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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

Type of Documentation

Document Typecode

Internal File Reference

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


Bosch Rexroth AG III/129

Table of Contents


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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-W0350

HCS04.2E-W0420

HCS04.2E-W0520

HCS04.2E-W0640

Performance 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


HCS04.2E-W1010

HCS04.2E-W1240

HCS04.2E-W1540

Power 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


HCS04.2E-W1010

HCS04.2E-W1240

HCS04.2E-W1540

Installation altitude Up to 1,000m, above derating by 1% per 100m up to the maximum instal‐lation altitude of 3,000m

Allowed 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 UNOM

Tolerance of the relative short-circuit voltage: 5.0 % of uK_NOM

The 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-W0520

HCS04.2E-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-W1010

HCS04.2E-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)





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 % ofUNOM

Tolerance of the relative short-circuit voltage: 5.0 % of uK_NOM

The 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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IndraDrive HCS04.2E

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" sf

Lines 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 overload and to protect the input rectifier inthe case of an internal short circuit.The specified cross sections for 3-conductor cables are guide values for cablerouting in free air at an ambient temperature of max. 40°C, based on the ÖVNEN 1 and VDE 0100 regulations.The lines in the control cabinet have been sized according to the specificationfor wires XLPE/EPR copper 90°C.The motor cables have been sized for the max. continuous current. This appliesto 0...100 Hz (up to 300 Hz, the cable losses are increased by approx. 25% dueto the skin effect).

The cable cross sections must be adjusted for different ambientconditions and differing regulations.

Mains supply Converter Motor linePre- orconduitfuse1.)

Cu cablemm2

Mains fuseConverter protection"sf"

Lines in con‐trol cabinetmm2

(per phase)

HCS04.2E Max. con‐tin. current

Max. con‐nection

Motor cablemm2

3.)

Power 1 – high overload



IndraDrive HCS04.2E

Mains supply Converter Motor line

315 A 3 x 185315 A sfC

120HCS04.2E-W0350-N-04-NNBN

215 A M10 3 x 120

400 A2 x(3 x 120)

350 A sfD

150HCS04.2E-W0420-N-04-NNBN

259 A M10 3 x 150

400 A2 x(3 x 120)

400 A sfD

185HCS04.2E-W0520-N-04-NNBN

314 A M122 x(3 x 95)

500 A2 x(3 x 150)

500 A sfE

2 x 120HCS04.2E-W0640-N-04-NNNN

387 A M122 x(3 x 120)

630 A2 x(3 x 185)

630 A sfF

2 x 150HCS04.2E-W0790-N-04-NNNN

481 A M122 x(3 x 150)

800 A3 x(3 x 185)

800 A sfF

3 x 150HCS04.2E-W1010-N-04-NNNN

616 A M123 x(3 x 150)

1000 A4 x(3 x 185)

2 x 500 A sf 2.)

E2 x 2 x 120

HCS04.2E-W1240-N-04-NNNN

759 A M123 x(3 x 185)

1250 A4 x(3 x 240)

2 x 630 A sf 2.)

F2 x 2 x 150


941 A M124 x(3 x 185)

Mains supply Converter Motor linePre- orconduitfuse1.)

Cu cablemm2

Mains fuseConverter protection"sf"

Lines in con‐trol cabinetmm2

(per phase)

HCS04.2E Max. con‐tin. current

Max. con‐nection

Motor cablemm2

3.)

Power 2 – high continuous load

315 A 3 x 185 315 A sf C 120HCS04.2E-W0350-N-04-NNBN

259 A M10 3 x 150

400 A2 x(3 x 120)

400 A sf D 185HCS04.2E-W0420-N-04-NNBN

314 A M102 x(3 x 95)

500 A2 x(3 x 150)

500 A sf D 2 x 120HCS04.2E-W0520-N-04-NNBN

387 A M122 x(3 x 120)

630 A2 x(3 x 185)

630 A sf E 2 x 150HCS04.2E-W0640-N-04-NNNN

481 A M122 x(3 x 150)

800 A3 x(3 x 185)

800 A sf F 3 x 150HCS04.2E-W0790-N-04-NNNN

616 A M123 x(3 x 150)

1000 A4 x(3 x 185)

900 A sf F 3 x 185HCS04.2E-W1010-N-04-NNNN

759 A M123 x(3 x 185)


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IndraDrive HCS04.2E

Mains supply Converter Motor line

1250 A4 x(3 x 240)

2 x 630 A sf 2.) E2 x2 x 150


941 A M124 x(3 x 185)

1600 A6 x(3 x 240)

2 x 800 A sf 2.) F2 x3 x 150


1188 A M125 x(3 x 185)

1.) Recommended pre-fuse for direct motor start with bypass circuit2.) 2 x 3-pole fuses for parallel supply3.) With bypass operation, the motor cable must be sized with regard to the

pre-fuse or conduit fuse!It is recommended that you use super-fast fuses (semiconductor protection).You can also use fast fuses or circuit breakers, but in this case the rectifier canbe damaged when an internal error occurs.To protect the rectifier in the case of a short circuit, the fuses mustn't exceedthe following I2t switch-off levels (with reference to 10 ms):

A B C D E F

5.103 A2s 50.103 A2s 160.103 A2s 320.103 A2s 780.103 A2s 1000.103 A2s

If the mains fuses are blown, a primary defect has already occurredinside the converter. Therefore, changing the fuses and switchingthe converter on again does not make sense. Furthermore, it is notadvantageous to use circuit breakers. This has the disadvantage ofa slower switch-off.

Using NYCY or NYCWY cables for the motor cables (power cableswith a concentric equipment grounding conductor) is a low-pricealternative to shielded cables.

Design according to UL/CSA

To comply with the requirements according to UL/CSA, you mustuse copper cables of temperature class 60/75°C. The specified ca‐ble cross sections correspond to the temperature class 75°C andhave been designed for an ambient temperature of 30°C.

Type UL fuses 600VtypeFast acting

Max. mains short-circuit current at480V mains voltage according to UL

listing

Cable cross section for mains ca‐bles and motor cables (per phase)

Withoutchoke

With HLLchoke

Withmainschoke

HCS04.2E-W0350-N-04-NNBN

Class J 350 Amax.

(10 kA) 50 kA 100 kA 2x AWG 4/0


Class J 400 Amax.

(18 kA) 50 kA 100 kA 2x 250 MCM


Class J 450 Amax.

(18 kA) 50 kA 100 kA 2x 350 MCM


Class J 600 Amax.

(18 kA) 50 kA 100 kA 3x 250 MCM



IndraDrive HCS04.2E

Type UL fuses 600VtypeFast acting

Max. mains short-circuit current at480V mains voltage according to UL

listing

Cable cross section for mains ca‐bles and motor cables (per phase)

Withoutchoke

With HLLchoke

Withmainschoke


Class J 800 Amax.

(30 kA) 50 kA 100 kA 3x 350 MCM


2 x Class J 450 Amax.

(30 kA) 50 kA 100 kA 4x 350 MCM


Class J 2 x 600 Amax.

(30 kA) 50 kA 100 kA Mains: 2x (2x 500 MCM)Motor: 4x 500 MCM


Class J 2 x 800 Amax.

(30 kA) 50 kA 100 kA Mains: 2x (3x 500 MCM)Motor: 5x 500 MCM

For detailed information on the values in brackets, see chapter "DC Choke",page 71

3.7.3 Braking Unit HLT01.1A


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IndraDrive HCS04.2E

General InformationWhen a motor is decelerated at the deceleration ramp, the motor acts as agenerator. As infeeding converters as a standard cannot regenerate to themains, the DC bus voltage is increased in the case of regenerative operation.When the motor is decelerated and the energy returned to the DC bus is morethan the losses in motor and converter, the DC bus voltage is increased andthe device is switched off with overvoltage.The regenerative power depends, among other things, on the load inertia andthe deceleration that was set."IndraDrive HCS04.2E" With Internal Braking Transistor

Fig.3-20: "IndraDrive HCS04.2E" With Internal Braking Transistor"IndraDrive HCS04.2E" With External HLT Braking Unit

Fig.3-21: "IndraDrive HCS04.2E" With External HLT Braking UnitWhen the DC bus voltage, due to a deceleration process, exceeds a value tobe set, the external braking resistor (as a load) is connected to the DC bus. The



IndraDrive HCS04.2E

HLR01.1 braking resistor converts the generated energy into thermal energyand thereby keeps the DC bus voltage from rising.Connecting an HLR01.1 braking resistor allows using the IndraDrive HCS04.2Econverters for applications in the 4-quadrant range. Depending on the selectedcombination of converter/(braking unit)/braking resistor, optimization can takeplace with regard to high peak braking power, high continuous braking poweror both.Size the resistor in accordance with the corresponding assignment table. Forthis purpose, take the allowed braking power and braking duration into account.The IndraDrive HCS04.2E converters have parameters for monitoring the brak‐ing power.

If 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.

① The encoder is connected according to the Project Planning Manual"Rexroth IndraDrive, Drive Controllers, Control Sections"

② HCS04.2E-W0640 to HCS04.2E-W1540③ HCS04.2E-W0350 to HCS04.2E-W0520Fig.3-22: Mains ContactorWhen an additional thermal relay is used, the auxiliary contact has to be inte‐grated in the circuit of the mains contactor.


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IndraDrive HCS04.2E

Minimum resistance value of the braking resistorIn the technical data of the respective converter, RMIN specifies the nominalvalue of the braking resistor; to protect the braking resistor, the nominal valuemustn't fall below this value. A resistance tolerance of -10% has been takeninto account in the data.Maximum resistance value of the braking resistorIn the technical data of the respective converter, RMAX specifies the nominalresistance value which still allows achieving a peak braking power of 150% ofthe converter's nominal power. A resistance tolerance of +20% (incl. tempera‐ture rise) has been taken into account in the data. When you use a brakingresistor with a higher resistance value, the deceleration ramp must be longerdepending on the generated peak braking power; this will avoid fault shutdownwith overvoltage.

Principle and Calculation of the Braking ProcessTo get quantitative information on the drive power or braking power, the torqueand speed in the corresponding working point must be known. The diagram ofthe 4 load quadrants shows the graphic comparison of these two values.

Fig.3-23: 4 Load QuadrantsIn general, the following applies to the power:

Fig.3-24: PowerMotive power (+P) is in the load quadrants I (+M, +n) and III (-M, -n).Regenerative power is in the quadrants II (+M, -n) and IV (-M, +n).In principle, the cases of regenerative load are divided into the following groups:



IndraDrive HCS04.2E

1. Evenly delayed deceleration

n1 Initial speedML Load torque (motive)MB Braking torque (regenerative)PSB Peak braking powerPMB Average value of braking power during tBtB Braking timeFig.3-25: Evenly Delayed DecelerationThe character of the braking power curve is the peak braking power PSB andthe average value of the braking power which corresponds to PSB/2 when de‐celerating to zero (triangular surface).Example: Shutting down processing units, centrifuges, travelling gear, revers‐ing of speed, ...2. Deceleration at constant velocity


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IndraDrive HCS04.2E

n1 Initial speedML Load torque (motive)MB Braking torque (regenerative)PMB Average value of braking power during tBtB Braking timeFig.3-26: Deceleration at Constant VelocityIn the case of deceleration at constant velocity, the braking power generatedduring the braking time is constant.Example: Testing stands for motors and gears, ...3. Deceleration with constant velocity and subsequent delay

n1 Initial speedML Load torque (motive)MB Braking torque (regenerative)PBD Peak braking powerPSB Continuous braking powertB Braking timeFig.3-27: Deceleration With Constant Velocity and Subsequent DelayIn this case, deceleration takes place with constant velocity and constant brak‐ing power. Subsequently, there is a dynamic delay; due to the centrifugal mass



IndraDrive HCS04.2E

to be decelerated, the peak braking power can be the 2- to 3-fold continuousbraking power.Example: Crane lifting gears when lowering


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IndraDrive HCS04.2E

Determining the Braking Power● 1. Decelerating centrifugal masses with a constant delay

MB Braking torque at motor [Nm]J Sum of inertias related to the motor shaft [kgm2]n1 Speed before deceleration [rpm]n2 Speed after deceleration [rpm]tB Braking time [t]Fig.3-28: Braking Torque at Motor

Fig.3-29: Braking Power

Fig.3-30: Rotational VelocityCalculating the inertia

JM JMotor

Jr Jred

JL JLoad

Fig.3-31: Inertia● 2. Decelerating transversal motions (e.g. travelling gear) with constant

delay

Wkin Kinetic energy [joule]m Mass [kg]v Velocity [m/s]Fig.3-32: Decelerating t B With Constant Delay - Kinetic Energy



IndraDrive HCS04.2E

PMB Average value of braking power during tB [W]Wkin Kinetic energy [joule]tB Braking time [s]Fig.3-33: Decelerating t B With Constant Delay - Average Value of Braking Power

PSB Peak braking power [W]PB Braking powerFig.3-34: Decelerating t B With Constant Delay - Peak Braking Power● 3. Decelerating actively driving loads (e.g. testing stands)

PMB Average value of braking power during tB [W]MB Braking torque [Nm]n Braking speed [rpm]Fig.3-35: Decelerating Actively Driving Loads - Average Value of Braking Power● 4. Decelerating lifting gears during the lowering motion

PMB Average value of braking power during tB [W]m Mass [kg]g Gravitational acceleration 9.81 m/s2

v Lowering velocity [m/s]Fig.3-36: Decelerating Lifting Gears During the Lowering Motion - Average Value

of Braking Power

PSB Peak braking power [W]m Mass [kg]g Gravitational acceleration 9.81 m/s2

a Braking delay [m/s2]v Lowering velocity [m/s]J Inertia [kgm2]ω Angular velocity [rad/s]tB Braking time [s]Fig.3-37: Decelerating Lifting Gears During the Lowering Motion - Peak Braking

Power

ω Angular velocity [rad/s]n Motor speed in lowering operation [rpm]Fig.3-38: Decelerating Lifting Gears During the Lowering Motion - Angular Veloc‐

ity


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IndraDrive HCS04.2E

For all previously determined braking powers, we assumed that there were nosystem losses (i.e. η=1) and no motive load torques.These two components reduce the generated braking power; it is thereforenecessary to have a closer look at them:1. System lossesThe losses occurring in motive operation not only need to be generated duringdeceleration (regenerative operation, quadrants II and IV), they also activelysupport deceleration. Therefore, the squared efficiency must be used for cal‐culating the braking power.2. Load torquesPossibly existing load torques (insofar as not yet taken into account in the totalefficiency), such as friction, wind power, quadratic counter-torque of blowers,air resistance, etc., reduce the braking power. The load torques or power mustbe subtracted when calculating the braking power.The actually required braking power is calculated as follows:

PSB Real Actually occurring peak braking power [W]PLast Braking power of the load components [W]total Total efficiencyFig.3-39: Actually Occurring Peak Braking Power

PMB Real Actually occurring continuous braking power [W]PLast Braking power of the load components [W]total Total efficiencyFig.3-40: Actually Occurring Continuous Braking Power

η Efficiencyηtotal Total efficiencyηmech Mechanical efficiencyηmot Motor efficiencyFig.3-41: Total EfficiencySelecting the braking optionThe necessary braking option is primarily selected in accordance with the re‐quired braking power (PSB,PMb); but the following aspects, too, can be ofimportance when selecting the braking option:● Mounting position and degree of protection of the braking resistors● Required cabling● Problems with generated thermal energy (air conditioning)● Price and possible amortization by reduced energy costsWith braking unit operation, select the braking resistor while taking the requiredpowers into account; for this purpose, use the braking time/cycle diagram, aswell as the selection tables contained in this manual.Generally, the following applies:



IndraDrive HCS04.2E

PS max Maximum peak braking power [W]Ud Braking unit switch-on level [V]R Resistance value of braking resistor [Ω]Fig.3-42: Maximum Peak Braking Power

Pdauer Thermal continuous braking power [W]I Thermal continuous limit current of braking resistor (see setting value

TH) [A]R Resistance value of braking resistor [Ω]Fig.3-43: Thermal Continuous Braking Power

The IndraDrive HCS04.2E converters have parameters for moni‐toring the braking power. If the braking resistor does not match theoverload characteristic, or if the local regulations require an addi‐tional protection device, it is necessary to include a thermal relay inthe line disconnection path.

Assignment table for typical crane applicationsTypical sizing of lifting gears

The table below contains examples. Depending on the application,use different braking resistors. For this purpose, it is necessary toindividually consider the generated braking power/kinetic energy.

Typ. motorpower Converter Braking unit Braking resistor

Pmax @785 V PB Pdauer

110 kW

HCS04.2E-W0350-N-04-NNBN Internal

1 x HLR01.1N-44K0-N03R3-B-007-NNNN 165 kW 97 kW 44 kW

132 kW



160 kW



200 kW


HLT01.1A-200K-N-007-NNNN

2 x HLR01.1N-44K0-N03R3-B-007-NNNN 1) 300 kW 176 kW 88 kW

250 kW




315 kW





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IndraDrive HCS04.2E


Pmax @785 V PB Pdauer

400 kW




500 kW




1) Resistors in parallel connection


HCS04.2E-W0420

HCS04.2E-W0520 HCS04.2E-W0640

External braking resistor (lifting gear)


HCS04.2E-W0420

HCS04.2E-W0520 HCS04.2E-W0640

Resistance value ohm 3,3 2,1 2,1 2 x 3.3

Continuous power kW 44 66 66 2 x 44

Peak power @ UDCbus = 680V DC

kW 140 220 220 2 x 140

Peak power @ UDCbus = 785V DC

kW 165 200 240 300

Connection cross section mm2 50 95 95 50

Width B mm 995 995 995 2 x 995

Height H mm 770 1100 1100 2 x 770

Depth T mm 490 490 490 2 x 490

Mass approx. kg 101 138 138 2 x 101

Converter HCS04.2E-W0790 HCS04.2E-W1010 HCS04.2E-W1240 HCS04.2E-W1540External braking resistor (lifting gear)Type designation 2 x

HLR01.1N-66K0-N02R1

2 xHLR01.1N-66K0-

N02R1

3 x HLR01.1N-66K0-N02R1

3 xHLR01.1N-66K0-

N02R1Resistance value ohm 2 x 2.1 2 x 2.1 3 x 2.1 3 x 2.1Continuous power kW 2 x 66 2 x 66 3 x 66 3 x 66Peak power @ UDCbus = 680 VDC

kW 2 x 220 2 x 220 3 x 220 3 x 220

Peak power @ UDCbus = 785 VDC

kW 375 475 600 750

Connection cross section mm2 95 95 95 95Width B mm 2 x 995 2 x 995 3 x 995 3 x 995Height H mm 2 x 1100 2 x 1100 3 x 1100 3 x 1100Depth T mm 2 x 490 2 x 490 3 x 490 3 x 490Mass approx. kg 2 x 138 2 x 138 3 x 138 3 x 138

Typical braking power and cycle for lifting gear applications



IndraDrive HCS04.2E

Pm Peak braking powerPB Braking power when lowering the loadPD Continu‐ous brakingpower

Max. cycle time: 120 s

Fig.3-44: Typical Braking Power and Cycle for Lifting Gear ApplicationsTypical sizing of travelling gears


Pmax @ 785V Pdauer

110 kWHCS04.2E-W0350-N-04-NNBN Internal

1 x HLR01.1N-22K0-N03R5-B-007-NNNN 165 kW 22 kW


2 x HLR01.1N-22K0-N03R5-B-007-NNNN 1) 200 kW 44 kW



200 kWHCS04.2E-W0640-N-04-NNNN















1) Resistors in parallel connection


HCS04.2E-W0420

HCS04.2E-W0520

HCS04.2E-W0640

Type designation HLR01.1N-22K0-N03R5

2 xHLR01.1N-22K0-N03R5

2 xHLR01.1N-22

K0-N03R5

2 xHLR01.1N-22K0-N03R5

Resistance value ohm 3,5 2 x 3.5 2 x 3.5 2 x 3.5Continuous power kW 22 2 x 22 2 x 22 2 x 22


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IndraDrive HCS04.2E


HCS04.2E-W0420

HCS04.2E-W0520

HCS04.2E-W0640

Peak power @ UDC‐bus = 680 V DC

kW 132 2 x 132 2 x 132 2 x 132

Peak power @ UDC‐bus = 785 V DC

kW 165 200 240 300

Connection crosssection

mm2 16 16 16 16

Width B mm 995 2 x 995 2 x 995 2 x 995Height H mm 520 2 x 520 2 x 520 2 x 520Depth T mm 490 2 x 490 2 x 490 2 x 490Mass approx. kg 61 2 x 61 2 x 61 2 x 61


HCS04.2E-W1010

HCS04.2E-W1240

HCS04.2E-W1540

Type designation 3 xHLR01.1N-22K0-N03R5

3 xHLR01.1N-22K0-N03R5

4 xHLR01.1N-22

K0-N03R5

5 xHLR01.1N-22K0-N03R5

Resistance value ohm 3 x 3.5 3 x 3.5 4 x 3.5 5 x 3.5Continuous power kW 3 x 22 3 x 22 4 x 22 5 x 22Peak power @ UDC‐bus = 680VDC

kW 3 x 132 3 x 132 4 x 132 5 x 132

Peak power @ UDC‐bus = 785VDC

kW 375 475 600 750

Connection crosssection

mm2 16 16 16 16

Width B mm 3 x 995 3 x 995 4 x 995 5 x 995Height H mm 3 x 520 3 x 520 4 x 520 5 x 520Depth T mm 3 x 490 3 x 490 4 x 490 5 x 490Mass approx. kg 3 x 61 3 x 61 4 x 61 5 x 61

Typical Braking Power and Cycle for Travelling Gear Applications



IndraDrive HCS04.2E

Pm Peak braking powerPD Continuous braking powerMax. cycletime

120 s

Fig.3-45: Typical Braking Power and Cycle for Travelling Gear Applications

3.7.4 Motor Cable LengthsThe distance between converter and motor(s) is limited by allowed mains dis‐turbances, allowed overvoltages at the motor, occurring bearing currents andallowed power dissipation. The maximum distance strongly depends on themotor cable type (shielded/unshielded) and the options which are used.Overvoltages at the motorOvervoltages at the motor terminals are caused by reflection in the motor cable.With cable lengths of 50 m and more, motors are basically loaded with meas‐urably higher voltage peaks. The motor load is almost independent of theconverter used!

Mains voltage400 V

Motor insulation for 1300 V phase-to-phase peak voltage and dv/dtStrength > 8 kV/µs

Mains voltage460 V

Motor insulation for 1600 V phase-to-phase peak voltage and dv/dtStrength > 8 kV/µs

For even longer motor cables it is necessary to use a "dv/dt filter". The optionHMF01.1N (output motor filter) acts as a filter together with the cable capaci‐tance, and limits both the voltage peaks at the motor and the rise of voltage ofthe output pulses.Observing the indicated motor cable lengths significantly extends the motorservice life:

Mains voltage400 V Max. 1000 V phase-to-phase peak voltage and dv/dt < 500 V/µs

Mains voltage460 V Max. 1300 V phase-to-phase peak voltage and dv/dt < 750 V/µs

To protect the motor, it is absolutely necessary that you comply withthe indicated motor cable lengths!

EMC interference


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IndraDrive HCS04.2E

Both the mains rectifier and the IGBT inverter cause high-frequency interfer‐ence that drains off into the ground potential more strongly with increasingmotor cable length. As a result, the line-conducted interference on the mainsside increases. The attenuation of the mains filters is no longer sufficient, andthe allowed interference limit values are exceeded.

To comply with the EMC limit values, you must observe the indica‐ted motor cable lengths!

Bearing currentsUsing the option HMF01.1N clearly reduces common-mode bearing currentswhich cannot be avoided, even if the motor is equipped with one-sidedly insu‐lated bearings.The option HMF01.1N therefore considerably increases the availability of themotor, particularly for big motors with middle to great motor cable lengths.Multiplication factors

The specified motor cable lengths are recommended limit valuesbased on typical motor cables, routing in cable trays, the smallestparameterizable clock frequency and the maximum output frequen‐cy of 100 Hz.

In the case of deviations from these conditions, you must convert the recom‐mended cable lengths using the following multiplication factors.If several factors are applicable, you have to multiply them.The clock frequency for the given line lengths corresponds to 2kHz:

IndraDrive HCS04.2E-W0350 ...-W1540At 4 kHz All table values multiplied by 0.7At 8 kHz All table values multiplied by 0.4

At output frequencies of more than 100 Hz:

Up to 200 Hz All table values multiplied by 0.8Up to 300 Hz All table values multiplied by 0.5

One thicker cable is used instead of two parallel cables: All table values multi‐plied by 1.5With 6-pole motor cabling (e.g., for star/delta starting circuit): All table valuesmultiplied by 0.75For motors switched in parallel with the center near the inverter, you must con‐vert in accordance with the number of motors: If an adjusted HMF01.1N is usedfor each motor, the factors indicated in brackets apply.

For 2 motors All table values multiplied by 0.40 (0.80)For 3 motors All table values multiplied by 0.25 (0.60)For 4 motors All table values multiplied by 0.15 (0.40)For 5 motors All table values multiplied by 0.10 (0.25)

If the center of the parallel motors is near the motors, the following factors apply:

For 2 motors All table values multiplied by 0.80For 3 motors All table values multiplied by 0.60For 4 motors All table values multiplied by 0.40For 5 motors All table values multiplied by 0.25



IndraDrive HCS04.2E

Two motors switched in parallel and two parallel cables have already beenconsidered in the table: All table values multiplied by 0.8

3.7.5 Guide Values for Maximum Motor Cable Lengths in 1st EnvironmentGeneral Information

Options HCS04.2E Type of motor cable

C1 residential areas - unrestricted distribution (EN 55011 - Class B Group 1)

HNF Shielded

C2 residential areas - EMC-expert users (EN 55011 - Class A Group 1)

No options Shielded

Option HNF *) 100 m Shielded

Options HNF + HMF 120 m Shielded

Guide Values for Maximum Motor Cable Lengths in 2nd Environment (Industrial Areas)

OptionsHCS04.2E-W0350 ...-W1540 Type of motor cable

C3 (EN 55011 – Class A Group 2)No options 50 m ShieldedOption HMF01.1N 80 m ShieldedOption HNF01.1B *) 100 m ShieldedOptions HNF01.1B +HMF01.1N 200 m Shielded

C4 (EMC concept)No options *) 80 m ShieldedOption HMF01.1N 250 m Shielded2 x option HMF01.1N in ser‐ies 500 m Shielded

No options 100 m UnshieldedOption HMF01.1N 400 m Unshielded2 x option HMF01.1N in ser‐ies 600 m Unshielded

Using the option HMF01.1N for motor cables of a length of 50 mand more makes sense to reduce the voltage load and bearing cur‐rents in the motor.

The specified line lengths apply to a clock frequency of 2 kHz andup to an output frequency of 100 Hz. The clock frequency set at thefactory is 4 kHz. Please observe the required reduction factors forhigher clock frequencies, output frequencies and parallel connec‐tion, indicated on the previous page.

3.7.6 Notes on How to Wire Power Cables and Control CablesLay the control lines separately from the mains cables and motor cables, andseparately from other power cables. They should not exceed a length of 20 mand must be laid in in shielded form.


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If crossings with power cables cannot be avoided, they have to bein a 90° angle.

To insert the control lines, the HCS04.2E devices have an individual cable duct,separated from the power section. Below the control terminals, there are thecable clips to connect the shield.

Fig.3-46: Control Lines

The motor cable shield is connected to the converter-internal radiointerference filter or to the option HNF01.1B via a mounting platewith good electroconductive properties.

3.7.7 Options Available for IndraDrive HCS04.2E ConvertersGeneral Information

To extend the fields of application, there are several options available for controland operation, extensions with regard to the electrical arrangement and for in‐creasing the degree of protection.



IndraDrive HCS04.2E

External options Brief description Reference toOption HNF01.1B(Assignment table)

Additional radio interference filter to reduce high-fre‐quency mains pollution for use in residential areas

Option HLL(Assignment table)

DC choke to reduce the mains current harmonics toTHD I ≤ 45 % Page 71

Option HNL01.1E(Assignment table)

Three-phase current choke to reduce the mains currentharmonics to THD I ≤ 45 % (as an alternative to HLL) Page 71

Option HLT(Assignment table)

External braking unit for IndraDrive HCS04.2EW0640 ... W1540 Page 77

Option HLR01.1(Assignment table)

Braking resistor for rapid deceleration or temporary re‐generative loads Page 81

Option HMF01.1N(Assignment table)

Output motor filter, allows using the converter with longmotor cables and limits the voltage peaks in the motor Page 84

Option HAS07.1(Assignment table)

Mounting frame to mount the converter in push-throughtechnology (heat sink outside of control cabinet) Page 88

Option HAS08.1(Assignment table)

Control cabinet assembly kit for mounting the converterin a Rittal TS8 control cabinet Page 91

Assignment Table of the Performance-Dependent OptionsType Option HNF01.1B Option HLL Option HNL01.1E


HNF01.1B-A0100-E0300-N-480-NNNN

HLL01.1A-150U-N0290-C-008-0471-NNNN

HNL01.1E-0098-N0280-N-690-NNNN


HNF01.1B-A0100-E0300-N-480-NNNN

HLL01.1A-138U-N0558-C-008-0471-NNNN

HNL01.1E-0085-N0315-N-690-NNNN


HNF01.1B-A0100-E0580-N-480-NNNN

HLL01.1A-105U-N0486-C-008-0471-NNNN

HNL01.1E-0066-N0365-N-690-NNNN


HNF01.1B-A0100-E0580-N-480-NNNN

HLL01.1A-095U-N0574-C-008-0471-NNNN

HNL01.1E-0060-N0475-N-690-NNNN


HNF01.1B-A0100-E0580-N-480-NNNN

HLL01.1A-069U-N0702-C-008-0471-NNNN

HNL01.1E-0038-N0650-N-690-NNNN


HNF01.1B-A0100-E0740-N-480-NNNN

HLL01.1A-063U-N0861-C-008-0471-NNNN

HNL01.1E-0032-N0760-N-690-NNNN


2 xHNF01.1B-A0100-E0580-N-480-NNNN

HLL01.1A-037U-N1160-C-008-0471-NNNN

2 xHNL01.1E-0038-N0540-N-690-NNNN


2 xHNF01.1B-A0100-E0580-N-480-NNNN

HLL01.1A-034U-N1404-C-008-0471-NNNN

2 xHNL01.1E-0026-N0620-N-690-NNNN


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IndraDrive HCS04.2E

Type Option HLT Option HLR01.1 lifting gear Option HLR01.1 travelling gearHCS04.2E-W0350-N-04-NNBN Built-in braking unit 1 x HLR01.1N-44K0-N03R3-B-007-

NNNN1 x HLR01.1N-22K0-N03R5-B-007-NNNN

HCS04.2E-W0420-N-04-NNBN Built-in braking unit 1 x HLR01.1N-66K0-N02R1-B-007-


HCS04.2E-W0520-N-04-NNBN Built-in braking unit 1 x HLR01.1N-66K0-N02R1-B-007-




2 x HLR01.1N-44K0-N03R3-B-007-NNNN

2 x HLR01.1N-22K0-N03R5-B-007-NNNN



2 x HLR01.1N-66K0-N02R1-B-007-NNNN

3 x HLR01.1N-22K0-N03R5-B-007-NNNN



2 x HLR01.1N-66K0-N02R1-B-007-NNNN

3 x HLR01.1N-22K0-N03R5-B-007-NNNN



3 x HLR01.1N-66K0-N02R1-B-007-NNNN

4 x HLR01.1N-22K0-N03R5-B-007-NNNN



3 x HLR01.1N-66K0-N02R1-B-007-NNNN

5 x HLR01.1N-22K0-N03R5-B-007-NNNN

Type Option HMF01.1N Option HAS07.1HCS04.2E-W0350-N-04-NNBN HMF01.1N-N0K1-M0320-N-690-NNNN HAS07.1-350-NNN-NNHCS04.2E-W0420-N-04-NNBN HMF01.1N-N0K1-M0320-N-690-NNNN HAS07.1-330-NNN-NNHCS04.2E-W0520-N-04-NNBN HMF01.1N-N0K1-M0480-N-690-NNNN HAS07.1-430-NNN-NNHCS04.2E-W0640-N-04-NNNN HMF01.1N-N0K1-M0480-N-690-NNNN HAS07.1-585-NNN-NNHCS04.2E-W0790-N-04-NNNN HMF01.1N-N0K1-M0760-N-690-NNNN HAS07.1-585-NNN-NNHCS04.2E-W1010-N-04-NNNN HMF01.1N-N0K1-M0760-N-690-NNNN --HCS04.2E-W1240-N-04-NNNN HMF01.1N-N0K1-M1190-N-690-NNNN --HCS04.2E-W1540-N-04-NNNN HMF01.1N-N0K1-M1190-N-690-NNNN --

*) When an HLT01.1A-200K-N-007-NNNN is used, the option "HAS07.1-660-NNN-NN" is required!

TypeOptionHAS08.1-IP23

OptionHAS08.1-IP54FL

OptionHAS08.1-IP54GL

HCS04.2E-W0350-N-04-NNBN HAS08.1-002-P23-NN HAS08.1-002-P54-FL HAS08.1-002-P54-GLHCS04.2E-W0420-N-04-NNBN HAS08.1-003-P23-NN HAS08.1-003-P54-FL HAS08.1-003-P54-GLHCS04.2E-W0520-N-04-NNBN HAS08.1-004-P23-NN HAS08.1-004-P54-FL HAS08.1-004-P54-GLHCS04.2E-W0640-N-04-NNNN HAS08.1-005-P23-NN HAS08.1-005-P54-FL HAS08.1-005-P54-GLHCS04.2E-W0790-N-04-NNNN HAS08.1-005-P23-NN HAS08.1-005-P54-FL HAS08.1-005-P54-GLHCS04.2E-W1010-N-04-NNNN HAS08.1-006-P23-NN HAS08.1-006-P54-FL HAS08.1-006-P54-GLHCS04.2E-W1240-N-04-NNNN HAS08.1-006-P23-NN CMHAS08.1-006-P54-FL HAS08.1-006-P54-GLHCS04.2E-W1540-N-04-NNNN HAS08.1-007-P23-NN HAS08.1-007-P54-FL HAS08.1-007-P54-GL



IndraDrive HCS04.2E

3.8 External Options3.8.1 Radio Interference Filter HNF01.1B

Fig.3-47: HNF01.1B

As a standard, the converters have an integrated radio interference filter for usein industrial areas. For HCS04.2E-W, this filter complies with the requirementsof the category "C3 Use in industrial areas". For applications in "1st environment- residential area" of category C1 or C2 and for long motor cables, additionalfilters of option HNF01.1B must be used. They are connected on the mains sidebefore the converter.

A good HF connection between the motor, motor cable shield andfilter is imperative for the radio interference filter to be effective!

HNF01.1B filters are not suited for ungrounded (IT) mains and"Corner Grounded Networks". The radio interference filters inte‐grated as a standard can be set to IT mains.

To select the appropriate HNF01.1B option for the converter, pleaseuse the assignment table.See also "Radio interference filter (C2 – residential areas)"

The allowed motor cable lengths are contained in the tables on the followingpages:See also "Guide Values for Maximum Motor Cable Lengths in 1st Environ‐ment" page 64See also "Guide Values for Maximum Motor Cable Lengths in 2nd Environment(Industrial Areas)" page 64Mount the filters of option HNF01.1B in such a way that there is a connectionof good electroconductive properties over a large surface area between theshield connection of the motor cable and the converter. This good HF connec‐tion is decisive for the radio interference suppression of the drive.The supplied protective covering is used to avoid accidental contact to the ter‐minal connectors.

General technical dataOperating voltage HNF01.1B 3AC 380 V -15 % ... 480 V +10 %Nominal frequency 50/60 Hz ±5 %Overload capability 150 % for 60 s per 10 min, 200 % for 2 sAmbient temperature -10... + 50 °C (up to 60 °C with derating)Storage temperature -40... + 70 °CInstallation altitude 0... 1,000 m (up to 3,000 m with derating, but a max. of 2,000 m for "Corner Grounded

Networks")


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IndraDrive HCS04.2E

General technical dataVibration resistance 1.5 mm at 3... 13 Hz, 1 g at 13... 200 Hz in accordance with IEC/EN 60068-2-6Shock resistance 15 g for 11 ms in accordance with IEC/EN 60068-2-27

Radio interference filter (C2 – residential areas)

Converter HCS04.2E-W0350 HCS04.2E-W0420 HCS04.2E-W0520 HCS04.2E-W0640

Type designation HNF01.1B-A0100-E0300

HNF01.1B-A0100-E0300

HNF01.1B-A0100-E0580

HNF01.1B-A0100-E0580

Nominal current A 300 300 580 580

Power dissipation W 60 60 125 125

Continuous leakage current mA 3 3 3 3

Max. leakage current mA 350 350 350 350

Width B mm 260 260 260 260

Height H mm 306 306 306 306

Depth T mm 135 135 135 135

Mass approx. kg 13 13 15 15

Converter HCS04.2E-W0790 HCS04.2E-W1010 HCS04.2E-W1240 HCS04.2E-W1540

Type designation HNF01.1B-A0100-E0580

HNF01.1B-A0100-E0740

2 x HNF01.1B-A0100-E0580

2 x HNF01.1B-A0100-E0580

Nominal current A 580 740 580 740

Power dissipation W 125 210 210 210

Continuous leakage current mA 3 3 3 3

Max. leakage current mA 350 350 350 350

Width B mm 260 280 2 x 260 2 x 260

Height H mm 306 356 2 x 306 2 x 306

Depth T mm 135 170 2 x 135 2 x 135

Mass approx. kg 15 25 2 x 15 2 x 15



IndraDrive HCS04.2E



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IndraDrive HCS04.2E

3.8.2 DC Choke HLL

Fig.3-49: DC Choke HLL

The DC choke reduces the mains current harmonics and thereby reduces thetotal mains current.The HCS04.2E converters can be connected to a standard industrial mainswithout any additional measures.The HCS04.2E converters have been sized for operation at an adjusted trans‐former. An external choke is obligatory for mains with a higher short-circuitpower; an external choke is always recommended to reduce the current har‐monics.

HNL can be used as an alternative. However, HNL and HLL mustn'tever be used simultaneously.

Using the option HLL01.1A is generally required:● For using the converter in residential areas● For mains short-circuit currents at the converter supply up to 50 kA● When several converters are operated at the same mains node● When reactive-current compensation equipment is overloaded by the

converter● When the converter is operated at a generator● When the supplying mains has unbalance ≥ 1.8 %Depending on the device size, observe the following aspects:HCS04.2-W0350 ... -W1540The option HLL01.1A is required when supply does not take place via an ad‐justed transformer. Maximum mains short-circuit current 50 kA.To select the appropriate HLL01.1A option for the converter, please use theassignment table on page 66:Typical current harmonics when using a DC choke at 400 V, 50 Hz

IndraDrive HCS04.2EPN

[kW]Icc

[kA]IN[A]

H1[A]

Harmonics at nominal load [%]

H5 H7 H11 H13 H17 H19 H23 H25 H29

HCS04.2E-W0350-N-04-NNBN 132 35 226 210 34,9 17,1 8,21 5,36 4,66 3,33 3,11 2,40 2,22

HCS04.2E-W0420-N-04-NNBN 160 50 271 252 34,0 17,2 8,28 5,59 4,80 3,51 3,23 2,56 2,35

HCS04.2E-W0520-N-04-NNBN 200 50 338 314 34,4 16,8 8,23 5,33 4,65 3,32 3,09 2,39 2,20

HCS04.2E-W0640-N-04-NNNN 250 50 418 391 32,7 14,9 8,15 5,14 4,56 3,26 2,98 2,32 2,07

HCS04.2E-W0790-N-04-NNNN 315 50 527 492 33,1 14,4 8,08 4,85 4,41 3,05 2,81 2,15 1,90

HCS04.2E-W1010-N-04-NNNN 400 50 660 623 31,2 12,6 7,95 4,71 4,26 2,99 2,63 2,06 1,71



IndraDrive HCS04.2E

HCS04.2E-W1240-N-04-NNNN 500 50 835 782 33,5 13,1 7,75 4,28 3,97 2,65 2,37 1,82 1,49

HCS04.2E-W1540-N-04-NNNN 630 50 1037 980 31,1 11,1 7,64 4,23 3,81 2,63 2,15 1,73 1,27


[kW]Icc

[kA]IN[A]

H1[A]


H31 H35 H37 H41 H43 H47 H49 THD

HCS04.2E-W0350-N-04-NNBN 132 35 226 210 1,82 1,64 1,41 1,24 1,10 0,94 0,86 40,9

HCS04.2E-W0420-N-04-NNBN 160 50 271 252 1,94 1,76 1,51 1,34 1,20 1,04 0,95 40,2

HCS04.2E-W0520-N-04-NNBN 200 50 338 314 1,81 1,63 1,38 1,22 1,07 0,91 0,84 40,2

HCS04.2E-W0640-N-04-NNNN 250 50 418 391 1,71 1,48 1,29 1,07 0,97 0,78 0,72 38,0

HCS04.2E-W0790-N-04-NNNN 315 50 527 492 1,57 1,32 1,15 0,92 0,84 0,65 0,61 38,0

HCS04.2E-W1010-N-04-NNNN 400 50 660 623 1,45 1,12 1,01 0,75 0,70 0,51 0,49 35,6

HCS04.2E-W1240-N-04-NNNN 500 50 835 782 1,26 0,96 0,88 0,63 0,61 0,43 0,42 37,5

HCS04.2E-W1540-N-04-NNNN 630 50 1037 980 1,13 0,77 0,73 0,50 0,48 0,39 0,36 34,6

HLL01.1A is provided as an option for HCS04.2 converters and is connectedon the top of the converters. It is electrically connected to the converter at theterminals PO und PA/+ on top. HLL01.1A needs the converter's air flow forcooling, but increases the degree of protection on the top to IP31. The coolingair duct in the choke box and in the converter has been designed in the degreeof protection IP54.

General technical data of option HLL01.1A

Operating voltage 400... 850 V DC

Overload capability 1.25-fold for 60 s per 10 min, 1.35-fold for 2 s

Ambient temperature -10... +50 °C (up to 60 °C with derating)

Storage temperature -25... +70 °C

Installation altitude 0... 1,000 m (up to 3,000 m with derating)

Vibration resistance 1.5 mm at 3... 13 Hz, 1 g at 13... 200 Hz in accordance withIEC/EN 60068-2-6

Shock resistance 7 g for 11 ms in accordance with IEC/EN 60068-2-27

Cooling Forced, by the converter's air flow

Degree of protection IP31, cooling air duct IP54

DC chokeConverter HCS04.2E-

W0350HCS04.2E-W0420

HCS04.2E-W0520

HCS04.2E-W0640

Type designation HLL01.1A-150U-N0290

HLL01.1A-138U-N0558

HLL01.1A-105U-N0486

HLL01.1A-095U-N0574

Nominal current (therm.)@50°C

A 290 A 351 486 574

Nominal inductance µH 150 138 105 95Power dissipation W 210 270 345 390Width B mm 360 340 440 595Height H mm 240 240 240 240Depth T mm 377 377 377 377Mass approx. kg 32 36 53 67


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IndraDrive HCS04.2E


HCS04.2E-W1010

HCS04.2E-W1240

HCS04.2E-W1540

Type designation HLL01.1A-069U-N0702

HLL01.1A-063U-N0861

HLL01.1A-037U-N1160

HLL01.1A-034U-N1404


A 702 861 1160 1404

Nominal inductance µH 69 63 37,5 34,5Power dissipation W 495 625 700 920Width B mm 595 890 890 1120Height H mm 240 240 240 240Depth T mm 377 377 377 377Mass approx. kg 67 105 115 135

HLL01.1A-210U-N0243-C-008-NNNN-NNNN to HLL01.1A-069U-N0702-C-008-NNNN-NNNN




IndraDrive HCS04.2E

HLL01.1A-063U-N0861-C-008-NNNN-NNNN to HLL01.1A-034U-N1404-C-008-NNNN-NNNN


3.8.3 Mains Choke HNL01.1E

Fig.3-52: Mains Choke HNL01.1EThe option HNL01.1E can be used to reduce the mains current harmonics.The HCS04.2E converters have been sized for operation at an adjusted trans‐former. An external choke is obligatory for mains with a higher short-circuitpower; an external choke is always recommended to reduce the current har‐monics.Using the option HNL01.1E is required:● For using the converter in residential areas● When several converters are operated at the same mains node● When reactive-current compensation equipment is overloaded by the

converter● When the converter is operated at a generator● When the supplying mains has unbalance ≥ 1.8 %● With mains short-circuit currents up to 100 kA● When HLL01.1A cannot be used with HCS04.2 for lack of space

At full load, the converter can no longer compensate the voltagedrop at the choke, i.e. the output voltage is by up to 3% smaller thanthe applied mains voltage before the choke.


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IndraDrive HCS04.2E

To select the appropriate HNL01.1E option for the converter, pleaseuse the assignment table.HCS04.2: Page 65 et seq.In the performance assignment, the current reduction in accord‐ance with the respective maximum ambient temperature of theconverter has already been taken into account.

HLL can be used as an alternative. However, HNL and HLL mustn'tever be used simultaneously.

The option HNL01.1E is connected on the mains side before the converter. Themains chokes can be mounted in any position. In either case, make sure toprovide good ventilation.Due to the transport brackets, it is also possible to fix them at the mounting wall.

General technical dataOperating voltage 3AC 380 V -15 % ... 690 V +10 %Nominal frequency 50/60 Hz ±5 %Overload capability HNL01.1E: 1.25-fold for 60 s per 10 min, 1.35-fold for 2Ambient tempera‐ture

-10...+50 °C (up to 60 °C with derating)

Storage tempera‐ture

-40... +70 °C

Installation altitude 0... 1,000 m (up to 3,000 m with derating)Vibration resistance 1.5 mm at 3... 13 Hz, 1 g at 13... 200 Hz in accordance with IEC/

EN 60068-2-6Shock resistance 15 g for 11 ms in accordance with IEC/EN 60068-2-27Degree of protec‐tion

IP00

Connection With terminal lugs

Mains chokeConverter HCS04.2E-

W0350HCS04.2E-W0420

HCS04.2E-W0520

HCS04.2E-W0640

Type designation HNL01.1E-0098-N0280

HNL01.1E-0085-N0315

HNL01.1E-0066-N0365

HNL01.1E-0060-N0475


A 280 315 365 475

Nominal inductance µH 98 85 66 60Power dissipation W 260 280 280 320Mass approx. kg 40 46 43 70Dimension A1 mm 380 380 380 380Dimension A2 mm 350 350 350 350Dimension A3 mm 300 300 300 300Dimension B1 mm 320 320 320 320Dimension B2 mm 225 225 225 225Dimension C1 mm 210 210 250 250Dimension C2 mm 200 200 230 230



IndraDrive HCS04.2E

Mains chokeDimension C3 mm 150 150 150 150Fixing D1 mm 9 9 11 11Connection D2 mm 11 11 13 13Connection PE M10 M10 M12 M12


HCS04.2E-W1010

HCS04.2E-W1240

HCS04.2E-W1540

Type designation HNL01.1E-0038-N0650

HNL01.1E-0032-N0760

2 xHNL01.1E-0038-N0540

2 xHNL01.1E-0026-N0620


A 650 760 2 * 540 2 * 620

Nominal inductance µH 38 32 2 x 38 2 x 26Power dissipation W 320 450 2 x 320 2 x 320Mass approx. kg 55 60 2 x 55 2 x 60Dimension A1 mm 440 440 380 380Dimension A2 mm 400 400 350 350Dimension A3 mm 310 340 300 300Dimension B1 mm 360 385 320 320Dimension B2 mm 300 300 225 225Dimension C1 mm 250 275 250 250Dimension C2 mm 230 250 230 230Dimension C3 mm 150 125 150 150Fixing D1 mm 13 13 11 13Connection D2 mm 2*13 2*13 13 13Connection PE M12 M12 M12 M12

Typical current harmonics when using an HNL01.1E mains choke at 400 V,50 Hz


[kW]

Icc

[kA]

IN[A]

H1[A]


H5 H7 H11 H13 H17 H19 H23 H25

HCS04.2E-W0350-N-04-NNBN 132 35 231 213 37,7 13,1 7,03 3,33 2,97 1,88 1,52 1,25HCS04.2E-W0420-N-04-NNBN 160 50 279 257 38,1 13,5 6,96 3,31 2,96 1,89 1,51 1,23HCS04.2E-W0520-N-04-NNBN 200 50 347 319 37,8 13,2 6,97 3,31 2,95 1,90 1,48 1,23HCS04.2E-W0640-N-04-NNNN 250 50 428 398 35,8 11,6 6,70 3,24 2,72 1,89 1,31 1,19HCS04.2E-W0790-N-04-NNNN 315 50 543 501 37,5 13,2 6,93 3,30 2,93 1,88 1,46 1,24HCS04.2E-W1010-N-04-NNNN 400 50 683 634 36,1 11,8 6,68 3,21 2,73 1,88 1,31 1,19HCS04.2E-W1240-N-04-NNNN 500 50 858 791 37,6 13,0 6,89 3,28 2,90 1,87 1,44 1,23HCS04.2E-W1540-N-04-NNNN 630 50 1072 992 36,8 12,3 6,86 3,24 2,85 1,89 1,40 1,2112-pulse rectificationHCS04.2E-W1240-N-04-NNNN 500 50 793 791 0 0 5,41 3,25 0 0 0,89 0,81HCS04.2E-W1540-N-04-NNNN 630 50 995 992 0 0 5,59 3,23 0 0 0,93 0,88


[kW]

Icc

[kA]

IN[A]

H1[A]


H29 H31 H35 H37 H41 H43 H47 H49 THD


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HCS04.2E-W0350-N-04-NNBN 132 35 231 213 0,83 0,83 0,53 0,53 0,43 0,36 0,33 0,29 40,9HCS04.2E-W0420-N-04-NNBN 160 50 279 257 0,82 0,82 0,55 0,55 0,41 0,38 0,33 0,27 41,4HCS04.2E-W0520-N-04-NNBN 200 50 347 319 0,82 0,82 0,53 0,53 0,42 0,37 0,33 0,29 41,0HCS04.2E-W0640-N-04-NNNN 250 50 428 398 0,73 0,73 0,51 0,46 0,41 0,34 0,32 0,28 38,6HCS04.2E-W0790-N-04-NNNN 315 50 543 501 0,80 0,80 0,52 0,52 0,41 0,37 0,34 0,28 40,8HCS04.2E-W1010-N-04-NNNN 400 50 683 634 0,73 0,73 0,51 0,47 0,40 0,33 0,31 0,28 38,9HCS04.2E-W1240-N-04-NNNN 500 50 858 791 0,79 0,79 0,52 0,52 0,40 0,36 0,33 0,28 40,7HCS04.2E-W1540-N-04-NNNN 630 50 1072 992 0,77 0,77 0,51 0,50 0,40 0,35 0,33 0,27 39,812-pulse rectificationHCS04.2E-W1240-N-04-NNNN 500 50 793 791 0 0 0,45 0,40 0 0 0,23 0,21 6,46HCS04.2E-W1540-N-04-NNNN 630 50 995 992 0 0 0,47 0,40 0 0 0,23 0,22 6,62

HNL01.1E 40 ... 760

3.8.4 Braking Unit HLT

Fig.3-53: Braking Unit HLT

Using a braking unit is required when, during the braking process, more energythan the losses in motor and converter is returned to the DC bus, or when theapplication requires very short braking times.IndraDrive HCS04.2E controls and monitors the braking unit (internal or as ex‐ternal option). When the DC bus voltage, due to a deceleration process,exceeds a value to be set, an external braking resistor (as a load) is connectedto the DC bus. This braking resistor converts the generated energy into thermalenergy and thereby keeps the DC bus voltage from rising; this avoids shutdownwith overvoltage.



IndraDrive HCS04.2E

Parameters allow entering the resistance data and thus protect thebraking resistor against a too long duty cycle.

If 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.

When the braking function has been activated, it starts working as soon asIndraDrive HCS04.2E is in the "Ready" or "Operation" status, but not in the caseof "Failure".The braking unit needs the following connection lines:● Control line (contained in scope of supply)● Supply cable for the blower (contained in scope of supply)● Power line converter - braking unit (DC bus connections BU+ and BU-)

(contained in scope of supply)● Power line braking unit - braking resistor (connections PA and PB); max.

50 m

Ground the braking unit at the bolts marked with PE with at least 10mm2.

The IndraDrive HCS04.2E" -W0350 ...-W0520 converters have an integratedbraking transistor. Therefore, it is only necessary to connect an externalHLR01.1 braking resistor and to activate the braking function.

Fig.3-54: HLR01.1 With Braking TransistorFor IndraDrive HCS04.2E converters, the braking unit has been designed asan external option. The converter supplies, controls and monitors the brakingunit in such a way as if it would have been integrated. Operating the brakingunit without the converter or at another device than the assigned one is there‐fore impossible.


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IndraDrive HCS04.2E

Fig.3-55: Braking Unit as External Option

General technical data

OscillationIn accordance with IEC/EN 60068-2-61.5 mm in the range of 3... 10 Hz, 0.6 g from 10... 200 Hz(3M3 in accordance with IEC/EN 60721-3-3)

ShockIn accordance with IEC/EN 60068-2-274 g for 11 ms (3M2 in accordance with IEC/EN 60721-3-3)

Operating temperature-10... +45°C(3K3 in accordance with IEC/EN 60721-3-3)Up to +60°C with derating

Storage/transport temperature -25... +70°C

Degree of protectionLateral, front IP31Top IP20Bottom IP00

Environment class / humidity Class 3K3 in accordance with IEC/EN 60721-3-3 / no moisture condensation, max.95% relative humidity

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 61800-5-13C2 and 3S2 in accordance with EN 60721-3-3

Protection class Class 1 in accordance with EN 50178Basic 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)



IndraDrive HCS04.2E


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

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


HCS04.2E-W0420

HCS04.2E-W0520

HCS04.2E-W0640

External braking unitsType designation - - - HLT01.1A-200

KPeak braking power kW - - - 420Max. continuous braking power kW - - - 200Cycle time s - - - 240Minimum braking resistance ohm - - - 1,05Power dissipation at 100% IN W - - - 550Width B mm - - - 70Height H mm - - - 950Depth T mm - - - 377Mass approx. kg - - - 30


HCS04.2E-W1010

HCS04.2E-W1240

HCS04.2E-W1540

External braking units

Type designation HLT01.1A-200K

HLT01.1A-400K

HLT01.1A-400K

HLT01.1A-400K

Peak braking power kW 420 750 750 750

Max. continuous braking power kW 200 400 400 400

Cycle time s 240 240 240 240

Minimum braking resistance ohm 1,05 0,7 0,7 0,7

Power dissipation at 100% IN W 550 1050 1050 1050

Width B mm 70 310 310 310

Height H mm 950 1150 1150 1150

Depth T mm 377 377 377 377


HLT01.1A-200K-N-007-NNNN HLT01.1A-400K-N-007-NNNN

Peak braking power 420 kW 750 kW

Max. continuous braking power 200 kW 400 kW

Possible braking power depending onthe duty cycle

420 kW for 5%320 kW for 15%250 kW for 50%

750 kW for 5%550 kW for 15%440 kW for 50%

Cycle time 240 s 240 s


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HLT01.1A-200K-N-007-NNNN HLT01.1A-400K-N-007-NNNN

Typ. braking power for crane opera‐tion

Min. braking resistance 1.05 Ω 0.7 Ω

Power dissipation at 100% IN 550 W 1050 W

Cooling air volume 100 m3/h 600 m3/h

Mass 30 kg 70 kg

Mounting Attached to the left side wall of the con‐verter. This increases the device width to655 mm.

Mounted on the left next to the converter;the connection lines for a distance of 110mm to the converter housing are inclu‐ded. A distance of up to 1 m is allowedwith adjusted connection lines.

HLT01.1A

Ⓐ HLT01.1A-200K-N-007-NNNNⒷ HLT01.1A-400K-N-007-NNNNFig.3-56: HLT01.1A

3.8.5 Braking Resistor HLR01.1

Fig.3-57: Braking Resistor HLR01.1



IndraDrive HCS04.2E

The braking resistor converts the energy generated in regenerative operationinto thermal energy and thereby keeps the DC bus voltage from rising.The following converters are suited for direct connection of a braking resistor:IndraDrive HCS04.2E" W0350 ...-W0520An external braking unit is required forIndraDrive HCS04.2E, for W0640 and higherWhen assigning HLR braking resistors to the converters, observe the followingaspects:● Minimum braking resistance for converter power● Required peak braking power to avoid overvoltage cut-off● Necessary continuous power depending on the application requirements● Correct parameter setting to protect the resistor● If necessary, install an additional thermal relay

The temperature on the surface of the resistorcan be up to 250°C.

CAUTION

Therefore, do not mount the resistor on combustible material.

The HLR01.1 braking resistors protect the converter, the brakingunit and the lines. In the case of overload, internal switch-off occurs(like with a fuse). Afterwards, the braking resistor must be replaced.

HLR01.1 braking resistors have been designed for self-cooling withair in the case of vertical mounting (or horizontal with the coolingribs upwards).

Other devices or device parts mustn't impede the unrestricted airflow!

To select HLR01.1, please use the information given on page 51and the assignment table on page 65.

Option

HLR01.1N-22K0-N03R5-B-007-NNNN



Resistance 3.5 Ω 3.3 Ω 2.1 ΩContinuous power 22 kW 44 kW 66 kWPeak power @ 680 V DC 132 kW 140 kW 220 kWPeak power @ 785 V DC 176 kW 187 kW 293 kWPeak power @ 975 V DC 272 kW 288 kW 453 kWPeak power @ 1075 V DC 330 kW 350 kW 550 kWDuty cycle at 120 s cycle @680V / 785V / 975V /1075V 10 / 7 / 5 / 4 % 23 / 16 / 9 / 8 % 21 / 15 / 9 / 7 %Value to be set for thermal relay 79 A 115 A 177 ADegree of protection IP23 IP23 IP23Dimension A1 520 mm 770 mm 1,100 mm


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Dimension B1 995 mm 995 mm 995 mmDimension B2 970 mm 970 mm 970 mmConnection cross section 16 mm2 50 mm2 95 mm2

Connection D1 M8 M10 M10Mass 61 kg 101 kg 138 kg

Fig.3-58: Braking Resistor HLR01.1



IndraDrive HCS04.2E

3.8.6 Output Motor Filter HMF01.1N

Fig.3-59: Output Motor Filter HMF01.1N

At the output, the converters have a pulsed voltage with a clock frequency of2… 8 kHz, at a rise of voltage of more than 5 kV/μs. Using the option HMF01.1Nprovides considerable advantages for operating the drive in a trouble-free way:● Reduces the voltage load of the motor – recommended for 50 m and more,

necessary for 100 m and more● Reduces common-mode bearing currents in the motor – particularly im‐

portant for high power● Clearly reduces interference injection to other lines – this is important

when separate routing of motor lines is not ensuredDue to the special system, the voltage drop at HMF01.1N is negligible.

To select the appropriate HMF01.1N option for the converter,please use the assignment table:See page 65.

In addition, observe the information given on the correspondingconverter line to ensure trouble-free operation.See page 62

The option HMF01.1N is connected to the output side of the converter in theconnection to the motor.The HMF01.1N filters must be mounted vertically to allow sufficient cooling. Inaddition, it is important to ensure the necessary distance to other devices andhousing parts.


Operating voltage 3AC 0... 690 V

Operating frequency 0... 100 Hz

Overload capability 150 % for 60 s per 10 min, 165 % for 2 s

Ambient temperature -10... +50 °C (up to 60 °C with derating)

Storage temperature -40 … +70 °C

Installation altitude 0... 1,000 m (up to 3,000 m with derating)

Vibration resistance 1.5 mm at 3...13 Hz, 1 g at 13... 200 Hz in accordance withIEC/EN 60068-2-6

Shock resistance 15 g for 11 ms in accordance with IEC/EN 60068-2-27

Degree of protection IP00, with touch guard

For better efficiency and cooling, the HMF01.1N filters consist of three single-phase chokes. Each of them must be connected in one motor phase.


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IndraDrive HCS04.2E


HCS04.2E-W0420

HCS04.2E-W0520

HCS04.2E-W0640

Motor filter

Type designa‐tion

HMF01.1N-N0K1-M0320

HMF01.1N-N0K1-M0320

HMF01.1N-N0K1-M0480

HMF01.1N-N0K1-M0480

Operating fre‐quency

Hz 0 … 100

Overload capa‐bility

150% for 60 s per 10 min; 165% for 2 s

Nominal cur‐rent @ 50°C

A 314 314 481 481

Power dissipa‐tion

W 475 475 530 530

Width B mm 3 x 110 3 x 110 3 x 200 3 x 200

Height H mm 3 x 210 3 x 210 3 x 245 3 x 245

Depth T mm 3 x 250 3 x 250 3 x 250 3 x 250



HCS04.2E-W1010

HCS04.2E-W1240

HCS04.2E-W1540

Motor filter

Type designa‐tion

HMF01.1N-N0K1-M0760

HMF01.1N-N0K1-M0760

HMF01.1N-N0K1-M1190

HMF01.1N-N0K1-M1190

Operating fre‐quency

Hz 0 … 100

Overload capa‐bility

150 % for 60 s per 10 min; 165% for 2 s


A 759 759 1188 1188

Power dissipa‐tion

W 600 600 680 680

Width B mm 3 x 210 3 x 210 3 x 230 3 x 230

Height H mm 3 x 315 3 x 315 3 x 370 3 x 370

Depth T mm 3 x 250 3 x 250 3 x 250 3 x 250


Option

HMF01.1N-N0K1-M0320-A-690-NNNN





314 A 481 A 759 A 1188 A

Losses 475 W 530 W 600 W 680 W

Mass 32 kg 58 kg 93 kg 120 kg



IndraDrive HCS04.2E





Dimension A1 210 mm 245 mm 315 mm 370 mm

Dimension A2 175 mm 225 mm 275 mm 325 mm

Dimension B1 110 mm 200 mm 210 mm 230 mm

Dimension B2 75 mm 175 mm 200 mm 200 mm

Dimension C1 250 mm 250 mm 250 mm 250 mm

Fixing D1 9 x 13 mm 9 x 13 mm 9 x 13 mm 9 x 13 mm

Connection D2 M10 2 x M12 2 x M12 3 x M12

Connection PE M8 M8 M8 M8

HMF01.1N-N0K1-M0320-A-690-NNNN Required minimum distances

Fig.3-60: HMF01.1N-N0K1-M0320-A-690-NNNNHMF01.1N-N0K1-M0760-A-690-NNNN andHMF01.1N-N0K1-M1190-A-690-NNNN

Required minimum distances

Fig.3-61: HMF01.1N-N0K1-M0760-A-690-NNNN and HMF01.1N-N0K1-M1190-A-690-NNNN

The HMF01.1N filters consist of three single-phase chokes.For mounting, make sure there is the required minimum distance between thethree components, apart from the clearance above and below.


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IndraDrive HCS04.2E

Side-by-side arrangement Stacked arrangement



IndraDrive HCS04.2E

3.8.7 Flange Assembly Kit HAS07.1

Fig.3-62: Flange Assembly Kit

When the converter is mounted by means of the flange assembly kit, most ofthe power dissipation is generated outside of the control cabinet. Within thecontrol cabinet, only the control section power dissipation must be discharged.There are several options available for dissipating the heat from the controlcabinet:● Heat dissipation via the control cabinet surface● Heat dissipation by means of filter blowers● Heat dissipation by means of active cooling unit

The DC chokes or blower transformers must be installed immediately abovethe converter for sufficient cooling.

Without derating, the inside temperaturemustn't exceed +40°C.

CAUTION

To avoid zones with too high temperature, it might possibly be necessary toinstall an internal ventilator for forced air circulation.

It is possible to replace the power section blower from the inside over the entirepower range. The entire converter, too, is dismounted and mounted from theinside of the control cabinet.

To select the appropriate HAS07.1 option for the converter, pleaseuse the assignment table:HCS04.2: Page 65 et seq.


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Design Mounting frame made of solid steel plate and glued-ongaskets

Degree of protection external IP54

Degree of protection internal IP20/IP00

Option HAS07.1

HAS07.1-350-NNN-NN

HAS07.1-330-NNN-NN

HAS07.1-430-NNN-NN

HAS07.1-585-NNN-NN

HAS07.1-660-NNN-NN

Mass 3.6 kg 4.3 kg 4.7 kg 4.7 kg 4.9 kg

Dimension A1 885 mm 1,062 mm 1,062 mm 1,062 mm 1,062 mm

Dimension A2 845 mm 970 mm 970 mm 970 mm 970 mm

Dimension B1 440 mm 442 mm 542 mm 697 mm 772 mm

Dimension B2 360 mm 360 mm 460 mm 610 mm 685 mm

Dimension B3 190 mm 190 mm 2x 180 mm 2x 190 mm 2x 190 mm

Dimension C1 240 mm 240 mm 240 mm 240 mm 240 mm

HAS07.1

Fig.3-63: HAS07.1

Please see the mounting instructions for the number and dimen‐sions of the required mounting holes. The mounting instructionsalso contain comprehensive information on how to size the controlcabinet surface, filter blower and cooling unit.



IndraDrive HCS04.2E

To avoid air short circuit (the converter draws in the heated outletair), make sure there is an appropriate air flow in the outer coolingarea and a sufficiently big air space.


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3.8.8 Control Cabinet Assembly Kit HAS08.1

Fig.3-64: Control Cabinet Assembly Kit HAS08.1

The control cabinet assembly kit HAS08.1 is used for mounting the converterin a Rittal TS8 control cabinet. This option is suited for HCS04.2 W0350 ... -W1540.There are 3 different types available:● IP23 prepared for HNL01.1E mains choke or HLL01.1A DC choke● IP54 with filter blower● IP54 with separate air flow

ConverterDimensions of control cabinet

Height Width Depth Type-- 2,000 mm 600 mm 600 mm TS 8606HCS04.2E-W0350-N-04-NNBN 2,000 mm 600 mm 600 mm TS 8606HCS04.2E-W0420-N-04-NNBN 2,000 mm 600 mm 600 mm TS 8606HCS04.2E-W0520-N-04-NNBN 2,000 mm 600 mm 600 mm TS 8606HCS04.2E-W0640-N-04-NNNN 2,000 mm 800 mm 600 mm TS 8806HCS04.2E-W0790-N-04-NNNN 2,000 mm 800 mm 600 mm TS 8806



IndraDrive HCS04.2E

ConverterDimensions of control cabinet

Height Width Depth TypeHCS04.2E-W1010-N-04-NNNN 2,000 mm 1,000 mm 600 mm TS 8006HCS04.2E-W1240-N-04-NNNN 2,000 mm 1,000 mm 600 mm TS 8006HCS04.2E-W1540-N-04-NNNN 2,000 mm 1,200 mm 600 mm TS 8206

You must comply with the control cabinet dimensions specifiedabove, because otherwise it is not ensured that the control cabinetassembly kit fits exactly.

Option HAS08.1-IP23

The internal blower of the converter ensures that there is enoughcooling air for the control cabinet (including the installed mainschoke or DC choke). If it is necessary to install a motor filter in thecontrol cabinet, put it beneath the converter. In this case, integratean additional blower in the control cabinet door near the motor filter.

Fig.3-65: Option HAS08.1-IP23This assembly kit allows mounting the converter in a Rittal TS8 control cabinetin accordance with the degree of protection IP23. The cooling air is let in throughthe control cabinet door and let out at the top of the control cabinet. The internalblower of the converter ensures that there is enough cooling air for the controlcabinet.The assembly kit consists of the following parts:● 1. Cover


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● 2. Air guide● 3. Support with guide bar● 4. Holding plate● + Fixing materialFor a higher degree of protection, there are two IP54 solutions: IP54 with filterblower or separate air flow.Option HAS08.1-IP54FL

Fig.3-66: Option HAS08.1-IP54FLWith the degree of protection IP54 with filter blower, the cooling air is let inthrough the filters in the control cabinet door and let out through the blower ontop of the control cabinet. The mains choke HNL01.1E is required for this as‐sembly kit!The assembly kit consists of the following parts:● 1. Filter blower● 2. Support with guide bar● 3. Holding plate● + Fixing material● Specification of the filter blower:Volumetric capacity: 1,200 m3/hNominal voltage: 3 AC 400 V, 50 HzNominal current: 0.3 ASound pressure level: 73 dB(A)



IndraDrive HCS04.2E

Number of blowers:1 in HAS08.1-002-P23-NN... HAS08.1-004-P23-NN2 in HAS08.1-005-P23-NN… HAS08.1-006-P23-NN3 in HAS08.1-007-P23-NNOption HAS08.1-IP54GL

Ⓐ Cooling air control sectionⒷ Cooling air power sectionFig.3-67: Option HAS08.1-IP54GLWith the degree of protection IP54 with separate air flow, the air for the powersection is let in through the control cabinet base or from the bottom (cablebasement). The air is let out through the top of the control cabinet. The powersection is cooled by the filter blower in the control cabinet door or an air condi‐tioning unit.

The DC choke HLL01.1A is required for this assembly kit!

The assembly kit consists of the following parts:● 1. Cover● 2. Air guide● 3. Support with guide bar● 4. Air duct● + Fixing material


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3.9 Protecting the Installation3.9.1 Responsibility

It is the user's responsibility to include the IndraDrive HCS04.2Econverters in the protection and safety concept of the installation ormachine.

Therefore, all the circuit recommendations and notes on project planning areonly suggestions; they must be adjusted to the on-site conditions and regula‐tions with regard to the installation and use.In particular, this applies to the safety regulations for machines, the EMC reg‐ulations and the general regulations for personal protection.

3.9.2 Frequencies > 60 HzTo operate motors and drives with frequencies of more than 60 Hz,you must check whether the components used are suitable.

Always consult the manufacturer of the motor and/or machine first. 4- ... 8-polemotors are generally suited for operation up to 100 Hz.

3.9.3 Residual-Current-Operated Circuit-BreakersConverters, especially those with additional HNF01.1B radio interference filtersand shielded motor cables, carry an increased leakage current against ground.The leakage current depends on:● The length of the motor cable● The way the cable is routed, and whether it is shielded or not● The clock frequency which has been set● The use of the additional HNF01.1B radio interference filter● The grounding of the motor on site (grounded or not grounded)

At the moment of switching on, the residual-current-operated circuit breaker can be acci‐dentally triggered, especially by the capacitorsof the filter.

CAUTION

It can also be accidentally triggered in operation by the capacitances to ground.On the other hand, it is possible to block the switch-off function through com‐ponents of direct current, with mains rectification at the converter input.

Therefore, you should observe the following aspects:● Only use short-time-delay and pulse-current-sensitive residual-current-

operated circuit breakers with a higher nominal triggering current.● Protect other loads by individual residual-current-operated circuit break‐

ers.● Residual-current-operated circuit breakers before a converter do not pro‐

vide absolute protection in the case of direct contact! Therefore, theyshould always be used in combination with other protective measures.

● IndraDrive HCS04.2E converters do not have a current-limiting function(in the case of fault currents) and therefore they do not violate the ground‐ing specifications.



IndraDrive HCS04.2E

In installations with great cable lengths, the leakage current can be greater than100 mA, depending on the conditions!

The built-in ground fault detection does nothave a current-limiting effect.

WARNING

It is a device protection and not a personal protection.

3.9.4 Switching the Motor Off and OnA safety switch or a motor contactor can be used to switch the motor off andon. The converter detects the respective switching status and the risk of de‐struction or disconnection on faults is excluded.

3.9.5 Suppressor CircuitAll inductances, such as relays, contactors, magnetic brakes, mustbe equipped with a suppressor circuit. It prevents malfunction of theconventional device control and of the field bus.

Provide a free-wheeling diode for DC control circuits.For AC control circuits, the RC circuit is better than a circuit with varistors, be‐cause it not only reduces the crest value of the overvoltage, but also the risetimes.

3.9.6 Insulation MeasurementsAll HCS04.2 converters are tested for dielectric strength and insulation resist‐ance in accordance with EN 50178 (test voltage: 2.8 kV DC for HCS04.2). Forinsulation resistance measurements, e.g. within the scope of inspections, ob‐serve the following aspects:● 1.1 Short-circuit all power terminals of the converter (L1, L2, L3, U, V, W,

PO, PA/+, PB, PC/-).1.2 Put the internal filter in the position for ungrounded mains (switch or

screw on the filter circuit board). See chapter "Ungrounded Mains",page 22

1.3 It is only allowed to make insulation resistance measurements be‐tween the short-circuited power terminals and ground.

1.4 Test voltage: Max. 2 kV DC1.5 Before any insulation resistance measurement of the motor, safely

disconnect the motor from the converter by branching it off or byopening the motor contactor. If you do not do this, the converter willbe damaged!

Never make insulation measurements at the control terminals!

3.9.7 External Blower SupplyWith devices of the HCS04.2 line, the power sections are cooled by three-phasecurrent blowers. In the condition as supplied, the blowers are supplied by theconverter's mains supply. Power supply can also be external (e.g., when theconverter is supplied via a DC bus).Technical data:3 AC 400 V -10% to 440 V +10%, 50 Hz ± 5%3 AC 400 V -10% to 480 V +10%, 60 Hz ± 5%


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Power: HCS04.2E-W0350-N-04-NNBN: 550 VA HCS04.2E-W0640-N-04-NNNN: 1100 VA HCS04.2E-W1010-N-04-NNNN: 1650 VA *) HCS04.2E-W1540-N-04-NNNN: 2200 VA *) *) HLT01.1A-400K-N-007-NNNN 550 VA

When the external blower supply is used, the connectors X1 and X4 at theblower supply module must be interchanged.

Fig.3-68: Internal Supply of the Three-Phase Current Blowers

Fig.3-69: External Supply of the Three-Phase Current Blowers



IndraDrive HCS04.2E

Service life of the DC blowers: 30,000 hoursService life of the three-phase current blowers 48,000 hours

The blowers for the control section start running as soon as theconverter is under voltage. As a matter of precaution, you shouldtherefore replace the blowers after five years!

3.9.8 General Notes on Connection1. Power lines with single wires, especially motor lines, should always be laidas close to the corresponding PE conductor as possible.

2. Control, mains supply and motor lines should be separated from each other,if possible.

3. Never lay control lines, supply feeders and motor cables in the same cableduct!

4. Only use shielded control lines (exception: relay contacts and possibly digitalinputs, if they are completely separated from the power cables). Always groundthe shield at both ends (exception: in the case of problems with ground loopscaused by compensating currents that heat the shield, ground only on the signalinput side or use a parallel compensating line).


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IndraDrive HCS04.2E

5. Implement EMC grounding of the HNF01.1B filter, the mounting plate andthe control cabinet.

Since mains disturbances and the actual influence on other loadsare measured with reference to the ground potential, the inductanceof the "grounding" is essential. This means that large-surfaceground connections, which can run in parallel to the yellow/greenprotective grounding PE, are very important.

6. Free cores in the motor cable (e.g., a blue N conductor) must be connectedto the PE motor at least on the converter side. Otherwise, they could carrydangerous voltages.7. The motor cable shield prevents the dissipation of interference currents viathe grounded motor (motor foundation). It leads them back to the mains filter ofthe converter.Its second task is to reduce the interfering radiation and to reduce interferenceinjection to neighboring lines.Therefore, shielded 4-pole motor cables should be used, and the shield shouldbe connected at both ends in accordance with the valid HF rules. The type ofshield material (copper or steel) is less important than a good connection atboth ends. Alternatively, a closed and continuously connected cable duct madeof metal and of good electroconductive properties can be used.

Ⓐ Converter and filterFig.3-70: ShieldingA low-price possibility for large line cross sections (use in industrial areas) is touse power cables with a concentric equipment grounding conductor (e.g., NY‐CY or NYCWY). The equipment grounding conductor has the same protectivefunction as the PE conductor, as well as the shielding effect.Connection design for NYCY motor cables:Because of the dual function of the PE conductor, it is necessary to implementthe cable connection on the converter side and motor side correctly:



IndraDrive HCS04.2E

Fig.3-71: Cable ConnectionEquipment grounding conductor function: Bundled connection of the PE con‐ductor for a safe and corrosion-proof connection, e.g. using a ring terminalShielding function: Connection of the PE conductor over a large surface areafor a low HF resistance with good induction of the interference currents into theHNF01.1B filter, e.g. using a clip

3.9.9 Wiring the Power ConnectionsHow to access the power terminalsIndraDrive HCS04.2ETo access the power terminals, remove the front panel.

Fig.3-72: Front Panel

3.9.10 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 be


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IndraDrive HCS04.2E

impeded by built-in components or filter mats. For the HCS04.2 devices, sealoff the power section air to avoid internal air short circuits.Control cabinet mounting in degree of protection IP23 of the HCS04.2 line

Fig.3-73: Degree of Protection IP23● Mains choke option HNL01.1E● Air inlet grid (without filter mat) for control section and power section● Cover plate with splash guard● Sealing wall to avoid internal air short circuits

Degree of protection: IP23● Ambient temperature: -10... +40°C

An optional assembly kit for RITTAL TS8 control cabinets is avail‐able.

3.9.11 Control Cabinet Mounting IP54Control cabinet mounting IP54 with separate air flow or flange assembly:The power section has been designed in IP54 for all devices and sealed offfrom the control electronics. With control cabinet mounting, a base is requiredfor separate air flow. The power section losses (external) are dissipated by thedevice-internal power section blower. The control section losses must be dis‐sipated by means of filter blowers or a sufficiently large control cabinet surface.The values specified in the technical data apply to the power dissipation andcooling air volume of the converter including HLL01.1A. Other heat sources,such as HLL, HNL01.1E, HMF01.1N, fuses and contactors must be additionallytaken into account.



IndraDrive HCS04.2E

Control cabinet mounting in degree of protection IP54 for converters of theHCS04.2 line

Fig.3-74: Control Cabinet Mounting in Degree of Protection IP541. IndraDrive HCS04.2E2. HLL01.1A3. Air inlet grid (with filter blower) for control section4. Cover plate with splash guard5. Sealing wall to avoid internal air short circuits6. Air outlet (with filter mat) for control section7. Cooling air for power section

Degree of protection: IP54Ambient temperature: -10... +40°C


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IndraDrive HCS04.2E

3.9.12 IndraDrive HCS04.2E-W0350Dimensions

Fig.3-75: IndraDrive HCS04.2E-W0350Power connections

Description Connection Tightening torquePO, PA/+ and PC/- M12 41 NmPA, PB M8 12 NmMains and motor M10 24 NmPE M10 24 Nm

Technical data

IndraDrive HCS04.2E W0350Power dissipation at 100% IN (P1/P2) 2520 W / 3330 WCooling air volume (IP23) 600 m3/hMin. air inlet/outlet (IP23) 7 dm2

Internal power dissipation 260 W / 300 WExternal power dissipation 2460 W / 3280 WCooling air volume (IP54) 145 m3/hMass 74 kg



IndraDrive HCS04.2E


Fig.3-76: Dimensions IndraDrive HCS04.2E-W0420Power connections

Description Connection Tightening torque

PO, PA/+ and PC/- M12 41 Nm

PA, PB M10 24 Nm

Mains and motor M10 24 Nm

PE M10 24 Nm

Technical data

IndraDrive HCS04.2E W0420Power dissipation at 100% IN (P1/P2) 2950 W / 3710 WCooling air volume (IP23) 600 m3/hMin. air inlet/outlet (IP23) 7 dm2

Internal power dissipation 300 W / 360 WExternal power dissipation 2900 W / 3670 WCooling air volume (IP54) 165 m3/hMass 80 kg


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IndraDrive HCS04.2E


Fig.3-77: IndraDrive HCS04.2E-W0520Power connections



BU+, BU- M10 24 Nm

Mains and motor M12 41 Nm

PE M12 41 Nm

Technical data

IndraDrive HCS04.2E -W0520

Power dissipation at 100% IN (P1/P2) 3490 W / 4450 W

Cooling air volume (IP23) 800 m3/h

Min. air inlet/outlet (IP23) 8 dm2

Internal power dissipation 350 W / 430 W

External power dissipation 3460 W / 4450 W


Mass 110 kg



IndraDrive HCS04.2E

3.9.15 IndraDrive HCS04.2E-W0640, -W0790Dimensions

Fig.3-78: Dimensions IndraDrive HCS04.2E-W0640, -W0790Power connections

Description Connection Tightening torquePO, PA/+ and PC/- M12 41 NmBU+, BU- M10 24 NmMains and motor M12 41 NmPE M12 41 Nm

Technical data

IndraDrive HCS04.2E -W0640 -W0790

Power dissipation at 100%IN (P1/P2) 4560 W / 5890 W 5430 W / 7250 W

Cooling air volume (IP23) 1,200 m3/h 1,200 m3/h

Min. air inlet/outlet (IP23) 10 dm2 10 dm2

Internal power dissipation 490 W / 610 W 600 W / 770 W

External power dissipation 4440 W / 5770 W 5290 W / 7100 W

Cooling air volume (IP54) 270 m3/h 330 m3/h

Mass 140 kg 140 kg


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IndraDrive HCS04.2E


Fig.3-79: Dimensions IndraDrive HCS04.2E-W1010Technical data


Power dissipation at 100% IN (P1/P2) 6880 W / 7660 W

Cooling air volume (IP23) 1,800 m3/h



External power dissipation 6680 W / 7470 W


Mass 215 kg



IndraDrive HCS04.2E

Fig.3-80: ConnectionsPower connections



BU+, BU- M12 41 Nm

Mains and motor M12 41 Nm *)

PE M12 41 Nm

*) To improve the access to phase V/T2, observe the informationon page 112


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IndraDrive HCS04.2E




Power dissipation at 100%IN (P1/P2) 8630 W / 11,150 W



Internal power dissipation 930 W / 1,190 W

External power dissipation 8360 W / 10,870 W



IndraDrive HCS04.2E


Mass 225 kg




BU+, BU- M12 41 Nm


PE M12 41 Nm

*) To improve the access to phase V/T2, observe the information on page112


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IndraDrive HCS04.2E




Power dissipation at 100%IN (P1/P2) 10,530 W / 13,830 W




External power dissipation 10,230 W / 13,510 W



IndraDrive HCS04.2E



Mass 300 kg




BU+, BU- M12 41 Nm


PE M12 41 Nm

*) To improve the access to phase V/T2, observe the information on page112

3.9.19 Accessing Phase V/T2To access phase V/T2, remove the lower part of the center bar.Required tool: Torx TX30


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IndraDrive HCS04.2E

Fig.3-85: Accessing Phase V/T2

3.9.20 Braking Unit HLT01.1A -200KDimensions

Fig.3-86: Dimensions Braking Unit HLT01.1A -200KPower connections

Description Connection Tightening torqueHLT01.1A+, HLT01.1A- M10 24 NmPA, PB M10 24 Nm

Technical data

Braking unit HLT01.1A-200K-N-007-NNNN

Power dissipation at 100%IN 550 W

Cooling air volume 100 m3/h

Peak braking power 420 kW



IndraDrive HCS04.2E

Max. continuous brakingpower 200 kW

Possible braking powerdepending on the duty cy‐cle

420 kW for 5 %320 kW for 15 %250 kW for 50%

Cycle time 240 s

Typ. braking power forcrane operation

Min. braking resistance 1.05 Ω

Mass 30 kg

Installing HLT01.1A -200Mount the braking unit at the left hand side of the converter. To do this, proceedas follows:

1. Mount the converter.2. Remove the cover of the converter; when doing this, take the safety rec‐

ommendations described in this manual into account.3. Remove the detachable part A at the left of the converter.


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IndraDrive HCS04.2E

4. Mount the braking unit at the left hand side of the converter. There are 5mounting points (5xM8).



IndraDrive HCS04.2E

5. Connect the bus bar B between the terminals BU- and BU+ of the con‐verter and the terminals BU- and BU+ of the braking unit.

6. Connect the braking resistor to PA and PB.

The bus bar used to connect the braking unit to IndraDriveHCS04.2E (BU+, BU-) is part of the scope of supply.


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IndraDrive HCS04.2E

7. Connect the control cables:● Connect the control cable X20 of the braking unit to the cable X20 of

the converter.● Connect the control cable X92 of the braking unit to the plug-in con‐

nector X20 of the converter.● Disconnect the cable X3 of the converter from the plug-in connector

X3 on the converter circuit board.● Connect the cable X3 of the converter to the cable X3B of the braking

unit.● Connect the cable X3A of the braking unit to the plug-in connector

X3 on the converter circuit board.

8. Mount the housing of HLL01.1A (C) to the wall of the control cabinet.See chapter DC Choke HLL, page 71

9. Remove the detachable part (D) of the DC bus choke housing.10. Mount the cover (E) of the braking unit to the DC bus choke housing.11. Mount the DC choke(s) of the converter. See chapter DC Choke HLL,

page 71



IndraDrive HCS04.2E

3.9.21 Braking Unit HLT01.1A -400KDimensions


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IndraDrive HCS04.2E

Fig.3-87: Dimensions Braking Unit HLT01.1A -400KPower connections

Description Connection Tightening torqueBU+, BU- M12 41 NmPA, PB M12 41 NmPE M12 41 Nm

The bus bars used to connect the braking unit to IndraDriveHCS04.2E (BU+, BU-) are part of the scope of supply. They areprovided for a mounting distance of 110 mm. The maximum dis‐tance is 1 m. The distance between the bars mustn't be greater than10 mm!

Technical data



IndraDrive HCS04.2E

Braking unit HLT01.1A -400

Power dissipation at 100% IN 1,050 W

Cooling air volume 600 m3/h

Peak braking power 750 kW

Max. continuous braking power 400 kW

Possible braking power depending on theduty cycle

750 kW for 5 %550 kW for 15 %440 kW for 50%

Cycle time 240 s

Typ. braking power for crane operation

Min. braking resistance 0.7 Ω

Mass 70 kg

Installing HLT01.1A -400Mount the braking unit at the left hand side of the converter with a distance of110 mm (+/- 5 mm). This distance must be complied with due to the bus barssupplied with the braking unit. If you use your own bus bars (63 x 5 x 1 mm),you can extend the distance up to one meter.

The distance between the bus bars of the power section BU+ andBU- mustn't exceed 10 mm!

1. Mechanically install the converter and the braking unit.2. Remove the cover of the converter; when doing this, comply with the

safety recommendations.3. Remove the detachable part A inside the converter.4. By means of the bus bars B, connect the terminals BU- and BU+ of the

converter to the terminals BU- and BU+ of the braking unit.


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IndraDrive HCS04.2E

5. Connect the control cable and supply cable of the blower:● Connect the control cable X1 coming from the braking unit to the

plug-in connector X1 of the converter.● Connect the supply cable of the blower coming from the braking unit

to the plug-in connector X2 of the converter.



IndraDrive HCS04.2E

Distances to other devices or to the wall


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IndraDrive HCS04.2E

Fig.3-88: HAS07.1-310-NNN-NN

Fig.3-89: HAS07.1-350-NNN-NN



IndraDrive HCS04.2E

Fig.3-90: HAS07.1-330-NNN-NN

Fig.3-91: HAS07.1-430-NNN-NN


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IndraDrive HCS04.2E

Fig.3-92: HAS07.1-585-NNN-NN

Fig.3-93: HAS07.1-660-NNN-NN



IndraDrive HCS04.2E


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IndexSymbols12-pulse circuit.................................................... 2512-pulse rectification..................................... 25, 4112-pulse supply................................................... 25

AAllowed pollution................................................. 19Appropriate use..................................................... 5

Applications .................................................... 5

BBearing currents.................................................. 63Blower: Supply.................................................... 22Braking function.................................................. 48Braking resistor....................................... 48, 65, 81Braking unit....................................... 22, 48, 65, 77Braking unit HLT01.1A........................................ 48Braking unit HLT01.1A -200.............................. 113Braking unit HLT01.1A -400K........................... 118

CCable cross section............................................. 45Cables: Motor cable lengths............................... 62Calculating the braking process.......................... 51CE label.............................................................. 21Choke: DC choke HLL.................................. 65, 71Choke: Mains choke........................................... 24Choke: Mains choke HNL01.1E.................... 65, 74Continuous current at output frequencies < 1Hz........................................................................ 37Continuous current Icont....................................... 19Control cabinet assembly kit............................... 91Control cabinet mounting...................... 36, 91, 100

DDC choke HLL..................................................... 71DC coupling........................................................ 42Derating.............................................................. 36Determining the braking power........................... 55Dimensions......................................................... 31Drive system......................................................... 7Dual Rating......................................................... 28

EElectric drive system............................................. 7EMC interference................................................ 62External blower supply........................................ 96

FFilter: Mains current harmonics filter HF............. 65Filter: Output motor filter HMF01.1N............. 65, 84

FFilter: Radio interference filter HNF01.1B 24,65, 68Flange assembly kit............................................ 88Fuses............................................................ 22, 45

GGeneral notes on connection.............................. 98

IInappropriate use.................................................. 6

Consequences, exclusion of liability .............. 5IndraDrive HCS04.2E-W0350........................... 103IndraDrive HCS04.2E-W0420........................... 104IndraDrive HCS04.2E-W0520........................... 105IndraDrive HCS04.2E-W0640, -W0790............ 106IndraDrive HCS04.2E-W1010........................... 107IndraDrive HCS04.2E-W1240........................... 109IndraDrive HCS04.2E-W1540........................... 111Installation altitude.............................................. 19Installation instructions........................................ 21

MMains: Current harmonics....................... 24, 71, 74Mains: Ungrounded............................................. 22Mains choke HNL01.1E...................................... 74Mains connection voltage................................... 19Mains current harmonics / mains voltage dis‐tortions................................................................ 24Mains input continuous current........................... 19Mains voltage...................................................... 22Maximum current Ipeak 60 s................................. 19Motor: Motor cable lengths................................. 62Motor power........................................................ 19Mounting: Control cabinet................................... 36Mounting: Control cabinet assembly kitHAS08.1 ....................................................... 65, 91Mounting: Control cabinet mounting................... 91Mounting: Flange assembly kit HAS07.1...... 65, 88

NNotes on connection........................................... 98

OOutput motor filter............................................... 84Overvoltages at the motor................................... 62

PPELV................................................................... 11Protective extra-low voltage................................ 11



Index

QQuality................................................................. 21

RRadio interference............................................... 24Radio interference filter................................. 24, 68Reactive-current compensation equipment........ 26Residual-current-operated circuit-breakers......... 95

SSafety instructions for electric drives and con‐trols....................................................................... 7State-of-the-art...................................................... 5

SSwitching rate..................................................... 26System impedance / short-circuit current............ 25

UUngrounded mains.............................................. 22Use

Appropriate use .............................................. 5Inappropriate use ........................................... 6

WWiring diagram.................................................... 38Wiring the power connections........................... 100


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Index

Q

Notes



Bosch Rexroth AGElectric Drives and ControlsP.O. Box 13 5797803 Lohr, GermanyBgm.-Dr.-Nebel-Str. 297816 Lohr, GermanyPhone +49 9352-40-5060Fax +49 [email protected]

Printed in Germany

mailto:[email protected]

http://www.boschrexroth.de

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