REXROTH IndraDrive HCQ02 Manuale tecnico
Project Planning Manual
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics
Rexroth IndraDrive
Drive Controllers
HCQ, HCT
R911324185
Edition 03
Rexroth IndraDrive
Drive Controllers
HCQ, HCT
Project Planning Manual
DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
RS-a3a3ad602ba8890e0a6846a00109da40-6-en-US-2
Provides information on the project planning of Rexroth IndraDrive systems
considering the components
● HCQ02
● HCT02
Edition Release Date Notes
DOK-INDRV*-HCQ-T+HMQ-T-PR01 2009/10 See index entry "Docu‐
mentation → Editions"
DOK-INDRV*-HCQ-T+HMQ-T-PR02 2011/07 See index entry "Docu‐
mentation → Editions"
DOK-INDRV*-HCQ-T+HMQ-T-PR03 2012/04 See index entry "Docu‐
mentation → Editions"
Copyright © Bosch Rexroth AG 2012
This document, as well as the data, specifications and other information set
forth in it, are the exclusive property of Bosch Rexroth AG. It may not be re‐
produced or given to third parties without its consent.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this docu‐
mentation and the availability of the product.
Published by Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr a. Main, Germany
Phone +49 9352 18 0 ■ Fax +49 9352 18 8400
http://www.boschrexroth.com/
Dept. DC-IA/EDY1 (RB, US, BB); DC-IA/EDH (TS, MN, GB)
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revision
Bosch Rexroth AG DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT
Table of Contents
Page
1 System Presentation...................................................................................................... 7
1.1 Drive System with Rexroth IndraDrive HCQ02, HCT02 ........................................................................ 7
1.2 Drive Controllers HCQ02, HCT02........................................................................................................... 9
1.3 Type Code............................................................................................................................................ 11
1.3.1 HCQ02............................................................................................................................................... 11
1.3.2 HCT02............................................................................................................................................... 12
1.4 Firmware............................................................................................................................................... 12
1.5 Operator Panels.................................................................................................................................... 13
1.6 About This Documentation................................................................................................................... 13
1.6.1 Purpose............................................................................................................................................. 13
1.6.2 Editions.............................................................................................................................................. 13
1.6.3 Documentations ................................................................................................................................ 14
Drive Systems, System Components............................................................................................. 14
Motors............................................................................................................................................. 14
Cables............................................................................................................................................ 14
Control Unit..................................................................................................................................... 15
1.6.4 Your Feedback.................................................................................................................................. 15
2 Important Directions for Use ....................................................................................... 17
2.1 Appropriate Use ................................................................................................................................... 17
2.1.1 Introduction........................................................................................................................................ 17
2.1.2 Areas of Use and Application............................................................................................................ 17
2.2 Inappropriate Use................................................................................................................................. 18
3 Safety Instructions for Electric Drives and Controls..................................................... 19
3.1 Definitions of Terms.............................................................................................................................. 19
3.2 General Information.............................................................................................................................. 20
3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 20
3.2.2 Requirements for Safe Use............................................................................................................... 20
3.2.3 Hazards by Improper Use.................................................................................................................. 21
3.3 Instructions with Regard to Specific Dangers....................................................................................... 23
3.3.1 Protection Against Contact With Electrical Parts and Housings........................................................ 23
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 24
3.3.3 Protection Against Dangerous Movements....................................................................................... 25
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 26
3.3.5 Protection Against Contact With Hot Parts........................................................................................ 26
3.3.6 Protection During Handling and Mounting......................................................................................... 27
3.3.7 Battery Safety.................................................................................................................................... 27
3.3.8 Protection Against Pressurized Systems........................................................................................... 28
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 28
4 General Data and Specifications................................................................................. 31
4.1 Acceptance Tests and Approvals......................................................................................................... 31
DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT
Bosch Rexroth AG I/145
Table of Contents
Page
4.2 Transport and Storage.......................................................................................................................... 33
4.2.1 Transport of the Components............................................................................................................ 33
4.2.2 Storage of the Components............................................................................................................... 33
4.3 Installation Conditions........................................................................................................................... 34
4.3.1 Ambient and Operating Conditions.................................................................................................... 34
4.3.2 Control Cabinet Design and Cooling................................................................................................. 35
4.3.3 Mounting Position.............................................................................................................................. 38
Mounting Positions of Components................................................................................................ 38
4.3.4 Compatibility With Foreign Matters.................................................................................................... 38
4.4 Voltage Test and Insulation Resistance Test....................................................................................... 38
4.5 Control Voltage (24V Supply) .............................................................................................................. 39
5 Technical Data of the Components.............................................................................. 41
5.1 HCQ02.................................................................................................................................................. 41
5.1.1 Brief Description, Use and Design..................................................................................................... 41
5.1.2 Technical Data................................................................................................................................... 41
Ambient and Operating Conditions................................................................................................. 41
Mechanical System and Mounting.................................................................................................. 42
Basic Data Power Section HCQ02................................................................................................. 44
5.2 HCT02.................................................................................................................................................. 50
5.2.1 Brief Description, Use and Design..................................................................................................... 50
5.2.2 Technical Data................................................................................................................................... 50
Ambient and Operating Conditions................................................................................................. 50
Mechanical System and Mounting.................................................................................................. 51
Basic Data Power Section HCT02.................................................................................................. 53
6 Electrical Connection Points........................................................................................ 61
6.1 Connection Diagrams........................................................................................................................... 61
6.1.1 Connection Diagram HCQ02............................................................................................................. 61
6.1.2 Connection Diagram HCT02............................................................................................................. 62
6.2 Arrangement of the Connection Points................................................................................................. 63
6.3 Connection of Equipment Grounding Conductor.................................................................................. 64
6.4 Ground Connection............................................................................................................................... 64
6.5 X3, Mains Connection........................................................................................................................... 65
6.6 X3L, Interface for Operator Panels....................................................................................................... 65
6.7 X4.1 … X4.4, Encoder Evaluation........................................................................................................ 66
6.8 X5.1 and X5.2, Motor Connection......................................................................................................... 66
6.9 X5.3 and X5.4, Motor Connection......................................................................................................... 67
6.10 X6.1 … X6.4, Motor Temperature Monitoring and Motor Holding Brake ............................................. 68
6.11 X6C, Memory Card............................................................................................................................... 71
6.12 X8, Optional Encoder Evaluation.......................................................................................................... 71
6.13 X9, External Braking and Charging Resistor........................................................................................ 71
6.14 X18, 24V Supply (Control Voltage)....................................................................................................... 72
6.15 X19, Bb Contact, DC Bus Short Circuit Control.................................................................................... 75
6.16 X24 and X25, sercos III Master............................................................................................................ 76
Bosch Rexroth AG DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT
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Table of Contents
Page
6.17 X26, Engineering Interface................................................................................................................... 77
6.18 X81 and X82, Digital Outputs............................................................................................................... 79
6.19 X83 ... X86, Digital Inputs..................................................................................................................... 80
6.20 Shield Connection................................................................................................................................. 82
6.20.1 Shield Connection Motor Cable......................................................................................................... 82
6.20.2 Shield Connection Control Lines....................................................................................................... 83
7 Optional Modules......................................................................................................... 85
7.1 OM1 and OM2...................................................................................................................................... 85
7.2 Digital I/O Extension............................................................................................................................. 86
7.2.1 Interfaces........................................................................................................................................... 86
7.2.2 X70, External 24V Supply.................................................................................................................. 86
7.2.3 X71 … X72, Digital Outputs............................................................................................................... 87
7.2.4 X73 … X76, Digital Inputs................................................................................................................. 88
8 Notes on Project Planning........................................................................................... 91
8.1 Mains Connection................................................................................................................................. 91
8.2 24V Supply........................................................................................................................................... 91
8.3 DC Bus Load........................................................................................................................................ 92
8.3.1 General Information........................................................................................................................... 92
8.3.2 Calculation of Performance Profile ................................................................................................... 93
8.4 External Braking Resistor..................................................................................................................... 94
9 Scope of Supply........................................................................................................... 95
10 Identifying and Checking the Delivered Components.................................................. 97
10.1 Type Plate............................................................................................................................................. 97
10.1.1 Arrangement...................................................................................................................................... 97
10.1.2 Design............................................................................................................................................... 97
11 Mounting and Installation............................................................................................. 99
11.1 Mounting............................................................................................................................................... 99
11.1.1 Dimensional Drawing......................................................................................................................... 99
11.1.2 Distances........................................................................................................................................... 99
11.2 Connection Diagram........................................................................................................................... 100
11.3 EMC Measures for Design and Installation........................................................................................ 103
11.3.1 Rules for Design of Installations With Drive Controllers in Compliance With EMC......................... 103
11.3.2 EMC-Optimal Installation in Facility and Control Cabinet................................................................ 104
General Information...................................................................................................................... 104
Division Into Areas (Zones).......................................................................................................... 105
Control Cabinet Design According to Interference Areas - Exemplary Arrangements................. 106
Design and Installation in Area A - Interference-Free Area of Control Cabinet............................ 107
Design and Installation in Area B - Interference-Susceptible Area of Control Cabinet................. 109
Design and Installation in Area C - Strongly Interference-Susceptible Area of Control Cabinet.. 109
DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT
Bosch Rexroth AG III/145
Table of Contents
Page
11.3.3 Ground Connections........................................................................................................................ 110
11.3.4 Installing Signal Lines and Signal Cables........................................................................................ 111
11.3.5 General Measures of Radio Interference Suppression for Relays, Contactors, Switches, Chokes and
Inductive Loads............................................................................................................................... 112
12 Commissioning, Operation, Diagnostics.................................................................... 113
12.1 Operation and Diagnostics................................................................................................................. 113
12.1.1 Diagnostic LED Displays................................................................................................................. 113
12.1.2 Diagnostic LED Displays with Drive Firmware MPM-16VRS.......................................................... 113
12.1.3 Diagnostic LED Displays with Drive Firmware MPM-17VRS.......................................................... 115
13 Technical Data - Encoder Evaluation......................................................................... 119
13.1 ES - Standard Encoder Evaluation..................................................................................................... 119
13.1.1 Interface Standard Encoder Evaluation ES..................................................................................... 119
13.1.2 Properties of ES.............................................................................................................................. 120
13.1.3 Signal Assignment to the Actual Position Value.............................................................................. 121
13.1.4 Connection for 12V Encoder Systems............................................................................................. 122
Power Supply............................................................................................................................... 122
Allowed Encoder Cable Lengths for 12V Encoder Systems......................................................... 122
Connection Diagrams for 12V Encoder Systems......................................................................... 122
Connection Diagrams for 12V Third-Party Encoder Systems...................................................... 122
13.1.5 Connection for 5V Encoder Systems............................................................................................... 124
Power Supply............................................................................................................................... 124
Allowed Encoder Cable Lengths for 5V Encoder Systems without Sense Evaluation................. 124
Connection Diagrams for 5V Encoder Systems with Third-Party Encoder................................... 125
14 Technical Data - Functions........................................................................................ 129
14.1 Relay Contacts................................................................................................................................... 129
14.1.1 Relay Contact Type 2...................................................................................................................... 129
14.2 Digital Inputs/Outputs......................................................................................................................... 129
14.2.1 General Information......................................................................................................................... 129
14.2.2 Digital Inputs.................................................................................................................................... 129
Digital Inputs Type A (Standard).................................................................................................. 129
Digital Inputs Type B (Probe)....................................................................................................... 130
14.2.3 Digital Outputs................................................................................................................................. 131
15 Accessories................................................................................................................ 133
15.1 HAS09................................................................................................................................................ 133
15.2 CompactFlash Memory Card.............................................................................................................. 134
16 Environmental Protection and Disposal .................................................................... 135
16.1 Environmental Protection.................................................................................................................... 135
16.2 Disposal.............................................................................................................................................. 135
Bosch Rexroth AG DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT
IV/145
Table of Contents
Page
17 Service and Support.................................................................................................. 137
Index.......................................................................................................................... 139
DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT
Bosch Rexroth AG V/145
Table of Contents
Bosch Rexroth AG DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT
VI/145
1 System Presentation
1.1 Drive System with Rexroth IndraDrive HCQ02, HCT02
Drive System Rexroth IndraDrive C with 4‑Axis Converter HCQ02
1 … 4 Motors (1: Powerful main drive; 2–4: Secondary drives)
24V 24V supply
DST Transformer (optional)
F Fuses
HCQ02 4-axis converter
HMI External operator panel
HNF Mains filter (optional)
HNL Mains choke (optional; you can do without mains choke in the case of
reduced performance)
K1 Mains contactor
RB External charging resistor
Fig.1-1: Drive System Rexroth IndraDrive C with 4‑Axis Converter HCQ02
DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT
Bosch Rexroth AG 7/145
System Presentation
Drive System Rexroth IndraDrive C with 3‑Axis Converter HCT02
1 … 4 Motors (1: Powerful main drive; 3–4: Secondary drives)
24V 24V supply
DST Transformer (optional)
F Fuses
HCT02 3-axis converter
HMI External operator panel
HNF Mains filter (optional)
HNL Mains choke (optional; you can do without mains choke in the case of
reduced performance)
K1 Mains contactor
RB External charging resistor
Fig.1-2: Drive System Rexroth IndraDrive C with 3‑Axis Converter HCT02
Bosch Rexroth AG DOK-INDRV*-HCQ-T+HMQ-T-PR03-EN-P
Rexroth IndraDrive Drive Controllers HCQ, HCT
8/145
System Presentation
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