................................................................. 223.4.1 Mains Voltage.................................................................................................................................... 223.4.2 Fuses................................................................................................................................................. 223.4.3 Braking Unit / Braking Resistor.......................................................................................................... 223.4.4 Ungrounded Mains............................................................................................................................ 223.4.5 Radio Interference ............................................................................................................................ 243.4.6 Mains Current Harmonics / Mains Voltage Distortions ..................................................................... 243.4.7 12-Pulse Supply................................................................................................................................ 253.4.8 System Impedance / Short-Circuit Current........................................................................................ 253.4.9 Reactive-Current Compensation Equipment..................................................................................... 263.4.10 Switching Rate................................................................................................................................... 263.5 IndraDrive HCS04.2E........................................................................................................................... 273.5.1 For all Drives in Industry, Mechanical Engineering and Automation................................................. 27

DOK-INDRV*-HCS04.2****-PR02-EN-P Rexroth IndraDrive Drive Controllers HCS04.2E

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Table of Contents

6 Specification......................................................................................................................................... 283.6.1 Technical Data................................................................................................................................... 283.6.2 Control Cabinet Mounting IP23......................................................................................................... 363.6.3 Derating............................................................................................................................................. 363.6.4 Continuous Current at Output Frequencies < 1 Hz........................................................................... 373.7 Connecting and Wiring......................................................................................................................... 383.7.1 Wiring Diagram.................................................................................................................................. 38

IndraDrive HCS04.2E-W0350 ... - W0520...................................................................................... 38IndraDrive HCS04.2E-W0640 ... - W1010...................................................................................... 39IndraDrive HCS04.2E-W1240 ...-W1540........................................................................................ 40IndraDrive HCS04.2E-W1240 ...-W1540 (12-Pulse Rectification).................................................. 41DC Coupling................................................................................................................................... 42DC Coupling of a Main Drive With Slave(s) at the DC Bus............................................................ 43Fuses for DC-Coupled Converters................................................................................................. 45

3.7.2 Fuses and Cable Cross Sections...................................................................................................... 453.7.3 Braking Unit HLT01.1A .................................................................................................................... 48

General Information........................................................................................................................ 49Principle and Calculation of the Braking Process........................................................................... 51Determining the Braking Power...................................................................................................... 55

3.7.4 Motor Cable Lengths......................................................................................................................... 623.7.5 Guide Values for Maximum Motor Cable Lengths in 1st Environment.............................................. 64

General Information........................................................................................................................ 64Guide Values for Maximum Motor Cable Lengths in 2nd Environment (Industrial Areas)............. 64

3.7.6 Notes on How to Wire Power Cables and Control Cables................................................................ 643.7.7 Options Available for IndraDrive HCS04.2E Converters................................................................... 65

General Information........................................................................................................................ 65Assignment Table of the Performance-Dependent Options........................................................... 66

3.8 External Options................................................................................................................................... 683.8.1 Radio Interference Filter HNF01.1B.................................................................................................. 683.8.2 DC Choke HLL.................................................................................................................................. 713.8.3 Mains Choke HNL01.1E.................................................................................................................... 743.8.4 Braking Unit HLT............................................................................................................................... 773.8.5 Braking Resistor HLR01.1................................................................................................................. 813.8.6 Output Motor Filter HMF01.1N.......................................................................................................... 843.8.7 Flange Assembly Kit HAS07.1.......................................................................................................... 883.8.8 Control Cabinet Assembly Kit HAS08.1............................................................................................ 913.9 Protecting the Installation..................................................................................................................... 953.9.1 Responsibility.................................................................................................................................... 953.9.2 Frequencies > 60 Hz......................................................................................................................... 953.9.3 Residual-Current-Operated Circuit-Breakers.................................................................................... 953.9.4 Switching the Motor Off and On........................................................................................................ 963.9.5 Suppressor Circuit............................................................................................................................. 963.9.6 Insulation Measurements.................................................................................................................. 963.9.7 External Blower Supply..................................................................................................................... 963.9.8 General Notes on Connection........................................................................................................... 983.9.9 Wiring the Power Connections........................................................................................................ 100


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Table of Contents

9.10 Control Cabinet Mounting IP23....................................................................................................... 1003.9.11 Control Cabinet Mounting IP54....................................................................................................... 1013.9.12 IndraDrive HCS04.2E-W0350......................................................................................................... 1033.9.13 IndraDrive HCS04.2E-W0420......................................................................................................... 1043.9.14 IndraDrive HCS04.2E-W0520......................................................................................................... 1053.9.15 IndraDrive HCS04.2E-W0640, -W0790........................................................................................... 1063.9.16 IndraDrive HCS04.2E-W1010......................................................................................................... 1073.9.17 IndraDrive HCS04.2E-W1240......................................................................................................... 1093.9.18 IndraDrive HCS04.2E-W1540......................................................................................................... 1113.9.19 Accessing Phase V/T2.................................................................................................................... 1123.9.20 Braking Unit HLT01.1A -200K......................................................................................................... 1133.9.21 Braking Unit HLT01.1A -400K......................................................................................................... 118

Index.......................................................................................................................... 127


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1 Important Directions for Use1.1 Appropriate Use1.1.1 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 causedby incorrect use of the products!

WARNING

The products have been designed for use in the industrial environment and mayonly 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 resultingfrom inappropriate use. In such cases, the guarantee and the rightto 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 theiroriginal state, in other words, no structural changes are permitted. It is notpermitted 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.

1.1.2 Areas of Use and ApplicationDrive controllers made by Rexroth are designed to control electrical motors andmonitor their operation.Control and monitoring of the Drive controllers may require additional sensorsand actors.

The drive controllers may only be used with the accessories andparts specified in this documentation. If a component has not beenspecifically 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 insingle- and multi-axis drive and control tasks.To ensure application-specific use of Drive controllers, device types of differentdrive power and different interfaces are available.


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Important Directions for Use

Typical applications include, for example:● 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 installationconditions described in this documentation, in the specified position of normaluse and under the ambient conditions as described (temperature, degree ofprotection, humidity, EMC, etc.).

1.2 Inappropriate UseUsing the Drive controllers outside of the operating conditions described in thisdocumentation and outside of the indicated technical data and specifications isdefined 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 whichhave not been expressly authorized by Rexroth. Please carefully followthe specifications outlined in the general Safety Instructions!

Components of the drive system Rexroth IndraDrive are productsof category C3 (with restricted distribution) according toIEC 61800‑3. These components are not provided for use in a publiclow-voltage mains supplying residential areas. If these componentsare used in such a mains, high-frequency interference is to be ex‐pected. This can require additional measures of radio interferencesuppression.


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Important Directions for Use

2 Safety Instructions for Electric Drives and Controls 2.1 Definitions of Terms

Application Documentation Application documentation comprises the entire documentation used to informthe user of the product about the use and safety-relevant features for config‐uring, integrating, installing, mounting, commissioning, operating, maintaining,repairing and decommissioning the product. The following terms are also usedfor this kind of documentation: User Guide, Operation Manual, CommissioningManual, Instruction Manual, Project Planning Manual, Application Manual, etc.

Component A component is a combination of elements with a specified function, which arepart of a piece of equipment, device or system. Components of the electric driveand control system are, for example, supply units, drive controllers, mainschoke, mains filter, motors, cables, etc.

Control System A control system comprises several interconnected control components placedon the market as a single functional unit.

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

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

Electric Drive System An electric drive system comprises all components from mains supply to motorshaft; this includes, for example, electric motor(s), motor encoder(s), supplyunits and drive controllers, as well as auxiliary and additional components, suchas mains filter, mains choke and the corresponding lines and cables.

Installation An installation consists of several devices or systems interconnected for a de‐fined purpose and on a defined site which, however, are not intended to beplaced on the market as a single functional unit.

Machine A machine is the entirety of interconnected parts or units at least one of whichis movable. Thus, a machine consists of the appropriate machine drive ele‐ments, as well as control and power circuits, which have been assembled fora specific application. A machine is, for example, intended for processing,treatment, movement or packaging of a material. The term "machine" also cov‐ers a combination of machines which are arranged and controlled in such a waythat they function as a unified whole.

Manufacturer The manufacturer is an individual or legal entity bearing responsibility for thedesign and manufacture of a product which is placed on the market in the in‐dividual's or legal entity's name. The manufacturer can use finished products,finished parts or finished elements, or contract out work to subcontractors.However, the manufacturer must always have overall control and possess therequired authority to take responsibility for the product.

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

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

Qualified Persons In terms of this application documentation, qualified persons are those personswho are familiar with the installation, mounting, commissioning and operationof the components of the electric drive and control system, as well as with thehazards this implies, and who possess the qualifications their work requires. Tocomply with these qualifications, it is necessary, among other things,



Safety Instructions for Electric Drives and Controls

1) to be trained, instructed or authorized to switch electric circuits and devicessafely on and off, to ground them and to mark them2) to be trained or instructed to maintain and use adequate safety equipment3) to attend a course of instruction in first aid

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

2.2 General Information2.2.1 Using the Safety Instructions and Passing Them on to Others

Do not attempt to install and operate the components of the electric drive andcontrol system without first reading all documentation provided with the product.Read and understand these safety instructions and all user documentation priorto working with these components. If you do not have the user documentationfor the components, contact your responsible Rexroth sales partner. Ask forthese documents to be sent immediately to the person or persons responsiblefor the safe operation of the components.If the component is resold, rented and/or passed on to others in any other form,these safety instructions must be delivered with the component in the officiallanguage of the user's country.Improper use of these components, failure to follow the safety instructions inthis document or tampering with the product, including disabling of safety de‐vices, could result in property damage, injury, electric shock or even death.

2.2.2 Requirements for Safe UseRead the following instructions before initial commissioning of the componentsof the electric drive and control system in order to eliminate the risk of injuryand/or property damage. You must follow these safety instructions.● Rexroth is not liable for damages resulting from failure to observe the

safety instructions.● Read the operating, maintenance and safety instructions in your language

before commissioning. If you find that you cannot completely understandthe application documentation in the available language, please ask yoursupplier to clarify.

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

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

● Only use accessories and spare parts approved by Rexroth.● Follow the safety regulations and requirements of the country in which the

components of the electric drive and control system are operated.● Only use the components of the electric drive and control system in the

manner that is defined as appropriate. See chapter "Appropriate Use".● The ambient and operating conditions given in the available application

documentation must be observed.● Applications for functional safety are only allowed if clearly and explicitly

specified in the application documentation "Integrated Safety Technolo‐gy". If this is not the case, they are excluded. Functional safety is a safety


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concept in which measures of risk reduction for personal safety dependon electrical, electronic or programmable control systems.

● The information given in the application documentation with regard to theuse of the delivered components contains only examples of applicationsand suggestions.The machine and installation manufacturers must– make sure that the delivered components are suited for their individ‐

ual application and check the information given in this applicationdocumentation with regard to the use of the components,

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

● Commissioning of the delivered components is only allowed once it is surethat the machine or installation in which the components are installedcomplies with the national regulations, safety specifications and standardsof the application.

● Operation is only allowed if the national EMC regulations for the applica‐tion are met.

● The instructions for installation in accordance with EMC requirements canbe found in the section on EMC in the respective application documenta‐tion.The machine or installation manufacturer is responsible for compliancewith the limit values as prescribed in the national regulations.

● The technical data, connection and installation conditions of the compo‐nents are specified in the respective application documentations and mustbe followed at all times.

National regulations which the user must take into account● European countries: In accordance with European EN standards● United States of America (USA):

– National Electrical Code (NEC)– National Electrical Manufacturers Association (NEMA), as well as

local engineering regulations– Regulations of the National Fire Protection Association (NFPA)

● Canada: Canadian Standards Association (CSA)● Other countries:

– International Organization for Standardization (ISO)– International Electrotechnical Commission (IEC)

2.2.3 Hazards by Improper Use● High electrical voltage and high working current! Danger to life or serious

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

electric shock!● Dangerous movements! Danger to life, serious injury or property damage

by unintended motor movements!● Health hazard for persons with heart pacemakers, metal implants and

hearing aids in proximity to electric drive systems!● Risk of burns by hot housing surfaces!




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

● Risk of injury by improper handling of batteries!● Risk of injury by improper handling of pressurized lines!

2.3 Instructions with Regard to Specific Dangers2.3.1 Protection Against Contact with Electrical Parts and Housings

This section concerns components of the electric drive and controlsystem with voltages of more than 50 volts.

Contact with parts conducting voltages above 50 volts can cause personaldanger and electric shock. When operating components of the electric driveand control system, it is unavoidable that some parts of these componentsconduct dangerous voltage. High electrical voltage! Danger to life, risk of injury by electric shock or seriousinjury!● Only qualified persons are allowed to operate, maintain and/or repair the

components of the electric drive and control system.● Follow the general installation and safety regulations when working on

power installations.● Before switching on, the equipment grounding conductor must have been

permanently connected to all electric components in accordance with theconnection diagram.

● Even for brief measurements or tests, operation is only allowed if theequipment grounding conductor has been permanently connected to thepoints of the components provided for this purpose.

● Before accessing electrical parts with voltage potentials higher than 50 V,you must disconnect electric components from the mains or from the pow‐er supply unit. Secure the electric component from reconnection.

● With electric components, observe the following aspects:Always wait 30 minutes after switching off power to allow live capacitorsto discharge before accessing an electric component. Measure the elec‐trical voltage of live parts before beginning to work to make sure that theequipment is safe to touch.

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

● Never touch electrical connection points of the components while poweris turned on.

● Do not remove or plug in connectors when the component has been pow‐ered.

● Under specific conditions, electric drive systems can be operated at mainsprotected by residual-current-operated circuit-breakers sensitive to uni‐versal current (RCDs/RCMs).

● Secure built-in devices from penetrating foreign objects and water, as wellas from direct contact, by providing an external housing, for example acontrol cabinet.


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High housing voltage and high leakage current! Danger to life, risk of injury byelectric shock!● Before switching on and before commissioning, ground or connect the

components of the electric drive and control system to the equipmentgrounding conductor at the grounding points.

● Connect the equipment grounding conductor of the components of theelectric drive and control system permanently to the main power supply atall times. The leakage current is greater than 3.5 mA.

● Establish an equipment grounding connection with a copper wire of across section of at least 10 mm2 (8 AWG) or additionally run a secondequipment grounding conductor of the same cross section as the originalequipment grounding conductor.

2.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock Protective extra-low voltage is used to allow connecting devices with basic in‐sulation to extra-low voltage circuits.On components of an electric drive and control system provided by Rexroth, allconnections and terminals with voltages between 5 and 50 volts are PELV("Protective Extra-Low Voltage") systems. It is allowed to connect devicesequipped with basic insulation (such as programming devices, PCs, notebooks,display units) to these connections. Danger to life, risk of injury by electric shock! High electrical voltage by incorrectconnection!If extra-low voltage circuits of devices containing voltages and circuits of morethan 50 volts (e.g., the mains connection) are connected to Rexroth products,the connected extra-low voltage circuits must comply with the requirements forPELV ("Protective Extra-Low Voltage").

2.3.3 Protection Against Dangerous MovementsDangerous movements can be caused by faulty control of connected motors.Some common examples are:● Improper or wrong wiring or cable connection● Operator errors● Wrong input of parameters before commissioning● Malfunction of sensors and encoders● Defective components● Software or firmware errorsThese errors can occur immediately after equipment is switched on or evenafter an unspecified time of trouble-free operation.The monitoring functions in the components of the electric drive and controlsystem will normally be sufficient to avoid malfunction in the connected drives.Regarding personal safety, especially the danger of injury and/or property dam‐age, this alone cannot be relied upon to ensure complete safety. Until theintegrated monitoring functions become effective, it must be assumed in anycase that faulty drive movements will occur. The extent of faulty drive move‐ments depends upon the type of control and the state of operation.




Dangerous movements! Danger to life, risk of injury, serious injury or propertydamage!A risk assessment must be prepared for the installation or machine, with itsspecific conditions, in which the components of the electric drive and controlsystem are installed.As a result of the risk assessment, the user must provide for monitoring func‐tions and higher-level measures on the installation side for personal safety. Thesafety regulations applicable to the installation or machine must be taken intoconsideration. Unintended machine movements or other malfunctions are pos‐sible if safety devices are disabled, bypassed or not activated.To avoid accidents, injury and/or property damage:● Keep free and clear of the machine’s range of motion and moving machine

parts. Prevent personnel from accidentally entering the machine’s rangeof motion by using, for example:– Safety fences– Safety guards– Protective coverings– Light barriers

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

● Mount emergency stopping switches in the immediate reach of the oper‐ator. Before commissioning, verify that the emergency stopping equip‐ment works. Do not operate the machine if the emergency stopping switchis not working.

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

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

● Additionally secure vertical axes against falling or dropping after switchingoff the motor power by, for example,– mechanically securing the vertical axes,– adding an external braking/arrester/clamping mechanism or– ensuring sufficient counterbalancing of the vertical axes.

● The standard equipment motor holding brake or an external holding brakecontrolled by the drive controller is not sufficient to guarantee personalsafety!

● Disconnect electrical power to the components of the electric drive andcontrol system using the master switch and secure them from reconnec‐tion ("lock out") for:– Maintenance and repair work– Cleaning of equipment– Long periods of discontinued equipment use

● Prevent the operation of high-frequency, remote control and radio equip‐ment near components of the electric drive and control system and theirsupply leads. If the use of these devices cannot be avoided, check themachine or installation, at initial commissioning of the electric drive andcontrol system, for possible malfunctions when operating such high-fre‐quency, remote control and radio equipment in its possible positions ofnormal use. It might possibly be necessary to perform a special electro‐magnetic compatibility (EMC) test.


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2.3.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐ation and Mounting

Magnetic and electromagnetic fields generated by current-carrying conductorsor permanent magnets of electric motors represent a serious danger to personswith heart pacemakers, metal implants and hearing aids.Health hazard for persons with heart pacemakers, metal implants and hearingaids in proximity to electric components!● Persons with heart pacemakers and metal implants are not allowed to

enter the following areas:– Areas in which components of the electric drive and control systems

are mounted, commissioned and operated.– Areas in which parts of motors with permanent magnets are stored,

repaired or mounted.● If it is necessary for somebody with a heart pacemaker to enter such an

area, a doctor must be consulted prior to doing so. The noise immunity ofimplanted heart pacemakers differs so greatly that no general rules canbe 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.

2.3.5 Protection Against Contact With Hot PartsHot surfaces of components of the electric drive and control system. Risk ofburns!● Do not touch hot surfaces of, for example, braking resistors, heat sinks,

supply units and drive controllers, motors, windings and laminated cores!● According to the operating conditions, temperatures of the surfaces can

be higher than 60 °C (140 °F) during or after operation.● Before touching motors after having switched them off, let them cool down

for a sufficient period of time. Cooling down can require up to 140 mi‐nutes! The time required for cooling down is approximately five times thethermal time constant specified in the technical data.

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

● Wear safety gloves or do not work at hot surfaces.● For certain applications, and in accordance with the respective safety reg‐

ulations, the manufacturer of the machine or installation must take meas‐ures to avoid injuries caused by burns in the final application. Thesemeasures can be, for example: Warnings at the machine or installation,guards (shieldings or barriers) or safety instructions in the applicationdocumentation.

2.3.6 Protection During Handling and MountingRisk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!● Observe the relevant statutory regulations of accident prevention.● Use suitable equipment for mounting and transport.● Avoid jamming and crushing by appropriate measures.




● Always use suitable tools. Use special tools if specified.● Use lifting equipment and tools in the correct manner.● Use suitable protective equipment (hard hat, safety goggles, safety shoes,

safety gloves, for example).● Do not stand under hanging loads.● Immediately clean up any spilled liquids from the floor due to the risk of

slipping.

2.3.7 Battery SafetyBatteries consist of active chemicals in a solid housing. Therefore, improperhandling can cause injury or property damage.Risk of injury by improper handling!● Do not attempt to reactivate low batteries by heating or other methods (risk

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

explosion.● Do not throw batteries into open flames.● Do not dismantle batteries.● When replacing the battery/batteries, do not damage the electrical parts

installed in the devices.● Only use the battery types specified for the product.

Environmental protection and disposal! The batteries contained inthe product are considered dangerous goods during land, air, andsea transport (risk of explosion) in the sense of the legal regulations.Dispose of used batteries separately from other waste. Observe thenational regulations of your country.

2.3.8 Protection Against Pressurized SystemsAccording to the information given in the Project Planning Manuals, motors andcomponents cooled with liquids and compressed air can be partially suppliedwith externally fed, pressurized media, such as compressed air, hydraulics oil,cooling liquids and cooling lubricants. Improper handling of the connected sup‐ply systems, supply lines or connections can cause injuries or property damage.Risk of injury by improper handling of pressurized lines!● Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐

sion).● Observe the respective manufacturer's operating instructions.● Before dismounting lines, relieve pressure and empty medium.● Use suitable protective equipment (safety goggles, safety shoes, safety

gloves, for example).● Immediately clean up any spilled liquids from the floor due to the risk of

slipping.


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Environmental protection and disposal! The agents (e.g., fluids)used to operate the product might not be environmentally friendly.Dispose of agents harmful to the environment separately from otherwaste. Observe the national regulations of your country.

2.4 Explanation of Signal Words and the Safety Alert SymbolThe Safety Instructions in the available application documentation contain spe‐cific signal words (DANGER, WARNING, CAUTION or NOTICE) and, whererequired, a safety alert symbol (in accordance with ANSI Z535.6-2006).The signal word is meant to draw the reader's attention to the safety instructionand identifies the hazard severity.The safety alert symbol (a triangle with an exclamation point), which precedesthe signal words DANGER, WARNING and CAUTION, is used to alert thereader to personal injury hazards.

DANGER

In case of non-compliance with this safety instruction, death or serious injurywill occur.

WARNING

In case of non-compliance with this safety instruction, death or serious injurycould occur.

CAUTION

In case of non-compliance with this safety instruction, minor or moderate injurycould occur.

NOTICEIn case of non-compliance with this safety instruction, property damage couldoccur.





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3 IndraDrive HCS04.2E3.1 Device Line IndraDrive HCS04.2E3.1.1 For all Drives in Industry, Mechanical Engineering and Automation

Safety functions are not contained in the pro‐totype status.

DANGER

Applications using integrated safety technology are forbidden with applicationprototypes of the HCS04.2E line.

IndraDrive HCS04.2E is a multi-purpose frequency converter / servo converter;it covers a wide range of applications when you use the adjusted IndraDrivecontrol sections.



IndraDrive HCS04.2E


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IndraDrive HCS04.2E

Converter HCS04.2E-W0350HCS04.2E-

W0420HCS04.2E-

W0520HCS04.2E-

W0640Performance data:High continuous load (20% overload for 60 s per 10 min, 35% overload for 2 s per 30 s)High overload (50% overload for 60 s per 10 min, 65% overload for 2 s per 30 s)(at 3AC 400 V mains voltage, switching frequency fs = 4 kHz)

Typical motor power kW 132/110 160/132 200/160 250/200Continuous current Icont A 259/215 300/257 366/313 459/387

Maximum current Ipeak 60 s A 311/323 360/386 439/470 551/581


Mains input continuous current A 226/194 271/229 338/277 418/340Mains connection voltage V 3 AC 380… 480 (+10 %/-15 %) // 50/60 Hz ±5 %

(TT, TN and IT mains)Overvoltage category Category III in accordance with EN 50178DC bus capacitance mF 7,8 7,8 10,4 10,8Operating temperature °C When sized with high overload: -10… +40

When sized with high continuous load: -10… +40Storage/transport temperature °C -25 … +70Installation altitude Up to 1,000 m, above derating by 1% per 100m up to the maximum instal‐

lation altitude of 3,000 mAllowed pollution Pollution degree 2 in accordance with EN 61800-5-1Basic standard EN 50178EMC immunity In accordance with EN 61800-3-1, environments 1 and 2EMC emission In accordance with EN 61800-3, environments 1 and 2,

Category C1, C2, C3Insulation Galvanic isolation in accordance with EN 50 178 PELV


W1010HCS04.2E-

W1240HCS04.2E-

W1540Power data high continuous load / high overload (at mains voltage 3AC 400V, switching frequency fs = 4 kHz)

Typical motor power kW 315/250 400/315 500/400 630/500Continuous current Icont A 586/477 720/614 894/749 1126/930



Mains input contin. current A 527/424 660/529 834/675 1037/834

Mains connection voltageV 3 AC 380… 480 (+10 %/-15 %) // 50/60 Hz ±5 %

(TT, TN and IT mains)Overvoltage category Category III in accordance with EN 50178DC bus capacitance mF 15,6 16,2 23,4 31,2

Operating temperature°C When sized with high overload: -10… +40

When sized with high continuous load: -10… +40Storage/transport temperature °C -25 … +70



IndraDrive HCS04.2E


W1010HCS04.2E-

W1240HCS04.2E-

W1540

Installation altitude Up to 1,000m, above derating by 1% per 100m up to the maximum instal‐lation altitude of 3,000mAllowed pollution Pollution degree 2 in accordance with EN 61800-5-1Basic standard EN 50178EMC immunity In accordance with EN 61800-3-1, environments 1 and 2

EMC emission In accordance with EN 61800-3, environments 1 and 2,

Category C1, C2, C3Insulation Galvanic isolation in accordance with EN 50 178 PELV

3.2 General Specification"HCS04.2E" for controlling asynchronous three-phase a.c. motors and syn‐chronous three-phase a.c. motors use state-of-the-art components and tech‐nology. This makes the design highly compact and provides user-friendlydevice properties.Our high degree of quality awareness comprises the basic requirements in theproduct specification, the development of the cooling system, the mechanicalconfiguration, the electrical circuit diagram, the individual functions and the de‐vice assembly. This quality level is guaranteed in the long term by qualityassurance systems in the individual business processes; besides, the qualitylevel is annually certified in accordance with DIN EN ISO 9001 by an inde‐pendent authority."IndraDrive HCS04.2E" converters are suited for motive and regenerative op‐eration of motors in both directions of rotation and both directions of power flow.They can dissipate the generated kinetic energy via an external braking resis‐tor."HCS04.2E" converters are independently working devices with an internalcontrol supply and forced ventilation.

Fig.3-1:The basic devices can or must be supplemented by options, depending on theon-site conditions and the requirements to the drive. There are options for thepower circuit, options for control and operation and mechanical options.


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IndraDrive HCS04.2E

3.3 Quality3.3.1 CE Label

All devices and installations of the electric drive technology can cause electro‐magnetic noise and be disturbed by such noise. Therefore, they have beensubject to the scope of the EMC Directive 2004/108/EG since 1996-01-01.The nominal operating voltage of the converters is clearly within the range of50...1000 V AC or 75...1500 V DC. Therefore, they have been subject to thescope of the Low-Voltage Directive 2006/95/EG since 1997-01-01.The radio interference filters integrated in the converter guarantee conformitywith EN 61800-3 and EN 50178.

Converters are not considered as machines with at least one me‐chanically moving part. Therefore, they are not subject to the scopeof the Machinery Directive 2006/42/EG.

Converters are products with restricted distri‐bution in accordance with IEC 61800-3.

CAUTION

In residential areas, this product can cause high-frequency interference. Theuser can be asked to take the appropriate measures.

Converters are products with restricted distribution in accordancewith IEC 61800-3. In residential areas, this product can cause high-frequency interference. The user can be asked to take the appro‐priate measures.

There is a CE label on the type plate of the converter. To reach the corre‐sponding limit values, it is necessary, however, to comply with the installationinstructions.

3.3.2 Installation Instructions● As a standard, the converters have an integrated radio interference filter

for industrial areas. With longer motor cables and for use in residentialareas, use an additional external filter to reduce, on the mains-side, cur‐rent harmonics caused by the DC bus.

● Mount the devices on a well grounded metal mounting plate with a goodHF connection between motor cable shield and filter.

● Use shielded motor cables. Connect and route the motor cable correctlyat both ends in a closed and continuously connected cable duct made ofmetal.

● For longer motor cables, use an output motor filter.● Use shielded control cables and connect them correctly.● Ground the converter with at least 10 mm2 (personal protection).● Route the motor lines separately from other cables, especially from control

lines.



IndraDrive HCS04.2E

3.4 Mains Conditions3.4.1 Mains Voltage

HCS04.2E devices have been designed for the following mains voltages:3 AC 380 V -15 % to 440 V +10 %, 50 Hz ± 5 %3 AC 380 V -15 % to 480 V +10 %, 60 Hz ± 5 %Blower supplyThe IndraDrive HCS04.2E converters are cooled by means of three-phase cur‐rent blowers. The blowers must be supplied with the following voltage:3 AC 400 V -10 % to 440 V +10 %, 50 Hz ± 5 %3 AC 400 V -10 % to 480 V +10 %, 60 Hz ± 5%

3.4.2 FusesThe HCS04.2E converters do not contain any input line fuses. These fusesmust be provided externally to protect the power cables against overload andto protect the input rectifier in the case of an internal short circuit.

It is recommended that you use super-fast fuses (semiconductorprotection).

You can also use fast fuses or circuit breakers, but in this case the rectifier canbe damaged when an internal error occurs.

3.4.3 Braking Unit / Braking ResistorIf the braking resistor does not match the overload characteristic,or if the local regulations require an additional protection device, itis necessary to include a thermal relay in the line disconnectionpath.

The correct setting of the braking parameters is fundamental in order to protectthe braking resistor in normal operation. In case the internal braking transistoror the external braking unit does not work correctly, the braking resistor canonly be protected by disconnection from line. A mains contactor is thereforerequired when using the braking function. In addition, it is recommended thatyou use the function "mains contactor control".

3.4.4 Ungrounded MainsUse is generally allowed in all mains variants.

For ungrounded mains (typically for industrial mains), the integratedradio interference filter must be adjusted by disconnecting/recon‐necting. In this case, the maximum allowed clock frequency is 4kHz.


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IndraDrive HCS04.2E

① TN or TT mains (factory setting)② IT mains or corner-groundedFig.3-2: IndraDrive HCS04.2-W0350

① TN or TT mains (factory setting)② IT mains or corner-groundedFig.3-3: IndraDrive HCS04.2E W420-W520



IndraDrive HCS04.2E

① TN or TT mains (factory setting)② IT mains or corner-groundedFig.3-4: IndraDrive HCS04.2EWith ungrounded mains, a single-pole ground fault in the supplying mains doesnot influence the function of the converter. If the ground fault occurs in the motoror motor cable, the converter switches off. The ground fault detection, however,strongly depends on the capacitance to ground of the mains.

The option HNF01.1B filter is not suited for ITmains!

WARNING

In IT mains it is only allowed, for reasons of personal protection, to use specialradio interference filters with very low leakage current (increasing the capaci‐tances to ground, ...).

3.4.5 Radio Interference As a standard, the HCS04.2E converters have an integrated radio interferencefilter. Depending on the device size, these filters comply with the requirementsof the categories C2 or C3 in accordance with EN/IEC 61800-3.

When using converters of higher power in residential areas andwhen using longer motor cables, additional filters of optionHNF01.1B must be used.


3.4.6 Mains Current Harmonics / Mains Voltage Distortions When a diode rectifier is used on the input side of the converter, harmonicsoccur in the mains current; the harmonics cause voltage distortion of the sup‐plying mains.To reduce these current harmonics and the total mains current, there are dif‐ferent options:● Use a DC choke, option HLL.● Use a three-phase current choke, option HNL, in the mains supply lines.


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IndraDrive HCS04.2E

● 12-pulse circuit: Supply takes place via an individual transformer with twophase-displaced secondary windings. As a standard, the following devi‐ces have been prepared for 12-pulse supply: IndraDrive HCS04.2EW1240 – W1540.

3.4.7 12-Pulse SupplyAs a standard, the following converters have been equipped with two parallelinput rectifiers and thus are suited for 12-pulse rectification: IndraDriveHCS04.2E W1240... W1540.Supply takes place via an individual transformer with two phase-displaced sec‐ondary windings (e.g. Yy6 d5).On the primary side of the transformer, the 5th and 7th current harmonics prac‐tically no longer exist, because they are eliminated by the displaced transformerwindings.

To ensure constant current distribution, the transformer must com‐ply with the tolerance values:Tolerance between the secondary voltages: 0.3 % of UNOMTolerance of the relative short-circuit voltage: 5.0 % of uK_NOMThe nominal output voltage of a transformer is defined at no-loadoperation. Therefore, this value must be approx. 5% higher than therated voltage of the drive.

Fig.3-5: Connection Diagram for 12-Pulse Supply

Radio interference filters integrated as a stand‐ard

CAUTION

For 12-pulse supply, the radio interference filters integrated as a standard inIndraDrive HCS04.2E must be set to "IT mains".

3.4.8 System Impedance / Short-Circuit CurrentHCS04.2E converters have been sized in accordance with a maximum allowedmains short-circuit current at the point of infeed (for values see "Technical Data"of the respective converter).

Using chokes (option HLL or Option HNL) allows much highermains short-circuit powers without affecting the operational safetyof the converter.



IndraDrive HCS04.2E

3.4.9 Reactive-Current Compensation EquipmentConverters cause current harmonics in the supplying mains. When reactive-current compensation equipment is used, its capacitors are additionally loadedby the harmonics.

As an overload protection, it is recommended that you use chokesin these parts of the installation.

3.4.10 Switching RateThe HCS04.2E converters can be switched on and off directly with the mainscontactor; the mains contactor can be easily controlled via a relay output (con‐trol section X31, 1-2) of the converter.For frequent start/stop commands, it is recommended, however, to apply themdirectly to the electronics of the converter, via the digital control inputs (or viaa serial bus).

Converter control Switching rate

The converter is controlled by switchingthe mains voltage on and off.

Max 60 switching actions per hour (safetycategory 1, stop category 0)

The motor is switched off by a motor con‐tactor.

Depending on the motor contactor (safetycategory 1, stop category 0)

The device blowers are controlled automatically, depending on thestart command and a temperature-dependent stop delay function.


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IndraDrive HCS04.2E

3.5 IndraDrive HCS04.2E3.5.1 For all Drives in Industry, Mechanical Engineering and Automation

Fig.3-6: IndraDrive HCS04.2EFully equipped as standard, multi-purpose use



IndraDrive HCS04.2E

Feature AdvantagesIntegrated radio interfer‐ence filter for industrialareas

No additional space required, reduced installation efforts

Wide range of options Standard solutions are available to adjust IndraDriveHCS04.2E to many applications. Many options which can beintegrated and mounted reduce the required space and in‐stallation effort

Push-through technology The power section of the converter, with the degree of pro‐tection IP54, is outside of the control cabinet; this minimizesadditional temperature rise.

Optimized for controlcabinet mounting

IndraDrive HCS04.2E are suited for each type of customer-specific control cabinets. Standard components are availa‐ble for realizing thermally optimized control cabinets indegree of protection IP54.

Industry-compatible design

Feature AdvantagesWide range of power andvoltage

One product series for all applications. This ensures consis‐tent interfaces, reduced training efforts and easy stockkeep‐ing of spare parts.

Rugged design of powersection and control sec‐tion

Highly reliable, even under rough ambient conditions. Powersection designed in IP54, cooling air of control section andpower section completely separated, circuit boards are lac‐quered.

Intelligent limitation andprotection concept

High degree of availability and less process interruptions.Converter, motor and application are protected in the bestpossible way.

Galvanically isolatedcontrol terminals

Safe and reliable operation in accordance with EN 50178PELV

Approved worldwide A product series having the most important approvals, suchas CE, cULus, and which can be operated worldwide.

3.6 Specification3.6.1 Technical Data

The IndraDrive HCS04.2E converters have been equipped with a Dual Ratingfunctionality.You can therefore use the converter either with● a high degree of dynamic overload capacity and nominal continuous pow‐

er or● increased continuous load at simultaneously reduced dynamic overload

capacityThe difference between the maximum allowed continuous output power is oneIEC motor type category.


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IndraDrive HCS04.2E

Fig.3-7: Example

Input

Voltage 380 V -15% to 480 V +10% for TT, TN or IT mains *)

Frequency 50 / 60 Hz ± 5 % *)

Overvoltage category Category III in accordance with EN 50178

Mains power factorFundamental wave cos φ:Total (λ) at full load:Total (λ) in no-load operation:

> 0,980,93...0,95 (with AC or DC choke)Approx. 0,7 (with AC or DC choke)

Output

Voltage 3 AC 0...100% mains voltage, dynamic voltage stabilization

OverloadPower 1: 50% for 60 s per 10 min., 65% for 2 s per 30 sPower 2: 20% for 60 s per 10 min, 35% for 2 s per 30 s

Clock frequency Nominal data for 4 kHz, can be set from 2 to 8 kHz

Frequency 0…300 Hz

Short-circuit protection All-pole short-circuit protection and ground-fault protection by overcurrent shutdown

Design Device for vertical mounting

Cooling Forced

Mechanical resistance

Oscillation

In accordance with IEC/EN 60068-2-6

HCS04.2-W0350...-W1540: 1.5 mm in the range of 3...10 Hz,0.6 g from 10...200 Hz(3M3 in accordance with IEC/EN 60721-3-3)

Shock

In accordance with IEC/EN 60068-2-27

HCS04.2-W0350 ...-W0420HCS04.2E-W0520-N-04-NNBN... HCS04.2-W1540

7 g for 11 ms(3M3 in accordance with IEC/EN 60721-3-3)4 g for 11 ms(3M2 in accordance with IEC/EN 60721-3-3)

Fig.3-8: *) For technical data and notes on mains voltage, see chapter "MainsConditions"



IndraDrive HCS04.2E

Ambient conditions

Operating temperature

When sized with high overload (power 1): -10... +40°CAt high continuous load (power 2): -10... +40°C(3K3 in accordance with IEC/EN 60721-3-3)Up to +60°C with derating

Storage/transport tem‐perature -25... +70°C

Degree of protectionIndraDrive HCS04.2E Lateral, front IP31

Top IP20 (IP31 with HLL choke box)Bottom IP00

Environment class / hu‐midity

Class 3K3 in accordance with IEC/EN 60721-3-3 / no moisture condensation, max. 95% relativehumidity

Installation altitude Up to 1,000 m, above derating by 1% per 100m up to 3,000 m

Allowed pollutionPollution degree 2 in accordance with EN 61800-5-1IndraDrive HCS04.2E W0350 ...W1540

3C2 and 3S2 in accordance withEN 60721-3-3

Protection class Class 1 in accordance with EN 50178Standards Basic standard The devices were developed, built and tested on the basis of EN 50178.

EMC immunityIn accordance with EN 61800-3, 1st and 2nd environment(IEC 1000-4-2; IEC 1000-4-3; IEC 1000-4-4; IEC 1000-4-5; IEC 1000-4-6)

EMC emissionIn accordance with product standard EN 61800-31st and 2nd environment, category C1, C2, C3

Insulation Galvanic isolation in accordance with EN 50178 PELV (Protective Extra Low Voltage)



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IndraDrive HCS04.2E

IndraDrive HCS04.2E HCS04.2E-W0350 HCS04.2E-W0420 Nominal data

When the devices are moun‐ted without lateral clearance,greater minimum distancesare required for sufficient cool‐ing (values in brackets).In either case, make sure toavoid air short circuit.1.) In conjunction with DCchoke, option HLL01.1A

Typical motor powerPN [kW] - power 1/2 110/132 132/160

PN [hp] - power 1/2 150/200 200/250

Continuous output powerSN 400 [kVA] UN = 400 V 149/179 179/218

SN 460 [kVA] UN = 460 V 171/206 206/250

Continuous output currentIN 400 [A] UN = 400 V 204/246 257/300

IN 460 [A] UN = 460 V 204/246 257/300

Maximum current for 60 s per 10 minutesIMAX [A] - power 1/2 323/311 386/360

Input current (with option HCS04.2E, HLL01.1A)IIN 400 [A] UN = 400 V 194/226 229/271

IIN 460 [A] UN = 460 V 173/224 225/275

Braking unitPCONTINUOUS [kW] 85 100

PMAX for 10 s [kW] 165 200

RMIN/RMAX [Ω] 2,1/4,0 1,75/3,5

Type dataEfficiency [%] > 97,5 > 97,6Losses [W] at IN 2520/3330 2950/3710

Mass approx. [kg] 74 80

Ambient conditions

Cooling air volume [m3/h] 600 600

Sound pressure level [dB(A)] 69 71

Mains short-circuit current [kA] 501.) 501.)

Dimensions

Dimension A1 [mm] 782 950



Dimension B1 [mm] 350 330

Dimension B2 [mm] 298 285

Dimension C1 [mm] 380 380

Dimension C3 [mm] 380 380

Fixing D1 [mm] 4 x Ø 11.5 4 x Ø 11.5



IndraDrive HCS04.2E

Fig.3-9: Dimensions


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IndraDrive HCS04.2E

IndraDrive HCS04.2E HCS04.2E-W0520HCS04.2E-W0640

HCS04.2E-W0790

Nominal data

When the devices are mounted withoutlateral clearance, greater minimum dis‐tances are required for sufficient cooling(values in brackets).In either case, make sure to avoid airshort circuit.1.) In conjunction with DC choke2.) External braking unit

Typical motor powerPN [kW] - power 1/2 160/200 200/250 250/315

PN [hp] - power 1/2 250/300 300/400 400/500

Continuous output powerSN 400 [kVA] UN = 400 V 218/268 268/333 333/427

SN 460 [kVA] UN = 460 V 250/308 308/383 383/491

Continuous output currentIN 400 [A] UN = 400 V 313/366 387/459 477/586

IN 460 [A] UN = 460 V 314/387 387/481 481/616

Maximum current for 60 s per 10 minutesIMAX [A] - power 1/2 470/439 581/551 716/703

Input current (with option HCS04.2E, HLL01.1A)IIN 400 [A] UN = 400 V 277/338 340/418 424/527

IIN 460 [A] UN = 460 V 281/331 333/435 442/544

Braking unitPCONTINUOUS [kW] 120 200 2.) 200 2.)

PMAX for 10 s [kW] 240 300 375

RMIN/RMAX [Ω] 1,75/2,75 1,05/2,2 1,05/1,75

Type dataEfficiency [%] > 97,7 > 97,7 > 97,7Losses [W] at IN 3490/4450 4560/5890 5430/7250

Mass approx. [kg] 110 140 140Ambient conditionsCooling air volume [m3/h] 800 1200 1200Sound pressure level [dB(A)] 72 73 73Mains short-circuit current [kA] 50 1.) 50 1.) 50 1.)

DimensionsDimension A1 [mm] 950 950 950Dimension A2 [mm] 920 920 920Dimension A3 [mm] 15 15 15Dimension B1 [mm] 430 585 585Dimension B2 [mm] 350 540 540Dimension C1 [mm] 380 380 380Dimension C3 [mm] 380 380 380Fixing D1 [mm] 4 x Ø 11.5 4 x Ø 11.5 4 x Ø 11.5



IndraDrive HCS04.2E

Fig.3-10: Dimensions


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IndraDrive HCS04.2E

IndraDrive HCS04.2E HCS04.2E-W1010HCS04.2E-W1240

HCS04.2E-W1540

Nominal data

When the devices are mountedwithout lateral clearance, greaterminimum distances are required forsufficient cooling (values in brack‐ets).In either case, make sure to avoidair short circuit.1.) In conjunction with DC choke2.) External braking unit

Typical motor powerPN [kW] - power 1/2 315/400 400/500 500/630

PN [hp] - power 1/2 500/600 600/700 700/900

Continuous output powerSN 400 [kVA] UN = 400 V 427/526 526/652 652/823

SN 460 [kVA] UN = 460 V 491/605 605/750 750/861

Continuous output currentIN 400 [A] UN = 400 V 614/720 749/894 930/1126

IN 460 [A] UN = 460 V 616/759 759/941 941/1080

Maximum current for 60 s per 10 minutesIMAX [A] - power 1/2 921/864 1124/1073 1395/1351

Input current (with option HCS04.2E, HLL01.1A)IIN 400 [A] UN = 400 V 529/660 675/834 834/1037

IIN 460 [A] UN = 460 V 547/644 660/760 761/964

Braking unitPCONTINUOUS [kW] 400 2.) 400 2.) 400 2.)

PMAX for 10 s [kW] 475 600 750

RMIN/RMAX [Ω] 0,7/1,4 0,7/1,1 0,7/0,85

Type dataEfficiency [%] > 97,8 > 97,8 > 97,8Losses [W] at IN 6880/8810 8630/11150 10530/13830

Mass approx. [kg] 215 225 300Ambient conditionsCooling air volume [m3/h] 1800 1800 2400Sound pressure level [dB(A)] 75 75 75Mains short-circuit current [kA] 50 1.) 50 1.) 50 1.)

DimensionsDimension A1 [mm] 1150 1150 1150Dimension A2 [mm] 1120 1120 1120Dimension A3 [mm] 15 15 15Dimension B1 [mm] 880 880 1110Dimension B2 [mm] 417.5 417.5 532.5Dimension C1 [mm] 380 380 380Dimension C3 [mm] 380 380 380Fixing D1 [mm] 5x Ø11.5 5x Ø11.5 6x Ø11.5



IndraDrive HCS04.2E

① HCS04.2E-W1010-N-04-NNNN...② HCS04.2E-W1540-N-04-NNNNFig.3-11: Dimensions

3.6.2 Control Cabinet Mounting IP23The specified power dissipations and minimum air-inlet cross sections refer tothe converter. Other heat sources, such as HLL, HNL01.1E, HMF01.1N, fusesand contactors must be additionally taken into account. The device-internalpower section blower ventilates the control cabinet. The air flow mustn't beimpeded by built-in components or filter mats. For devices of 110 kW and more,seal off the power section air to avoid internal air short circuits.

3.6.3 DeratingDerating is required depending on the selected clock frequency and the maxi‐mum ambient temperature. The derating can be determined from the figurebelow.IndraDrive HCS04.2E-W0350 …-W1540

① Power 1: High overload② Power 2: High continuous loadFig.3-12: Derating Depending on Clock Frequency / Ambient Temperature


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IndraDrive HCS04.2E

To ensure trouble-free operation of the installation, please observe the followingguidelines:● With higher clock frequencies, the allowed length of the motor cables is

reduced (see chapter "Motor Cable Lengths", page 62).● As a maximum, the selected motor can be one type category greater.

The installation of HLL does not have any influence on cooling, andthus does not have any influence on the power increase and thederating of the converter.

When the heat sink temperature is too high, the current is automat‐ically reduced to protect the converter against overload.

3.6.4 Continuous Current at Output Frequencies < 1 HzFor complete protection of the power semiconductors (IGBTs) against thermaloverload, the output current is automatically reduced during operation around0 Hz.When the converter is operated with output frequencies < 1 Hz, the overloadtime is less than 60 s.The output frequencies and overload times are● 0.0 Hz → 5 s● 0.5 Hz → 32 s● 1.0 Hz → 60 s

The restricted overload time only must be taken into account fordrives working around 0 Hz in continuous operation.

Practically, there isn't any effect on the start of a drive, becauseeven 500-kW motors have a nominal slip of 0.3 Hz and thereforean overload time of approx. 22 s is possible.



IndraDrive HCS04.2E

3.7 Connecting and Wiring3.7.1 Wiring DiagramIndraDrive HCS04.2E-W0350 ... - W0520

The figures below show the typical wiring of the converters, including the op‐tions, which can be required to protect the installation or device, depending onthe application.

*) Alternative optionsFig.3-13: Wiring Diagram: IndraDrive HCS04.2E-W0350 ... - W0520

F FilterPE M PE motorHS Main switch (is used if required and according to the local regulations)NH Mains fuses according to table (absolutely required)

K1 Mains contactor (is used if required and according to the local regu‐lations)

HNL01.1E Mains choke option for mains-side reduction of the current harmonicscaused by the DC bus; used as an alternative to option HLL

HNF01.1BRadio interference filter option for using the converter as per categoryC1 or C2 in accordance with EN 61800-3 "Use in 1st environment -residential area"

Internal filter Radio interference filter integrated as a standard; corresponds to cat‐egory C3 in accordance with EN 61800-3 "Use in industrial areas"

HMF01.1N Output motor filter option to reduce the voltage peaks at the motor inthe case of long motor cables

HLL DC choke option to reduce current harmonics; used as an alternativeto option HNL01.1E. Available as an option to be mounted.

HLR01.1 Braking resistor option for rapid deceleration or temporary regenera‐tive loads.DC+ / DC- Energy supply from a DC bar; as an alternative to 3AC mains supply


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IndraDrive HCS04.2E

IndraDrive HCS04.2E-W0640 ... - W1010

*) Alternative optionsFig.3-14: Wiring Diagram: IndraDrive HCS04.2E-W0640 ... - W1010

F FilterPE M PE motorHCS04.2E ConverterHS Main switch (is used if required and according to the local regulations)NH Mains fuses according to table (absolutely required)


HNL01.1E Mains choke option for mains-side reduction of the current harmonicscaused by the DC bus; used as an alternative to option HLL

HNF01.1BRadio interference filter option for using the converter as per categoryC2 in accordance with EN 61800-3 "Use in 1st environment - resi‐dential area"



HLL DC choke, option to be mounted, to reduce current harmonics; usedas an alternative to option HNL01.1E

HLT External braking unit option for "IndraDrive HCS04.2E-W0640-N-04-NNNN … HCS04.2E-W1540-N-04-NNNN"




IndraDrive HCS04.2E

IndraDrive HCS04.2E-W1240 ...-W1540

Fig.3-15: Wiring Diagram: IndraDrive HCS04.2E-W1240 ...-W1540

F FilterPE M PE motorPE N PE mainsHCS04.2E ConverterHS Main switch (is used if required and according to the local regulations)NH Mains fuses according to table (absolutely required)


TR Transformer with two phase-displaced secondary windings (e.g. Yy6d5)TS Disconnector (is used according to the local regulations)




HLR01.1 Braking resistor option for rapid deceleration or temporary regenera‐tive loads.DC+ / DC- Energy supply from a DC bar; as an alternative to 3AC mains supply1. Energy supply from a DC bar; as an alternative to 3AC mains supply

2.Fuse monitoring protects the rectifier against unequal load. Fusemonitoring must act on the mains contactor. Monitoring is not obliga‐tory, because the converter monitors the mains voltage.


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IndraDrive HCS04.2E

IndraDrive HCS04.2E-W1240 ...-W1540 (12-Pulse Rectification)

Fig.3-16: Wiring Diagram: IndraDrive HCS04.2E-W1240 ...-W1540

F FilterPE M PE motorPE N PE mainsHCS04.2E ConverterHS Main switch (is used if required and according to the local regulations)NH Mains fuses according to table (absolutely required)

NS K1 mains contactor (is used if required and according to the localregulations)

TS Transformer with two phase-displaced secondary windings (e.g. Yy6d5)TR Disconnector (is used according to the local regulations)





● Fuse monitoring protects the rectifier against unequal load. Fuse moni‐toring must act on the mains contactor. Monitoring is not obligatory,because the converter monitors the mains voltage.

● For supply via a three-winding transformer, the neutral point can be groun‐ded or optionally provided with an insulation monitoring relay.

● To ensure constant current distribution, the transformer must comply withthe tolerance values: Tolerance of the transformation ratios: 0.3 % ofUNOMTolerance of the relative short-circuit voltage: 5.0 % of uK_NOMThe nominal output voltage of a transformer is defined at no-load opera‐tion. Therefore, this value must be approx. 5% higher than the ratedvoltage of the drive.



IndraDrive HCS04.2E

DC CouplingDC coupling of several HCS04.2E-W.... with a mains contactorFor applications which must generate full motive power, but also are to work inregenerative operation by exchanging energy via the DC bus, it is recommen‐ded that you use DC coupling (e.g., for roller tables, belt conveyors, ...).

DC coupling is only allowed for the combination of "HCS04.2/HCS04.2" devices. It is not allowed for the combination of"HCS04.2/HCS03.1" or "HCS04.2/HCS02.1" devices.

Fig.3-17: DC Coupling of Several HCS04.2E-W...

K1Mains contactor: Due to the design with a common mains contactor,the charging circuits of the individual converters work in parallel whenpower is switched on and therefore cannot be overloaded.

NH

Mains-side device protection: To protect the individual rectifiersagainst overload, comply with the fuse recommendations containedin the chapter. Fuse monitoring which acts on the mains contactor canprevent consequential damage in the charging circuit when power isswitched on.

SI Fuse in the DC bus in accordance with table

① ② ③

HCS04.2E converter in standard design: Basically, the number of de‐vices and their sizes can be freely selected. However, it is onlypossible to combine devices of a maximum of three sizes.Example: When using HCS04.2E W790 as the biggest device, thesmallest size that can be used is HCS04.2E W520.

HNL01.1E The mains choke HNL01.1E option or DC choke option is absolutelynecessary!

HLT01.1A/HLR01.1

Braking unit and braking resistor for short-time reduction of regener‐ative power: For example, if all drives are to be decelerated simulta‐neously, the released energy can be reduced in the braking resistor.Using a braking unit is not obligatory.


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DC Coupling of a Main Drive With Slave(s) at the DC BusApplications in which drives work in regenerative form (in deceleration mode)while one or several drives run in motive form, can work very efficiently due toDC supply (e.g., winders/unwinders, levelling machines, testing stands, rollertables, lifting gear, travelling gear, ...).

However, the required motive power mustn't ever exceed the mo‐tive power necessary for the rectifier of the main drive (e.g., 250 kW+ 20 % for 60 s with HCS04.2E-W0640).

It is not allowed to switch on DC-supplied drives during operation!

When an HCS04.2E device is supplied via the DC bus, the three-phase current blowers of the converter must be supplied externally.See chapter 3.9.7 "External Blower Supply" on page 96

Fig.3-18: DC Coupling of a Main Drive With Slave(s) HCS04.2E

①

HCS04.2E (main drive)This converter determines the maximum possible motive power of theentire drive group. The converter can charge three devices of thesame size (or several smaller devices of the same total power).

② ③DC-supplied HCS04.2E converters (slave[s])In the case of supply via the DC bus, the three-phase current blowersof the converter must be supplied externally.

HNL The HNL mains choke option or HLL DC choke option is absolutelynecessary!

SI

Super-fast fuse according to table in chapter "Fuses for DC-CoupledConverters", page 45It does not make sense to use switching devices in the DC circuit,because the switching duty will cause the fuses to trip due to the highcharging current.

HLT/HLR

Braking unit and braking resistor for short-time reduction of regener‐ative power. For example, if all drives are to be decelerated simulta‐neously, the released energy can be reduced in the braking resistor.Using a braking unit is not obligatory.



IndraDrive HCS04.2E

Fig.3-19: DC Coupling of a Main Drive With Slave(s) IndraDrive M

①

HCS04.2E (main drive)This converter determines the maximum possible motive power of theentire drive group. The converter can charge three devices of thesame size (or several smaller devices of the same total power).

② DC-supplied IndraDrive devicesHLL Current-compensated DC bus choke

HNL The HNL mains choke option or HLL DC choke option is absolutelynecessary!

SI

Super-fast fuse according to table in chapter "Fuses for DC-CoupledConverters", page 45It does not make sense to use switching devices in the DC circuit,because the switching duty will cause the fuses to trip due to the highcharging current.

HLT/HLR

Braking unit and braking resistor for short-time reduction of regener‐ative power. For example, if all drives are to be decelerated simulta‐neously, the released energy can be reduced in the braking resistor.Using a braking unit is not obligatory.

In the case of operation as central supply, converters of theHCS04.2 line can charge the triple capacitance value of the DC buscapacitance installed in the converter. This must be taken into ac‐count for the project planning of the additional axes!

With this kind of interconnection, the total leakage capacitancemustn't exceed 100 nF.If the total leakage capacitance of the application exceeds the valueof 100 nF, it is obligatory that you use a current-compensated DCbus choke of the "HLL" type. When such an HLL choke is used, thetotal leakage capacitance can increase up to 500 nF. If the totalleakage capacitance exceeds the value of 500 nF, another DC busstring using another HLL choke is required.For higher leakage capacitances, see Project Planning Manual ofIndraDrive systems.


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IndraDrive HCS04.2E

Fuses for DC-Coupled ConvertersOnly super-fast fuses are suited for DC applications. Due to their design, theycan switch off both direct voltage and alternating voltage.

DC mains supply 400 V 440 V 460 V

Nominal voltageVoltage rangeOvervoltage cut-off

560 V DC405...650 V DC1.50 x UN-DC

620 V DC450...685 V DC1.35 x UN-DC

680 V DC490...745 V DC1.25 x UN-DC

Nominal current DC (ap‐prox.)

1.15 x IMOTOR 1.15 x IMOTOR 1.15 x IMOTOR

Fuse type, nominal voltage 690 V sf 690 V sf 690 V sf

HCS04.2E converter Mains fuse "converter pro‐tection" sfLines in control cabinet (perphase)

HCS04.2E-W0350 400 A 185 mm2

HCS04.2E-W0420 500 A 2 x 120 mm2

HCS04.2E-W0520 630 A 2 x 150 mm2

HCS04.2E-W0640 700 A 3 x 120 mm2

HCS04.2E-W0790 900 A 3 x 150 mm2

HCS04.2E-W1010 1250 A 4 x 150 mm2

HCS04.2E-W1240 1400 A 6 x 120 mm2

HCS04.2E-W1540 1600 A 6 x 150 mm2

3.7.2 Fuses and Cable Cross SectionsThe "IndraDrive HCS04.2E" converters do not contain any input line fuses.They must be provided externally for cases in which the converter's electronicprotective mechanisms fail. They are the converter's secondary protection toprotect the power cables against ov

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