Catálogos

Levante Sistemas de
Automatización y Control S.L.

LSA Control S.L. - Bosch Rexroth Sales Partner

Ronda Narciso Monturiol y Estarriol, 7-9
Edificio TecnoParQ Planta 1ª Derecha, Oficina 14
(Parque Tecnológico de Paterna)
46980 Paterna (Valencia)
Telf. (+34) 960 62 43 01
[email protected]
www.lsa-control.com
www.lsa-control.com
www.boschrexroth.es
Distribuidor oficial Bosch Rexroth, Indramat, Bosch y Aventics.
 Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service

Rexroth Diax 04 R911320338

Edition 01
HDD and HDS
Drive Controllers 2nd Generation
Instruction Manual

LSA Control S.L. www.lsa-control.com [email protected] (+34) 960 62 43 01

About this Documentation Rexroth Diax 04 HDD and HDS

Title Rexroth Diax 04

HDD and HDS
Drive Controllers 2nd Generation

Type of Documentation Instruction Manual

Document Typecode DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P

Internal File Reference 120-0800-B343-01/EN

Purpose of Documentation This documentation provides information on the installation and operation
of the described products, by persons trained and qualified to work with
electrical installations.

Record of Revisions Description Release Notes

Date
Instruction Manual 03.2007 1st edition

Copyright  2007 Bosch Rexroth AG

Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).

Validity The specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.

Published by Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 • D-97816 Lohr a. Main
Telephone +49 (0)93 52/40-0 • Tx 68 94 21 • Fax +49 (0)93 52/40-48 85
http://www.boschrexroth.com/
Dept. BRC/EDY4 (NN)

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

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Rexroth Diax 04 HDD and HDS Contents I

Contents
1 Important Notes 1-1
1.1 Safety Instructions ........................................................................................................................ 1-1
General Information................................................................................................................. 1-1
Contact with Electrical Parts.................................................................................................... 1-2
Handling and Assembly........................................................................................................... 1-2
Dangerous Movements ........................................................................................................... 1-2
Magnetic and Electromagnetic Fields ..................................................................................... 1-4
Hot Parts.................................................................................................................................. 1-4
1.2 Appropriate Use............................................................................................................................ 1-4

2 Identification 2-1
2.1 Type Codes .................................................................................................................................. 2-1
HDS ......................................................................................................................................... 2-1
HDD02.2-W0xx-HD32 ............................................................................................................. 2-2
2.2 Type Plates ................................................................................................................................... 2-2
2.3 Scope of Supply............................................................................................................................ 2-3

3 Ratings and Dimensions 3-1

3.1 HDD02.2 and HDS02.2-W040N ................................................................................................... 3-1
3.2 HDS03.2 … HDS05.2 ................................................................................................................... 3-3

4 Reference Documentations 4-1

4.1 Overview ....................................................................................................................................... 4-1

5 Instructions for Use 5-1

5.1 Overcurrent Protection.................................................................................................................. 5-1
5.2 Connections .................................................................................................................................. 5-1
Wiring Diagram (Supply Unit HVE).......................................................................................... 5-1
Wiring Diagram (Supply Unit HVR) ......................................................................................... 5-2
Connection Diagram ................................................................................................................ 5-3
Connection of Control Interfaces and Terminals ..................................................................... 5-6
X1, Connector for integrated bus connections from the neighboring unit ............................... 5-6
X5, DC bus and motor connections......................................................................................... 5-6
X6, Holding brake, motor temperature monitoring ................................................................ 5-10
5.3 Connecting drive controllers to the power supply unit................................................................ 5-12
Arranging the units horizontally ............................................................................................. 5-12
Arranging the units vertically.................................................................................................. 5-13
5.4 Installation................................................................................................................................... 5-15

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II Contents Rexroth Diax 04 HDD and HDS

General Information on How to Install the Drive Controller ................................................... 5-15

Touch Guard at Devices........................................................................................................ 5-16
Sizing of Enclosure and Control Cabinet............................................................................... 5-16

6 Appendix 6-1
6.1 Discharging of DC Bus Capacitors ............................................................................................... 6-1
6.2 Discharging Device....................................................................................................................... 6-2

7 Index 7-1

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Rexroth Diax 04 HDD and HDS Important Notes 1-1

1 Important Notes

1.1 Safety Instructions

General Information
• Do not attempt to install or commission this device without first reading
all documentations provided with the product. Read and understand
these safety instructions and all user documentation prior to working
with the device. If you do not have the user documentation for the
device, contact your responsible Bosch Rexroth sales representative.
Ask for these documents to be sent immediately to the person or
persons responsible for the safe operation of the device.
• If these documentations contain some information you do not
understand, it is absolutely necessary that you ask Bosch Rexroth for
explanation before you start working on or with the devices.
• Only persons who are trained and qualified for the use and operation
of the device may work on this device or within its proximity. The
persons are qualified if they have sufficient knowledge of the
assembly, installation and operation of the equipment as well as an
understanding of all warnings and precautionary measures noted in
this documentation.
• Only trained, instructed and qualified persons are allowed to switch
electrical circuits and devices on and off in accordance with technical
safety regulations, to ground them and to mark them according to the
requirements of safe work practices. These persons must have
adequate safety equipment and be trained in first aid.
• Technical data, connections and operational conditions are specified in
the reference documentations for the product and must be followed at
all times.
• If the products take the form of hardware, then they must remain in
their original state, in other words, no structural changes are permitted.
It is not permitted to decompile software products or alter source
codes.
• Do not mount damaged or faulty products or use them in operation.
• Only use spare parts and accessories approved by Bosch Rexroth.
• Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
• If the device is resold, rented and/or passed on to others in any other
form, these safety instructions must be delivered with the device in the
official language of the user's country.
• Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this device. Observe the data contained
in the corresponding product documentations.

Improper use of these devices, failure to follow the safety instructions in this
document or tampering with the product, including disabling of safety devices, may
result in material damage, bodily harm, electric shock or even death!

WARNING
⇒ Observe the following safety instructions!

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1-2 Important Notes Rexroth Diax 04 HDD and HDS

Contact with Electrical Parts

High electrical voltage! Danger to life, electric shock and severe bodily injury!
• Follow general construction and safety regulations when working on power installations.
• Before switching on the device, the equipment grounding conductor must have been
DANGER non-detachably connected to all electrical equipment and motors in accordance with the
connection diagram.
The equipment grounding conductor of the electrical equipment and the units must be
non-detachably and permanently connected to the power supply unit at all times. The
leakage current is greater than 3.5 mA.
2
Over the total length, use copper wire of a cross section of a minimum of 10 mm for
this equipment grounding connection!
• Before working with electrical parts with voltage potentials higher than 50 V, the device
must be disconnected from the mains voltage or power supply unit. Provide a safeguard
to prevent reconnection.
• Wait 30 minutes after switching off power to allow capacitors to discharge before
beginning to work. Measure the electric voltage on the capacitors before beginning to
work to make sure that the equipment is safe to touch.
• Never touch the electrical connection points of a component while power is turned on.
• Install the covers and guards provided with the equipment properly before switching the
device on. Before switching the equipment on, cover and safeguard live parts safely to
prevent contact with those parts.
• A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives!
Indirect contact must be prevented by other means, for example, by an overcurrent
protective device according to the relevant standards.

Handling and Assembly

Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting!
• Observe the general construction and safety regulations on handling and assembly.
• Use suitable devices for assembly and transport.
CAUTION • Avoid jamming and bruising by appropriate measures.
• Always use suitable tools. Use special tools if specified.
• Use lifting equipment and tools in the correct manner.
• If necessary, use suitable protective equipment (for example safety goggles, safety shoes,
safety gloves).
• Do not stand under hanging loads.
• Immediately clean up any spilled liquids because of the danger of skidding.

Dangerous Movements
Dangerous movements can be caused by faulty control of connected
motors. Some common examples are:
• improper or wrong wiring of cable connections
• incorrect operation of the equipment components
• wrong input of parameters before commissioning
• malfunction of sensors, encoders and monitoring devices
• defective components
• software or firmware errors

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Rexroth Diax 04 HDD and HDS Important Notes 1-3

Dangerous movements can occur immediately after equipment is

switched on or even after an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be sufficient to avoid
faulty operation in the connected drives. Regarding personal safety,
especially the danger of bodily harm and material damage, this alone
cannot be relied upon to ensure complete safety. Until the integrated
monitoring functions become effective, it must be assumed in any case
that faulty drive movements will occur. The extent of faulty drive
movements depends upon the type of control and the state of operation.

Dangerous movements! Danger to life, risk of injury, severe bodily harm or material
damage!
• For the above reasons, ensure personal safety by means of qualified and tested higher-
level monitoring devices or measures integrated in the installation.
DANGER
They have to be provided for by the user according to the specific conditions within the
installation and a hazard and fault analysis. The safety regulations applicable for the
installation have to be taken into consideration. Unintended machine motion or other
malfunction is possible if safety devices are disabled, bypassed or not activated.
To avoid accidents, bodily harm and/or material damage:
• Keep free and clear of the machine’s range of motion and moving parts. Possible
measures to prevent people from accidentally entering the machine’s range of motion:
– use safety fences
– use safety guards
– use protective coverings
– install light curtains or light barriers
• Fences and coverings must be strong enough to resist maximum possible momentum.
• Mount the emergency stop switch in the immediate reach of the operator. Verify that the
emergency stop works before startup. Don’t operate the device if the emergency stop is
not working.
• Isolate the drive power connection by means of an emergency stop circuit or use a safety
related starting lockout to prevent unintentional start.
• Make sure that the drives are brought to a safe standstill before accessing or entering the
danger zone.
• Additionally secure vertical axes against falling or dropping after switching off the motor
power by, for example:
– mechanically securing the vertical axes,
– adding an external braking/ arrester/ clamping mechanism or
– ensuring sufficient equilibration of the vertical axes.
• The standard equipment motor brake or an external brake controlled directly by the drive
controller are not sufficient to guarantee personal safety!
• Disconnect electrical power to the equipment using a master switch and secure the switch
against reconnection for:
– maintenance and repair work
– cleaning of equipment
– long periods of discontinued equipment use
• Prevent the operation of high-frequency, remote control and radio equipment near
electronics circuits and supply leads. If the use of such devices cannot be avoided, verify
the system and the installation for possible malfunctions in all possible positions of normal
use before initial startup. If necessary, perform a special electromagnetic compatibility
(EMC) test on the installation.

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1-4 Important Notes Rexroth Diax 04 HDD and HDS

Magnetic and Electromagnetic Fields

Health hazard for persons with heart pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
• Persons with heart pacemakers and metal implants are not permitted to enter following
areas:
WARNING
– Areas in which electrical equipment and parts are mounted, being operated or
commissioned.
– Areas in which parts of motors with permanent magnets are being stored, repaired or
mounted.
• If it is necessary for somebody with a pacemaker to enter such an area, a doctor must
be consulted prior to doing so. The interference immunity of present or future implanted
heart pacemakers differs greatly, so that no general rules can be given.
• Those with metal implants or metal pieces, as well as with hearing aids must consult a
doctor before they enter the areas described above.
Otherwise health hazards may occur.

Hot Parts

Hot surfaces at motor housings, on drive controllers or chokes! Danger of burns!

• Do not touch surfaces of device housings and chokes in the proximity of heat sources!
Danger of burns!
CAUTION • Do not touch housing surfaces of motors! Danger of burns!
• According to operating conditions, temperatures can be higher than 60 °C (140 °F)
during or after operation.
• Before accessing motors after having switched them off, let them cool down for a
sufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated,
the time required for cooling down is five times the thermal time constant specified in the
Technical Data.
• Wear safety gloves or do not work at hot surfaces.
• For certain applications, the manufacturer of the end product, machine or installation,
according to the respective safety regulations, has to take measures to avoid injuries
caused by burns in the end application. These measures can be, for example: warnings,
guards (shielding or barrier), technical documentation.

1.2 Appropriate Use

This product may only be used for the applications mentioned in the
reference documentations (see chapter “Reference Documentations”)
and under the described application, ambient and operating conditions.

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Rexroth Diax 04 HDD and HDS Identification 2-1

2 Identification

2.1 Type Codes

HDS

Note: The following figures illustrate the basic structure of the type
codes. Your sales representative will help you with the current
status of available versions.

Basic unit Configuration no.

Example H D S 0 2 . 2 - W 0 4 0 N - H S 0 1 - 0 1 - F W

1. Product group
1.1 HDS . . . . . . . .= HDS

2. Line
2 . . . . . . . . . . . . . . . . . . = 02
3 . . . . . . . . . . . . . . . . . . = 03
4 . . . . . . . . . . . . . . . . . . = 04
5 . . . . . . . . . . . . . . . . = 05
3. Version
2.........................=2

4. Cooling
4.1 air, internal (with built-in blower) = W

5. Rated current
40 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 040
75 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 075
100 A . . . . . . . . . . . . . . . . . . . . . . . . . . . = 100
200 A. . . . . . . . . . . . . . . . . . . . . . . . . . . = 200
300 A. . . . . . . . . . . . . . . . . . . . . . . . = 300

6. Other versions
6.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = N

7. Controller family
7.1 DIAX04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = H

8. Command communication
8.1 ANALOG interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . = A
8.2 SERCOS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . = S, T

9. Function id code
Determined and documented by Rexroth.
9.1 e.g.: 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 01

10. Version of function id

Determined and documented by Rexroth.
10.1 e.g.: 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 01

11. Firmware
11.1 Identification that firmware must be ordered as separate subitem
........................................... = FW

TL0208F1.FH7

Fig. 2-1: Type codes HDS

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2-2 Identification Rexroth Diax 04 HDD and HDS

HDD02.2-W0xx-HD32
Basic unit Configuration no.

Example: H D D 0 2 . 2 - W 0 x x N - H D 3 2 - 0 1 - F W

1. Product group
1.1 HDD . . . . . . . = HDD

2. Line
2.1 2 . . . . . . . . . . . . . . . . . . = 02

3. Version
3.1 2 . . . . . . . . . . . . . . . . . . . . . . . . . = 2

4. Cooling
4.1 air, internal (with built-in blower) = W

5. Rated current
5.1 16 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 016
40 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 040

6. Other versions
6.1 none . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = N

7. Controller family
7.1 DIAX04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = H

8. Command communication
8.1 SERCOS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . = D

9. Function id code
Determined and documented by Rexroth
9.1 e.g.: 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 32

10. Version of function id

Determined and documented by Rexroth
10.1 e.g.: 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 01

11. Firmware
11.1 Indicator showing that firmware must be ordered as separate subitem

TL0213F1.FH7

Fig. 2-2 Type codes HDD

2.2 Type Plates

Basic Unit

Fig. 2-3: Type plate

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Rexroth Diax 04 HDD and HDS Identification 2-3

Unit type

Fig. 2-4: Type plate – example

2.3 Scope of Supply

• Drive controller HDx0x.2
(According to the ordering with firmware module and plug-in modules)
• Contact guard
• 2 cables for DC bus connection
• Connectors:
for HDD02.2-W0xxN-HD32:
X3.1, X3.2, X5.1, X5.2, X6.1, X6.2, X12.1, X12.2

for HDS0x.2-W0xxx-RExx:
Type Connector Mounting plate Hose clamp Hose clamp
(Shield (small) (big)
X3 X5 X6 connection
motor cable)
HDS02.2 x x x - x -
HDS03.2 x - x - x x
HDS04.2 x - x - x x
HDS05.2 x - x x x x

• further parts for HDD02.2:

• 2 hose clamps (for mounting shield of motor cable)
• 2 protection caps for interfaces X10/X11
• covers for interfaces X7.1 and X7.2

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2-4 Identification Rexroth Diax 04 HDD and HDS

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Rexroth Diax 04 HDD and HDS Ratings and Dimensions 3-1

3 Ratings and Dimensions

3.1 HDD02.2 and HDS02.2-W040N

HDD02.2- HDD02.2- HDS02.2-
Description Symbol Unit W016N W040N W040N
-HD32 -HD32
listing according UL-standard (UL) UL 508 C
listing according CSA-standard (UL) Canadian National Standard(s) C22.2 No. 14-05
UL files (UL) E 134201
pollution degree (UL) Use in a pollution degree 2 environment
maximum ambient temperature with nominal
Tamax °C 45
data (UL)
maximum ambient temperature with reduced
Tamax_red °C 55
nominal data (UL)
Weight m kg 7 7 6,5
1)
device height (UL) H mm 498
2)
device depth (UL) T mm 308
3)
device width (UL) B mm 50
4)
minimum distance on the top of the device dtop mm 300
minimum distance on the bottom of the device
5) dbot mm 100
6)
rated control voltage input (UL) UN3 V 26 ±2%
rated power consumption control voltage input
without holding brake, without control section PN3 W 45 45 20
at UN3 = DC 24 V (UL)
short circuit current rating, SCCR,
7) ISCCR A rms 42000
symmetrical amperes (UL)
8)
rated input voltage, power (UL) V 530 … 670
9)
maximum input current (UL) IL_cont A 8,7 25 37
10) Use 60/75 °C copper wire only, use class 1 wire
field wiring material (UL)
only or equivalent
maximum output voltage (UL) Uout V 500
output number of phases (UL) 3
maximum output current (UL) Iout_max A 8,5 15 20
maximum output frequency (UL) fout Hz 1000
power dissipation at continuous current Iout_cont 75 110
and continuous DC bus power PDC_cont PDiss_cont W 125
11) per axis per axis
respectively (UL)
1) 2) 3)
housing dimension; see related dimension sheet also
4) 5)
see fig. "Air intake and air outlet of drive controller"
6)
observe supply voltage for motor holding brakes
7)
Suitable for use on a circuit capable of delivering not more than this
SCCR value, 600 V AC or less. The drive series shall be used with
listed AC input line fuses or listed circuit breakers specified in this
documentation.
8)
HDS, HDD, HZB, HZK: DC bus L+, L-; HVE/HVR: mains input U, V, W
9)
at PDC_cont
10)
tightening torque: see project planning manual, electrical terminals
11)
plus dissipation of braking resistor
Abb. 3-1: UL ratings and dimensions

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3-2 Ratings and Dimensions Rexroth Diax 04 HDD and HDS

Distances

A: air intake
B: air outlet
C: mounting surface in control cabinet
dtop: distance top
dbot: distance bottom
Fig. 3-2: Air intake and air outlet at drive controller

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Rexroth Diax 04 HDD and HDS Ratings and Dimensions 3-3

3.2 HDS03.2 … HDS05.2

HDS03.2- HDS03.2- HDS04.2- HDS05.2-
Description Symbol Unit W075N W100N W200N W300N
listing according UL-standard (UL) UL 508 C
listing according CSA-standard (UL) Canadian National Standard(s) C22.2 No. 14-05
UL files (UL) E 134201
pollution degree (UL) Use in a pollution degree 2 environment
maximum ambient temperature with
Tamax °C 45
nominal data (UL)
maximum ambient temperature with
Tamax_red °C 55
reduced nominal data (UL)
Weight m kg 11 11 19 25
1)
device height (UL) H mm 498
2)
device depth (UL) T mm 308
3)
device width (UL) B mm 100 100 150 200
minimum distance on the top of the
4) dtop mm 300
device
minimum distance on the bottom of the
5) dbot mm 100
device
6)
rated control voltage input (UL) UN3 V 26 ±2%
rated power consumption control
voltage input without holding brake,
PN3 W 25 25 30 55
without control section at
UN3 = DC 24 V (UL)
short circuit current rating, SCCR,
7) ISCCR A rms 42000
symmetrical amperes (UL)
8)
rated input voltage, power (UL) V 530 … 670
9)
maximum input current (UL) IL_cont A 37 60 60 140
10) Use 60/75 °C copper wire only, use class 1 wire only or
field wiring material (UL)
equivalent
maximum output voltage (UL) Uout V 500
output number of phases (UL) 3
maximum output current (UL) Iout_max A 40 50 120 175
maximum output frequency (UL) fout Hz 1000
power dissipation at continuous current
Iout_cont and continuous DC bus power PDiss_cont W 220 280 800 1200
11)
PDC_cont respectively (UL)
1) 2) 3)
housing dimension; see related dimension sheet also
4) 5)
see fig. "Air intake and air outlet of drive controller"
6)
observe supply voltage for motor holding brakes
7)
Suitable for use on a circuit capable of delivering not more than this
SCCR value, 600 V AC or less. The drive series shall be used with
listed AC input line fuses or listed circuit breakers specified in this
documentation.
8)
HDS, HDD, HZB, HZK: DC bus L+, L-; HVE/HVR: mains input U, V, W
9)
at PDC_cont
10)
find value for tightening torque in project planning manual, electrical
terminals
11)
plus dissipation of braking resistor
Abb. 3-3: UL ratings and dimensions

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3-4 Ratings and Dimensions Rexroth Diax 04 HDD and HDS

Distances

A: air intake
B: air outlet
C: mounting surface in control cabinet
dtop: distance top
dbot: distance bottom
Fig. 3-4: Air intake and air outlet at drive controller

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Rexroth Diax 04 HDD and HDS Reference Documentations 4-1

4 Reference Documentations

4.1 Overview
Title Type of documentation Document typecode
DIAX04 HVE and HVR 2nd Generation Power Application Manual DOK-POWER*-HVE+HVR**G2-AWxx-EN-P
Supply Units
"List of Connecting Cables for DIAX04 and Selection lists DOK-CONNEC-CABLE*STAND-AUxx-EN-P
ECODRIVE03"
"LWL - Handling" Application Manual DOK-CONNEC-CABLE*LWL-AWxx-EN-P
"Electromagnetic Compatibility (EMC) in Drive Project Planning Manual DOK-GENERL-EMV********-PRxx-EN-P
and Control Systems"
DIAX04 Drive With Electric Gear Function Functional Description DOK-DIAX04-ELS-05VRS**FKB1-EN-P
DIAX04 Drive With Electric Gear Function Troubleshooting Guide DOK-DIAX04-ELS-05VRS**-WAR1-EN-P
DIAX04 Drive With Servo Function Functional Description DOK-DIAX04-SSE-01VRS**FKB1-EN-P
DIAX04 Drive With Servo Function Troubleshooting Guide DOK-DIAX04-SSE-01VRS**-WAR1-EN-P
DIAX04 Drive With Servo Function Functional Description DOK-DIAX04-SSE-02VRS**FKB1-EN-P
DIAX04- Drive With Servo Function Troubleshooting Guide DOK-DIAX04-SSE-02VRS**-WAR1-EN-P
DIAX04 Drive With Servo Function Functional Description DOK-DIAX04-SSE-03VRS**-FK01-EN-P
DIAX04 Drive With Servo Function Troubleshooting Guide DOK-DIAX04-SSE-03VRS**-WA01-EN-P
DIAX04 Drive With Main Spindle Function, Functional Description DOK-DIAX04-SHS-03VRS**-FK01-EN-P
SERCOS interface
DIAX04 Drive With Main Spindle Function, Troubleshooting Guide DOK-DIAX04-SHS-03VRS**-WA01-EN-P
SERCOS interface
DIAX04 Drive With Servo Function, Analog- Functional Description DOK-DIAX04-ASE-02VRS**FKB1-EN-P
and Parallelinterface
DIAX04 Drive With Servo Function, Analog- Troubleshooting Guide DOK-DIAX04-ASE-02VRS**-WAR1-EN-P
and Parallelinterface
DIAX04 Drive With Main Spindle Function, Functional Description DOK-DIAX04-AHS-03VRS**FKB1-EN-P
Analog And Parallelinterface
DIAX04 Drive With Main Spindle Function, Troubleshooting Guide DOK-DIAX04-AHS-03VRS**-WAR1-EN-P
Analog And Parallelinterface
"Digital AC Motors MKD" Project Planning Manual DOK-MOTOR*-MKD********-PRxx-EN-P
"Digital AC Motors MHD" Project Planning Manual DOK-MOTOR*-MHD********-PRxx-EN-P
"MKE Digital AC Motors for potentially Project Planning Manual DOK-MOTOR*-MKE********-PRxx-EN-P
explosive areas"
"2AD AC Motor" Project Planning Manual DOK-MOTOR*-2AD********-PRxx-EN-P
"ADF Main Spindle Motors" Project Planning Manual DOK-MOTOR*-ADF********-PRxx-EN-P
"1MB Frameless Spindle Motor" Project Planning Manual DOK-MOTOR*-1MB********-PRxx-EN-P
"Synchronous MBS Kit Spindle Motors" Project Planning Manual DOK-MOTOR*-MBS********-PRxx-EN-P
LAR 070-132 Housing Linear Motor Selection and Project Planning DOK-MOTOR*-LAR********-AWxx-EN-P
"LAF050 – 121 Linear Motors" Selection and Project Planning DOK-MOTOR*-LAF********-AWxx-EN-P
"Linear Synchronous Direct Drives LSF" Project Planning Manual DOK-MOTOR*-LSF********-PRxx-EN-P
"AC Drive Units in Personnel Conveyor Application Manual DOK-GENERL-ANTR*PERSON-ANxx-EN-P
Systems"
"AC Drive Units in Hazardous Areas (Expl. Application Manual DOK-GENERL-ANTR*EXPLOS-ANxx-EN-P
Protection)"
1) In the document typecodes, "xx" is a wild card for the current edition
of the documentation (example: "PR01" is the first edition of a
Project Planning Manual)
Fig. 4-1: Documentations - Overview

DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P

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4-2 Reference Documentations Rexroth Diax 04 HDD and HDS

DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P

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Rexroth Diax 04 HDD and HDS Instructions for Use 5-1

5 Instructions for Use

5.1 Overcurrent Protection

Branch circuit protection has to be provided externally according to the
maximum values (voltage and current or voltage and percent of FLA of
the fuses [FLA: Full Load Ampacity]).

5.2 Connections

Wiring Diagram (Supply Unit HVE)

shielded control cabinet
compartment or intermediate
mains PE panel

control
cabinet HVE HDS HDS
connecting
clamps

main
switch

distributor
clamps

fuse

mains

to the motors

Filter earth rail

NFD

power connection
load

B01EMV.fh7

Fig. 5-1: Wiring Diagram (Supply Unit HVE)

DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P

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5-2 Instructions for Use Rexroth Diax 04 HDD and HDS

Wiring Diagram (Supply Unit HVR)

mains PE
ground connection

control
cabinet HZF HVR HDS HDS
connecting
clamps

main
switch control voltage
connection

distributor
clamps

fuse

KD

shielded cable power connection

to the motors
earth rail
shielded control cabinet compartment
or intermediate panel

B02EMV.fh7

Fig. 5-2: Wiring Diagram (Supply Unit HVR)

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Rexroth Diax 04 HDD and HDS Instructions for Use 5-3

Connection Diagram
Rexroth Diax 04 (HDS)

X1
drive controller
the following

power voltage
Bus connection

(bus rails)
DC bus
L+

L-
Connection for optional interface modules as per

Command
Software module

U5
U1

communications
module HSM
relevant terminal diagrams

Additional
U2

plugin module

Additional
U3

plugin module
X4
MKD/MKE MHD/MKE
resolver HSF
VT 0,252 7
IDO SDO 8
Additional plugin BU 0,252 4
SDI SDI 15
HDS drive controller
U4

module SCL SCL 7 RD 0,252 2

Feedback connector
(not with HDS02) BK 0,252 3
FS FS 14

AC Motor
R1 UG 12 BN 0,52 12

S2 cos- 10 GY 0,252 8
X3

S4 cos+ 3 PK 0,252 1
1 BN 0,252 5
diagnostics

AK1 S1 sin- 9
outputs
analog

2 S3 sin+ 2 GN 0,252 6
0VM
3 0VM 0VM 4 WH 0,52 10
AK2
9
4 n.c. n.c. 1
0VM
5
6
Bb
7
X6

Bb
8
AS+
7
starting
lockout

9
AS-
10 6
ASQ 0VB
11
ASQ 3
depends on

UB
motor type
PTC/ NTC

2 H
X2

TM-
1 E
1 TM+
0VM
2 5 G
TxD TxD_232 BR-
3
4 F
U

RxD RxD_232
BR+
interface

4
serial

RTS RS485+
Optional
holding
brake

5
CTS RS485-
7 D

10 C
A3

B
M
A1 A2

3
L+

L-

A
XE

XE
X1

.
.
.
.

X5
flat-ribbon cable
bus connection

motor cable
controller or supply

shield for
24VExt
power voltage

0VExt
previous drive

XS1
module

(bus rails)
DC bus
from

24V

AP5151F1.FH7
Fig. 5-3: Total connection diagram HDS

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5-4 Instructions for Use Rexroth Diax 04 HDD and HDS

Rexroth Diax 04 (HDD)

Nt_Data
Nt_CLK
Nt_R0V
Nt_Res

0V-LF
BbV
BbA

13,14,17,18, +UL
0VL
n.c.

15,16,19,20 -UL
Ud

21,22,25,26
23,24,27,28
6,8,10,12

29,30
11
1
2
3
4
5

7
9
the following
controller

X1

power voltage
drive

Bus connection

(bus rails)
DC bus
L+

L-

X7.2
HDD 02.2 -HD32 drive controller
BN 1,02 7
X12.2

external +5V_G2 12
WH 1,02 4
inputs 0VM 10
2
0VM11,13,14,15

Feedback connector 1Vss

Referenzschalter E1 1 REF A-_G2 8 BN 0,252 3
pos. Fahrbereichsgrenzschalter E2 2
FB+ GN 0,252 12
A+_G2 7
neg. Fahrbereichsgrenzschalter E3 3
FB- BK0,252 8
B+_G2 6
Meßtaster 1 E4 4
MT1 RD 0,252 1
B-_G2 5
Meßtaster 2 E5 5
GY 0,252
MT2 R+_G2 4 5
E-Stop E6 6
7
NOT-Aus R-_G2 3 PK 0,252 6
DC +24V extern Uext 10
8 UM_G2 2
DC 0V extern 9
9 GNDext n.c. 1,9
n.c. X4.2

MKD/MKE MHD
VT 0,252 7
SDO 8

Feedback connector HSF, RSF

IDO
SERCOS-Interface Zehnerwert S3.2 HIGH BU 0,252 4
SDI SDI 15
RD 0,252 2
SCL SCL 7
Antriebsadresse Einerwert S2.2 LOW FS FS 14 BK 0,252 3
R1 UG 12,5 BN 0,52 12

AC - Motor 2
S2 cos- 10 GY 0,252 8

S4 cos+ 3 PK 0,252 1
BN 0,252 5
sin- 9
U5.2

Softwaremodul S1
X3.2

HSM S3 sin+ 2 GN 0,252 6

0VM 0VM 4,6,11,13 WH 0,52 10

1
diagnostics

AK1 9
n.c. 1
outputs
analog

0VM
2 n.c.
3
AK2
4
X6.2

PTC / NTC entspr.

0VM
5
7
6
Bb 6
7 0VB
Bb
Motortyp

8 UB 3
AS+
starting
lockout

9 2 H
AS- TM-
10
ASQ TM+ 1 E
axis 2

11
ASQ 5 G
BR-
BR+ 4 F
U
X2.2

X5.2

Optional

1
bremse

0VM D
Halte-

2
TxD TxD_232
interface

3 A
A1
serial

RxD RxD_232
4
M

RTS A_485 A2 B
5
3

CTS B_485 A3 C
7
10
XS1

12
+5V +5V

LWL-Kabel
LWL-Kabel
X10
optischer Sender
axis 1
X11
optischer Empfänger
and
FSMA-Stecker H3, Verzerrungs-LED des SERCOS-Interface axis 2
2,2 Æ IN418 S4-1 Schalter zur Einstellung der Datenrate
6,0 Æ IN426 S4-2/3 Schalter zur Einstellung der Sendeleistung
SERCOS-
interface
Ap5343f1.fh7

Fig. 5-4: Total connection diagram HDD (to be continued)

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Rexroth Diax 04 HDD and HDS Instructions for Use 5-5

Drive controller HDD 02.2 -HD32

X12.1
external
inputs

reference switch
I1 1 REF
I2 2
TL+

X7.1
pos. travel limit switch
neg. travel limit switch
I3 3
TL-
measuring probe 1
I4 4
MP1 BN 1,02 7
I5 5 +5V_G2 12

Feedback connection 2 (1Vpp)

measuring probe 2 MP2 WH 1,02 4
I6 6 0VM 10
E-Stop E-Stop 2
DC +24V external
7 0VM11,13,14,15
8 Uext A-_G2 8 BN 0,252 3
DC 0V external
9 GNDext GN 0,252 12
n.c. A+_G2 7
B+_G2 6 BK0,252 8

B-_G2 5 RD 0,252 1

R+_G2 4 GY 0,252 5
SERCOS interface ten's units S3.1 HIGH R-_G2 3 PK 0,252 6

UM_G2 2 10
drive address units S2.1 LOW 9
n.c. 1,9

X4.1
MKD/MKE MHD
VT 0,252
X3.1

7
IDO SDO 8
BU 0,252 4
SDI SDI 15

Feedback connection 1 HSF,

1
diagnostic

AK1 RD 0,252 2
SCL SCL 7
outputs
analog

2
0VM FS 14 BK 0,252 3
Axis 1

3 FS
AK2 BN 0,52 12
4 R1 UG 12,5
0VM GY 0,252 8
5 S2 cos- 10

AC Motor 1
6 S4 cos+ 3 PK 0,252 1
Bb BN 0,252 5
7 S1 sin- 9
Bb 2
8 S3 sin+ 2 GN 0,25 6
AS+
starting
lockout

9 0VM 0VM 4,6,11,13 WH 0,5 2 10

AS-
9
ASQ
10 n.c. n.c. 1
11
ASQ
X6.1
X2.1

U5.1

Software module 7
PTC / NTC acc.
1
HSM
6
to motor type
0VM 0VB
2
TxD TxD_232 3
interface

3 UB
serial

RxD RxD_232 2 H
4 TM-
RTS A_485
5 1 E
CTS B_485 TM+
7
5 G
10 BR-
4 F
U

12 BR+
13,14,17,18,21,22,25,26
15,16,19,20,23,24,27,28

+5V +5V
optional
holding
X5.1

break

A1 A
6,8,10,12

A2 B
29,30

A3 C
11
1
2
3
4
5

7
9

L+

L-

motor cable
XE

shield for
XE

X1
drive controller or
supply module

XS1
previous

n.c.
BbV
BbA

Nt_R0V

0VL
Ud
Nt_Data

-UL
Nt_Res

Nt_CLK
+UL

0V-LF
from

24VExt
0VExt
power voltage
flat-ribbon cable
bus connection

(bus rails)
DC bus

24V

AP5344F1.FH7

Fig. 5-5: Total connection diagram HDD (continued)

DOK-DIAX04-HDD+HDS*UL*-IB01-EN-P

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5-6 Instructions for Use Rexroth Diax 04 HDD and HDS

Connection of Control Interfaces and Terminals

See project planning manual for more details.

X1, Connector for integrated bus connections from the neighboring unit
Technical data of connector

Connector X1, bus The control electronics of the drive controller receive their power via
connection connector X1. The connection starts at the supply unit and runs to the
drive controller with the help of the flat-ribbon cable integrated into the
units. Maximum length here also equals one meter (if extensions are
used)!

Illustration:

Ap5336f1.FH7

Fig. 5-6: Connector X1

Design
Type No. of pins Design
ribbon cable connector 30 connector at the unit
ribbon cable bushing 30 bushing at the ribbon
cable
Fig. 5-7: Design

Note: This is an internal connection between the supply unit and the
drive controller.

X5, DC bus and motor connections

Technical data of connector

Illustration:
A1 A2 A3

Ap5335f1.FH7

Fig. 5-8: Connector X5 HDD02, HDS02

A1 A2 A3

Ap5337f1.FH7

Fig. 5-9: Connector X5 HDS03, HDS04

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Rexroth Diax 04 HDD and HDS Instructions for Use 5-7

A1 A2 A3

Ap5338f1.FH7

Fig. 5-10: Connector X5 HDS05

Design: Type No. of pins Design

Screw-type terminal 4 socket at the unit
Fig. 5-11: Design

Connection cross section: Cross section Cross section Cross section

single wire multi core wire in AWG
[mm²] [mm²] gauge no.
HDD02, HDS02 0,2-4 0,2-4 24-10
HDS03 2,5-10 4-16 12-4
HDS04 2,5-16 2,5-35 12-2
HDS05 16-50 16-50 6-0
Fig. 5-12: Connection cross section: X5

Tightening torque: DC Bus Motor connection

HDD02, HDS02 3 Nm 0,5 - 0,6 Nm
HDS03 3 Nm 2 Nm
HDS04 3 Nm 4 Nm
HDS05 3 Nm 6 Nm
Fig. 5-13: Tightening torques: X5

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5-8 Instructions for Use Rexroth Diax 04 HDD and HDS

Ground connections to the HDD and HDS drive controllers are equipped with two ground
supply module connections (grounding system) to the supply module:
• back wall of the unit and the mounting rails as well as
• grounding bracket in the front of the unit (see illustration)

To ensure the connection of the devices to the protective conductor

system, connect the neighboring devices to both sides via the grounding
brackets:

Abb. 5-14: Grounding brackets

Lethal electric shock caused by live parts with

more than 50 V!
⇒ Check the continuity of the protective conductors
DANGER from the mains connection to the connected motors.

Motor power cable connection Rexroth motor power cables should be used to connect drive controller
and motor.
The Rexroth motor power cable contains:
• three supply wires for the motor power connection
• a wire for the grounded conductor connection
• a separately shielded pair of wires for the motor temperature monitor
• a separately shielded pair of wires for the motor holding brake
• a complete shield mounted to shield attachment

The motor power cable is available as a ready-made cable from Rexroth.

The cable can also be made of four twisted individual supply wires (3
phases, 1 grounded conductor) with a separately conducted, shielded
supply wire for temperature monitoring and the brake connection.
For supplementary technical data on connections and diameters, see the
relevant motor description.
Line length Maximum cable lengths equals 75 meters if Rexroth cables are used.
DC bus voltage connection Adjacent drive controllers are generally connected via the connection
wires (supplied with the drive).
If a connection with the connection wires should not be possible, then
establish the connection using twisted supply lines that are as short as
possible (maximum length equals one meter, minimum cross section
25 mm²).

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Rexroth Diax 04 HDD and HDS Instructions for Use 5-9

Connector XS1, shield The entire shield of the motor cable is mounted to shield attachment XS1
attachment of motor cable using the enclosed clamp fitting. It is matched to the diameter of the cable
by simply selecting the relevant clamp base on the mounting panel. The
cable output direction can be either horizontal or vertical and is achieved
by adjusting the mounting panel.

Note: Always connect shield of cables with a large metal-to-metal

contact surface to shield connection.

For cable cross-sections greater than 25 mm² you can use a special
mounting plate as shield attachment. The following figures show the
mounting plate at the drive controller. You can mount the mounting plate
horizontally or vertically at the drive controller.

mounting plate

Ap5415f1.fh7

2
Fig. 5-15: Mounting plate for cable cross-sections greater than 25 mm

Fig. 5-16: Vertically arranged mounting plate

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5-10 Instructions for Use Rexroth Diax 04 HDD and HDS

Fig. 5-17: Horizontally arranged mounting plate

X6, Holding brake, motor temperature monitoring

Technical data of connector

Illustration

1 2 3 4 5 6 7

Ap5332f1.FH7

Fig. 5-18: Connector X6

Design Type No. of pins Design

screw-type terminal 7 pins at the unit
Fig. 5-19: Design

Connection cross section Cross section Cross section Cross section

single wire multi core wire in AWG
[mm²] [mm²] gauge no.
0,14 - 1,5 0,14 - 1,5 28 - 16
Fig. 5-20: Connection cross section

Connector X6,holding brake, for

temperature monitor HDS
TM+
BR+

TM-

0VB
BR-

UB

X6
4

A1 A2 A3

XS1
shield for motor 0VExt 24V
cable
24VExt
G
C

H
A

E
F

U AC Motor
M
3
PTC /
holding NTC
brake (depends on motor type)

AP5154F1.FH7

Fig. 5-21: Motor cable, holding brake and temperature monitor connection

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Rexroth Diax 04 HDD and HDS Instructions for Use 5-11

Dangerous movements! Persons at risk by

falling or dropping axles!
⇒ The standard motor holding brake as delivered, or
DANGER any external motor holding brake activated by the
drive controller by itself does not provide adequate
personal protection!
⇒ Personal protection must be ensured by primary
failsafe measures:
The dangerous zone must be blocked off by a safety
fence or safety grates.
After the motor is switched off, vertical axes must be
additionally protected from falling or dropping, e.g.
as follows:
- by mechanically locking the vertical axis,
- by an external braking, catching or clamping unit,
- by adequately counterbalancing the weight of the
load.

If a motor holding brake is used, then it is necessary to

connect an external 24 V three-phase voltage source.
The 0 Vext ( = 0 VB ) must be galvanically connected with
the reference potential or housing of the drive controllers!
Warning
Maximum permissible brake current: 2 A
If the brake currents exceed this value, the motor holding
brake must be actuated via an external switching device.
When you use an external switching device the control of
the holding brake must not be done by the drive controller
directly.
Current consumption of the holding brake is listed in the Project Planning
Manual of AC motors.
The AC motor holding brake is not a dynamic brake. It wears down after
about 20,000 motor revolutions against the closed brake disc.

Note: To release a holding brake in the MHD/MKD servo motors, an

external +24 V DC / +10 % must be supplied to the drive. The
voltage to release the brake is applied to X6/3 (+24 V) and
X6/6 (0 V). It must be ensured that the brake will release even
if longer motor power cables are used (voltage drop with long
motor power cables can be compensated by increasing supply
voltage (up to DC +26.5 V) and/or with a regulated voltage
supply at X6/3 and X6/6).

Control of the motor holding The drive controller controls the holding brake. When you use an external
brake switching device the control of the holding brake must not be done by the
drive controller directly.

Motor temperature monitoring (TM+, TM)

Connections TM+ and TM- are used to evaluate the temperature of
connected Rexroth motors. These are equipped with a temperature-
dependent resistor (either PTC or NTC dependent on the motor type) to
monitor temperature. The connection leads are in the motor power cable.

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5-12 Instructions for Use Rexroth Diax 04 HDD and HDS

Connection device-external device-internal

monitoring
X6
TM+, TM-:
1 TM+
motor temperature monitoring 2
TM-
3
4

5
6
7
8

AP5297F1.FH7

Fig. 5-22: Motor temperature monitoring

Motor temperature evaluation: Drive Controller MOTOR

G U TM+

TM-

AP5326F1.FH7
Schematics
U: approximately 5 V
R: approximately 2 k
Fig. 5-23: Motor temperature evaluation

Note: Connections TM+ and TM- are only to be used with Rexroth
motors.

⇒ See also firmware functional description: "Temperature monitoring".

5.3 Connecting drive controllers to the power supply unit

Note: For the connection of the drive and control system to the
power supply unit it is necessary to distinguish between the
arrangement of the units one below the other and one above
the other.

Arranging the units horizontally

Power connection If the units in the control cabinet are arranged horizontally, use the copper
strands and PE bridges, included in the delivery scope, for the power
connection of the drive and control systems.
Connection to the control Use the flat cable for the connection to the control voltage bus (terminal
voltage supply X1). One side of the flat cable is firmly connected to the unit on one side.
Plug the connector of the free end onto terminal X1 of the next unit.

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Rexroth Diax 04 HDD and HDS Instructions for Use 5-13

If the units are not arranged directly horizontally, you will need a longer
cable for the connection of the X1 terminals:

Cable Length Item / Material number

INB648/0250 250 mm 292 519
INB648/0800 800 mm 282 398
INB648/1000 1000 mm 288 731
Fig. 5-24: Cable

Arranging the units vertically

Note: With a combined unit arrangement, it is absolutely necessary

that between the two rows of drive units a baffle is mounted, in
order to prevent the blowers of the upper row from sucking in
the warm air of the bottom row.

Property damages due to overheated units!

⇒ Mount a baffle between the two unit rows. Otherwise
the performance data of the units can decrease and
the units can be damaged with undiminished
CAUTION
performance requirement.

Mains connection If the units in the control cabinet are arranged vertically, you need to use
twisted single conductors for the power connection of the drive and
control systems (terminal L+, L-) instead of the supplied copper strands.
The single conductors for the power connection of the drive and control
systems may have a maximum length (twisted) of 1 m (Material number
of cable: 291 268; Length: 1,2 m).
The ground connections of units (unit rows) that are vertically arranged
must be connected by a separate cord. The minimum cross section for
2
this cord is 10 mm .
Connection to the control The control voltage bus must be connected with the designed Rexroth
voltage bus cable (designation: INB0647). Lay the shield of this cable to the unit
grounding bolt (terminal X12) on the supply module.
The cable lengths listed below are available:

Cable length [m] Item / Material number

0,8 282 300
1,0 287 677
Fig. 5-25: Shielded flat cable for the control voltage bus

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5-14 Instructions for Use Rexroth Diax 04 HDD and HDS

GLD (only with HVE)

1
2
twisted
max. 1 m
6

100 mm
4 5 300 mm

7 3

Line cross HVR02.2- HVR02.2- HVR03.2- HVE02.2-

Gewicht HVE03.2- HVE04.2-
section W010N W025N W045N W018N W030N W075N
1 --- --- --- 10
12 mm
2 16 mm2 50 mm2
2 10 mm2 10 mm2 16 mm2 10 mm2 16 mm2 25 mm2
3 10 mm2 10 mm2 16 mm2 10 mm2 16 mm 2 35 mm2

V04hva1b.fh7

3 Lêngth: 1,2 m; designation: INB730/1200

4 Minimum clearance 0,1m
5 Baffle. Prevents the blowers of the upper row from sucking in the warm air of the bottom row.
6 Flat cable designated INB648. This cable will be necessary, if units are not arranged directly next to
each other.
7 Flat cable designated INB647. This cable will be necessary, if units are arranged one below the other
or vertically.

Fig. 5-26: Connecting the drive controller

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Rexroth Diax 04 HDD and HDS Instructions for Use 5-15

5.4 Installation

General Information on How to Install the Drive Controller

Damage can be caused to the drive controller or circuit boards if
electrostatic charging present in people and/or tools is discharged across
them. Therefore, please note the following information:

Electrostatic charges can cause damage to

electronic components and interfere with their
operational safety!
CAUTION ⇒ Exposed conductive parts coming into contact with
components and circuit boards must be discharged
by means of grounding. Otherwise errors may occur
when triggering motors and moving elements.

Such exposed conductive parts include:

• the copper bit when soldering
• the human body (ground connection caused by touching a conductive,
grounded item)
• parts and tools (place them on a conductive support)

Endangered components may only be stored or dispatched in conductive

packaging.

Note: Rexroth connection diagrams are only to be used for

producing installation connection diagrams. The machine
manufacturer’s installation connection diagrams must be used
for wiring the installation!

• Lay signal lines separately from the load resistance lines because of
the occurrence of interference.
• Transmit analog signals (e.g. command values, actual values) via
shielded lines.
• Do not connect mains, DC bus or power leads to low voltages or allow
them to come into contact with these.
• When carrying out a high voltage test or an applied-overvoltage
withstand test on the machine’s electrical equipment, disconnect all
connections to the devices. This protects the electronic components
(allowed in accordance with EN 60204-1). During their routine testing,
Rexroth drive components are tested for high voltage and insulation in
accordance with EN 50178.

Risk of damage to the drive controller by

connecting and disconnecting live connections!
⇒ Do not connect and disconnect live connections.
CAUTION

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5-16 Instructions for Use Rexroth Diax 04 HDD and HDS

Touch Guard at Devices

Lethal electric shock caused by live parts with

more than 50 V!
• The appropriate touch guard must be mounted for
WARNING each device following connection work.
• Never mount a damaged touch guard.
• Immediately replace a damaged touch guard by an
undamaged touch guard.
• Keep the cutouts at the touch guard as small as
possible. Only remove the cutouts if necessary.

Abb. 5-27: Supply unit (left) and drive controllers with touch guards

Sizing of Enclosure and Control Cabinet

Control Cabinet with Multiple-Line Structure

Note: Particular attention should be paid to the maximum allowed air

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

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Rexroth Diax 04 HDD and HDS Instructions for Use 5-17

conveying direction of heated air

in flow-off area
outlet air to
cooling unit

intake area of cooling air for

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

intake area of cooling air for supply air

lower device line from cooling
unit

Fig. 5-28: Example of arrangement for multiple-line structure with components

Arrangement of Cooling Units

Possible damage to the drive controller
Operational safety of the machine endangered!
Note the following instructions!

CAUTION

Avoiding Dripping or Sprayed Due to the operating principle, condensation water is formed when cooling
Water units are used. For this reason, please observe the following information:
• Always position cooling units in such a way that condensation water
cannot drip onto electronic equipment in the control cabinet.
• Position the cooling unit in such a way that the blower of the cooling
unit does not spray accumulated condensation water onto electronic
equipment.

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5-18 Instructions for Use Rexroth Diax 04 HDD and HDS

correct incorrect

Cooling system Cooling system

warm cold warm cold

Air duct

electronic electronic
equipment equipment

Cabinet Cabinet
Eb0001f1.fh7

Fig. 5-29: Arranging the cooling unit on the control cabinet

correct incorrect

control cabinet control cabinet

air inflow air inflow

air air outflow

duct
cooling cooling
unit unit

electronic electronic
equip. equip.

Eb0002f1.fh7

Fig. 5-30: Arranging the cooling unit at the front of the control cabinet

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

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Rexroth Diax 04 HDD and HDS Appendix 6-1

6 Appendix

6.1 Discharging of DC Bus Capacitors

In the drive system capacitors are used in the DC bus as energy stores.
In the drive controllers and particularly in the supply units such capacitors
have already been integrated.
Energy stores maintain their energy even when energy supply has been
cut off and have to be discharged before somebody gets in contact with
them.
Discharging devices have been integrated in the components of the drive
system; within the indicated discharging time these devices discharge the
voltage below the allowed 50 V.
If additional capacitances in the form of
• DC bus capacitor units or
• additional capacitors
are connected, make sure that these capacitors, too, are discharged
before somebody gets in contact with them.

Due to the operating principle, the discharging time is the longer

• the bigger the energy store (the capacitance value)
• the higher the voltage to which the energy store has been charged
• the greater the resistance for discharging the capacitors.
Components of the drive system have been dimensioned in such a way
that after the energy supply was cut off the voltage value falls below 50 V
within a discharging time of a maximum of 30 minutes.

Lethal electric shock caused by live parts with

more than 50 V!
⇒ Wait at least 30 minutes after switching off power to
allow discharging.
⇒
WARNING
Check whether voltage has fallen below 50 V before
touching live parts!

To shorten the waiting time until voltage has fallen below 50 V you can
take the following measures:
• Activate the function "ZKS" (DC bus short circuit)

Lethal electric shock caused by live parts with

more than 50 V!
⇒ Before touching live parts check whether the voltage
WARNING has fallen below 50 V!

• Use the discharging device described below.

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6-2 Appendix Rexroth Diax 04 HDD and HDS

6.2 Discharging Device

Lethal electric shock caused by live parts with

more than 50 V!
⇒ Before touching live parts check in any case whether
WARNING the voltage between the DC bus terminals L+ and L-
has fallen below 50 V!

Operating Principle A contactor is installed to switch a resistor to the terminals L+ and L- of

the DC bus connection to discharge the capacitors. The contactor is
activated via a control input which is supplied with appropriate control
voltage.

R: discharging resistor
K: contactor contact
Fig. 6-1: Operating principle of discharging device

Dimensioning The individual components have to be sufficiently dimensioned:

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

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Rexroth Diax 04 HDD and HDS Index 7-1

7 Index

A
Appendix 6-1

B
Bus connection 5-6

C
Complete shield 5-8
Connection cross section
X5 5-7
X6 5-10
Connector for integrated bus connections from the neighboring unit 5-6
Connector X1 5-6
Connector X5 5-6
control cabinet
with multiple-line structure 5-16
cooling units 5-17

D
DC Bus 5-7
DC bus capacitors
discharging 6-1
DC bus voltage 5-8
Dimensions 3-1
Discharging
DC bus capacitors 6-1
Documentations
Overview 4-1
dripping or sprayed water 5-17

G
Ground connections 5-8
Grounded conductor connection 5-8
Grounding brackets 5-8

H
Holding brake 5-10
Holding brake control 5-11

I
Intermediate circuit, motor, and power connections 5-8

L
Line lengths 5-8

M
moisture condensation 5-18
Motor cable 5-10
Motor connection 5-7
Motor holding brake 5-8
Motor power cable 5-8
Motor power cable connection 5-8
Motor temperature monitor 5-8
Motor temperature monitoring (TM+, TM) 5-11

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7-2 Index Rexroth Diax 04 HDD and HDS

R
Ratings 3-1
Reference documentations 4-1

T
Technical data of connector 5-6, 5-10
Technical data of connector X5 5-8
Temperature monitor 5-10
Tightening torques
X5 5-7
TM+, TM- 5-12
Total connection diagram (HDS) 5-3
Type codes HDD HDD02.2-W0xx-HD32 2-2
Type codes HDS 2-1
Type plates 2-2

X
X6 Holding brake, motor temperature monitoring 5-10

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 Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 (0)93 52-40-50 60
Fax +49 (0)93 52-40-49 41
[email protected]
www.boschrexroth.com

Printed in Germany

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