IndustrialHydraulicsElectric Drivesand ControlsLinear Motion andAssembly Technologies PneumaticsServiceAutomationMobileHydraulicsRexroth IndraDrive Evolution in drive technologyMore complete, more intelligent, greater safety71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 12Rexroth IndraDrive More complete, more intelligent, greater safetyYou are probably wonder-ing, how can somethingbe more complete thancomplete? Fact is, ourIndraDrive sets new stan-dards in drive engineeringthat are best described bythe apparent contradictionin terms: It offers greatersafety, more intelligentfunctionality, and it reallydoes come more com-plete with software andhardware than any otherprevious drive system.No matter which industry you callyour own, the IndraDrive will pro-vide you with a complete, intelli-gent and above all, future-proofsolution to your automation tasks.The IndraDrive system, featuring aflexible combination of compactconverters or modular invertersand Rexroth high-speed IndraDynmotors, is designed for use inintelligent single-axis or complexmulti-axis applications.IndraDrive offers a wide range ofadvantages including:Safety on Board conforming to EN 954-1, category 3, for "SafeStandstill" and "Safe Motion" a wide power range from 1 kWto 110 kWopenness for international interfacesintegrated motion control and IEC 61131-3 PLChighest performance and preci-sionscalable power and functionalityfast initial startup power regeneration and directconnection to mains supply from380 V to 480 Vintegrated mains contactor andbraking resistor-Rexroth IndraDrive is an innovative servodrive and frequency converter solutionbased on a common platform. It is partof Rexroth's advanced modular system,which offers integrated safety function-ality and an IEC 61131-3 compliant PLC.This unique modular system designgives users everything they need to suc-cessfully complete their automation pro-jects: drives, controllers, a powerful engi-neering framework and user-friendlyoperation. The systems are intelligentand well engineered, making them asafe investment into the future.71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 23Safety on BoardSafety technology, compliant withEN 954-1, category 3, ensures thatpeople are protected - even frommoving axes. Unlike conventionalsafety concepts, this technologyworks without power contactors inthe mains or motor supply lines andwithout additional speed sensors.Integrated motion control with IEC61131-3 compliant PLCThe IndraDrive can be equiped witha drive-integrated, open motion con-trol with IEC 61131-3 PLC. Thismakes it easier to implement customerknow-how, and the costs of higher-level control systems and personneltraining courses can be avoided.Integrated technology functionsTechnology functions can be para-meterized on the basis of the drivePLC to perform the most diverseprocess-oriented tasks. The userdoes not need any programmingability whatsoever to implementthese functions.Open interfacesInternationally recognized inter-faces are available for communica-tingwith higher-level machinecontrol systems: SERCOSinterface,PROFIBUS-DP, CANopen,DeviceNet, analog and parallel.Quick and easy startupDriveTop startup software guidesyou through the entire startup process - quickly and reliably.A unique platformWe have developed two versions ofIndraDrive in order to better meetyour individual requirements:as a compact converter system for power ratings up to 110 kWas a modular inverter system for up to 75 kWParticulary economical drivesystems can be assembled by equip-ping either version of IndraDrivewith one of the common controlunits.A complete range of motorsThe newly developed generation ofIndraDyn motors meets all require-ments in modern factory automa-tion through a combination ofmodel diversity and unique perfor-mance:compact and powerful synchronous and asynchronous servo motorsservo motors for potentially explosive areas conforming to ATEX and UL/CSAlinear and torque motors for innovative direct drive conceptssynchronous and asynchronous motors for high-speed applica-tions, e.g. motor spindlesConvincing in performance and functionality71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 34Converters from 1.5 kWto 11 kW the mostcompact in their class,ideal for single-axisapplicationsIndraDrive is based on a uni-form hardware platform thatsets new standards with its unique continuity, flexibilityand future adaptability.All control components fromthe simple frequency converterto the high-end servo drive withintegrated motion control canbe installed into all IndraDrive Cconverters and IndraDrive Minverters.A further example of continuity and flexibility: Indradrive Cconverters can be combinedwith IndraDrive M inverters tocreate extremely compact andeconomical drive solutions.Standardized for all applicationsPower units Control unitsModular inverters upto 75 kW ideal formultiple-axis appli-cationsConverters from 15 kWto 110 kW can becombined with modularinverters to create eco-nomical and compactdrive solutionsControl units are available in differentversions:Basicoffers sufficient performance andfunctionality for standard applications Advancedfor applications requiring the highestperformance and interface flexibility71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 45The basic packages come equippedwith all essential functionalities forstandard applications, such aspositioning block mode, positioncontrol, and speed and torque con-trol.Extension packages are also availa-ble, e.g. for electronic axis synchro-nization, cam switches, error com-pensation, main spindle functionsor motion control with IEC 61131-3 PLC.Complex process functions areimplemented by means of applica-tion-oriented technology packages.Programming is easy and requiresno special programming knowl-edgeThe technology packages can alsobe used within the freely pro-grammable PLC.Scalable for your individual applicationMain spindle functionADVANCEDServo function enhancementADVANCEDClosed looppackagesMotion control with IEC 61131-3 PLCOpen looppackagesServo function enhancementBASICSynchronizationOpen loopMain spindle function BASICSynchronizationBASICSynchronizationADVANCEDProcess-orientedtechnology packages71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 5From now on, you can use a single,standardized engineering frame-work to handle all of your motionand control tasks. RexrothIndraWorks, an intuitive engineer-ing environment designed for allRexroth drive and control systems,is based on Microsoft.NET technol-ogy. This advanced system bringstogether all of the tools you needfor design planning, parameteriza-tion, diagnostics and commission-ing and implements them on afull-featured user interface. Youhave access to the complete IEC61131-3 language and function set.You can use the library of functionmodules for quick, transparentintegration of drive functions intoyour PLC programs across all plat-forms.The benefits to you:integrated framework for designplanning, parameterization, pro-gramming and diagnosticsintelligent user interfaceintuitive and user-friendly handlingstandardized IEC 61131-3 compliant PLC programmingPLCopen-compliant module libraryopen architecture based onintegrated FDT/DTM interface6Rexroth IndraWorks a framework designed to handle all of your engineering tasksRexroth IndraWorks a full-featured software package for designing, programming,parameterizing, operating and monitoring.71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 67With IndraDrivefrom Rexroth,the pioneer of drive-integratedsafety technology, you are onthe safe side. We have integrateddiverse safety functions directlyinto the drive without goingthrough a control system.Reliability is thus increased,while monitoring componentsand wiring are reduced.Convincing advantagesExploit these advantages anduse the integrated safety func-tions of our drives to provideeffective protection for man andmachine: high reliability thanks tocertified integrated safety functions ultra-fast response times(< 2 ms) for the addressing of the internal monitors elimination of additional measuring systems or sensors any type of higher level con-trols can be used Online dynamically-changinginputs and shutdown paths while work is in progress non-time-critical selection ofsafety functions, e.g. by the PLC PROFIsafe interface with less configuration and installation elimination of certification work by the customer shorter commissioning times and faster fault correctionMaximum safety and highestdrive dynamicsRedundant software and hard-ware components in the drivemake it all possible. The non-contact monitoring of all setlimit values enables very shortresponse times of less than 2 ms.Once a fault is detected, all thedrives are automatically stopped depending on which stopcategory is selected (0, 1 or 2) and immediate two-channeldisconnection from mains.Safety category 3 alreadycertified in the driveSince we first introduced driveswith Safety on Board technol-ogy to the market back in 1999,we have been regarded as thepioneers in this field.The results of our ongoing devel-opment work are safety functionsthat are convincingly imple-mented and certified as complyingwith EN 954-1, category 3:Safe Standstill Safe Operational StopDrive InterlockSafely Reduced Velocity Safely Reduced Maximum VelocitySafely Limited Increment Safely Limited Absolute Position Safe Direction of Movement Safely Monitored Stopping Process Safe Control of Protective DoorIn the time it takes anoperator in a protect-ed area with conven-tional safety function-ality to respond to anerror, a linear axis witha ball screw spindlewill have alreadycovered a distance of100 to 200 mm, and alinear motor a distanceof 400 to 800 mm.IndraDrive safetytechnology detectsthe error within 2 msand the axis moves adistance of no morethan 2 mm.Stay on the safe sideAxis movement in mmIndraDrive safety system from RexrothConventional safety system2800Safety increased 400-fold71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 7BASIC or ADVANCEDAlways optimum performance and functionality8General basic functionsmotor control with U/f curve,incl. slip compensation and stall protection electronic nameplateautomatic control circuit adjustmentsetpoint generator for control loop optimizationbrake control oscilloscope functionOpen loop basic functionsRPM ramp encoder motorized potentiometer function power failure trap and restart function positioning by limit switchesClosed loop basic functionsposition, speed and torque controldrive-controlled positioningdrive-integrated interpolationpositioning block modeposition, current and torque limitationmoving to fixed stopautomatic commutation adjustmentpath switching point with ONand OFF switching thresholdBasic packagesServo function enhancementeasy backlash compensation axis error correction quadrant error correction frictional torque compensation touch probe with fast stop 1 2Main spindle functionsparameter set changeover field-oriented control vector control, without encoder up to 2000 Hz spindle positioning mode drive-controlled swiveling for gear change Synchronizationspeed synchronization angle synchronization measuring wheel mode real and virtual leading axis cam plate (tabular value) cam plate ( analytical value) touch probe with time measurement 1 1 touch probe with synchronization function 1 2dynamic cam group Extension packagesSingle axis motion controlfreely programmable in compliance with IEC 61131-3 IL, LD, ST, SFC, CFC programming4 user tasks: periodic, unsolicited or event-controlledlibraries: system-specific, drive-specific, PLCopensupport of customer librariesprocess-oriented technology packagesDrive PLCBASIC ADVANCEDOpen Loop Closed Loop Open Loop Closed Loop71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 89IndraDrive control units are scalable in performance and configuration.Thanks to this flexibility, it is possi-ble to select the best suited andmost economical version for eachapplication:Advanced control units offer thehighest performance and can beequipped with the most diversecontrol, communication and enco-der interfaces as well as additionaloptions for safety technology.Digital and analog inputs and out-puts are already permanently inte-grated along with a relay output for communication with higher-level control systems. Advancedcontrol units have a level of perfor-mance to satisfy even the highestrequirements imposed on controlquality.Basic control units are the econom-ical solution for standard applica-tions. Basic control units with fixedconfigurations can be used forapplications with low requirementson interface flexibility. They areavailable with SERCOSinterface,PROFIBUSand analog interfaces,as well as with an encoder interfacefor IndraDyn Smotors.Configurable basic control compo-nents in single-axis as well as dou-ble-axis versions are also availablefor standard applications requiringadditional option modules.All control units are equipped witha standard display.A graphics-capable display is alsoavailable as an option. The confi-gurable control units can be equip-ped with a MultiMediaCard (MMC)for changing devices without a PCor for use as extended programmemory for the integrated PLC.Standard featuresOptionSingle-axis Double-axis Single-axisBASIC BASIC ADVANCEDConfiguration optionscommand communication option slot 1 fixed configuration/ option slot 2 / option slot 3 option safety starting lockout/ option display Control communication interfacesfrequency converter analog/digital analog interface option moduleparallel interface PROFIBUS-DP SERCOS interface CANopen DeviceNet Ethernet coming soon coming soon coming soonMulti-function encoder interfacesIndraDyn motors incl. Hiperface MHD, MKD and MKE motors EnDat 2.1 incl. 1 Vssand 5 V TTL EnDat 2.2 coming soon coming soon coming soonSafety options compliant with EN 954-1drive lock protection from unintended restarting safety technologyin compliance with safety category 3 Additional optionsanalog I/O extension encoder emulation digital I/O extension cross communication coming soon coming soon coming soonSoftware moduleMMC (MultiMediaCard) Control panelstandard (one line, four buttons) comfort (four lines, graphic, four buttons) 71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 9IndraDrive C Compact convertersParticularly economical solutionsfor both single-axis and multi-axisapplications with up to 11 kWrated motor power are possibleusing this series of space-savingconverters. These compact drivesfeature an integrated power supply,braking resistor, link circuit capaci-tors and axis inverters. The linkcircuit connection permits energycompensation for multi-axis appli-cations. Installation in compact300-mm control cabinets is possible.10HT BIndraDrive C HCS02.1E-W0012 HCS02.1E-W0028 HCS02.1E-W0054 HCS02.1E-W0070Continuous currentMaximum currentAA4.511.5112821542871Typical rated motor powerwithout/with chokekW 1.5/1.5 4/4 5.5/7.5 7/11Connection voltageof power unit3 x 200 500 V AC ( 10 %)50 60 Hz ( 2 Hz)1 x 200 250 V AC ( 10 %)50 60 Hz ( 2 Hz)Connection voltageof control unit24 V DC 20 % or autonomous voltage supply from the link circuitOutput frequency Hz 0 1600 Braking resistorContinuous braking powerMaximum braking power kWkWinternal0.054internal0.1510internal/external0.35/3.818internal/external0.5/5.525Width x Height x Depth mm 65 x 290 x 265 65 x 352 x 265 105 x 352 x 265 105 x 352 x 26571 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 1011These compact converters cover theentire range from 15 kW to 110 kWrated motor power and are ideal for400-mm control cabinets. They areavailable with braking transistor,braking resistor and line filter optimally scaled for your driveapplication. And together withIndraDrive M inverters they provideyou with a particularly economicaland compact drive system for multi-axis operations.IndraDrive C Converters with highest power ratingsHT BIndraDrive C HCS03.1E-W0070 HCS03.1E-W0100 HCS03.1E-W0150 HCS03.1E-W0210 HCS03.1E-W0350Rated currentMaximum currentAA45707310095150145210210350Typical rated motor powerwith chokekW 18 30 45 75 110Connection voltage of power unit3 x 200 V 500 V AC ( 10 %) 50 60 Hz ( 2 Hz)Connection voltageof control unit24 V DC ( 20 %) or autonomous voltage supply from the link circuitOutput frequenz Hz 0 1600 Braking resistorContinous braking powerMaximum braking power kWkW18930131544723743.5381101.955180Width x Height x Depth mm 125 x 440 x 315 225 x 440 x 315 225 x 440 x 315 350 x 440 x 315 coming soon71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 11IndraDrive M Modular inverters12B THParticularly economical multi-axissolutions with up to 75 kW can beimplemented with the slimline sin-gle-axis devices (HMS) and dou-ble-axis devices (HMD) of theIndraDrive M inverter system. Thedevices are optimized for highmaximum currents from 20 A to210 A and ensure that your machin-ing processes perform with maxi-mum dynamics. Supply units withpower regeneration are also availa-ble.IndraDrive M HMD01.1N-W0012 HMD01.1N-W0020 HMD01.1N-W0036Rated currentMaximum currentAA71210202036Connection voltage250 V 780 V DCOutput frequency Hz 0 800 Width x Height x Depth mm 50 x 440 x 309 50 x 440 x 309 75 x 440 x 309IndraDrive M HMS01.1N-W0020 HMS01.1N-W0036 HMS01.1N-W0054 HMS01.1N-W0070 HMS01.1N-W0150 HMS01.1N-W0210Rated currentMaximum currentAA12.12021.336355442.470100150150210Connection voltage250 V 780 V DCOutput frequency Hz 0 1600 Width x Height x Depth mm 50 x 440 x 309 50 x 440 x 309 75 x 440 x 309 100 x 440 x 309 150 x 440 x 309 200 x 440 x 30971 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 12BHTIndraDrive M Modular power supply units13With the IndraDrive M inverters,you have a choice of power supplyunits that are available with orwithout line regeneration depend-ing on the power and applicationrequirements. Wiring in the con-trol cabinet is minimized by inte-grated components such as mainscontactors and braking resistors,and by direct connection to amains voltage from 380 V to 480 V.Optional line filters suppress con-ducted interference, even withoutan additional transformer.IndraDrive M Power supply without regeneration Power supply with regenerationHMV01.1E-W0030 HMV01.1E-W0075 HMV01.1E-W0120 HMV01.1R-W0018 HMV01.1R-W0045 HMV01.1R-W0065Link circuit power with chokeLink circuit power without chokeMaximum link circuit powerkWkWkW30184575451121207218018454511265162Connection voltage 3 x 400 V 480 V AC(-15% 10%)50 60 Hz ( 2 Hz)Control voltage external 24 V DCMains contactor integrated Braking resistor integrated Continous braking powerMaximum braking powerEnergy consumptionkWkWkWs1.5361002902502.51305000.436800.4901000.4130150Width x Height x Depth mm 150 x 440 x 309 250 x 440 x 309 350 x 440 x 309 175 x 440 x 309 250 x 440 x 309 350 x 440 x 30971 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 13Rexroth IndraDyn an unparalleled range of motorsIndraDyn S Servo motors designed to meetall of your requirements MSK synchronous servo motorswith torque ratings up to 260 Nm up to 9,000 RPM natural convection, fan cooled orliquid cooled Hiperface and EnDat encodersystems, single-turn and multi-turn versions absolute encoder (optional) holding brake (optional)14IndraDyn S Servo motors designed for potentially explosive zones MKE synchronous servo motors with torque ratings up to 48 Nm up to 9,000 RPM natural convection cooling resolver with memory for storingmotor parameter data Hiperface and EnDat encodersystems, single-turn and multi-turn versions holding brake (optional) ATEX-compliant version UL-/CSA version (optional)IndraDyn A Servo motors designed to deliverhigh performance MAD and MAF asynchronousservo motors with power ratingsup to 100 kW fan cooled or liquid cooled Hiperface and EnDat encodersystems, single-turn and multi-turn versions incremental encoder (optional) holding brake (optional)Rexroth's complete range of motors offers impressive performance and a uniquevariety of designs versions and performance. When used in combination with RexrothIndraDrive, these synchronous and asynchronous motors deliver high-precision, high-speed, reliability and cost-effective performance in today's standard and high-end fac-tory automation applications. 71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 1415IndraDyn L linear motors designed for maxi-mum dynamic performance MLP/MLSsynchronous linearmotors with force ratings up to21,500 N speeds up to 600 m/min liquid cooled (thermal encapsulation)IndraDyn H High-speed kit motors MRS/MSSsynchronous kitmotors with torque ratings up to3,700 Nm Maximum speeds up to 30,000 RPM liquid cooled (thermal encapsulation)IndraDyn T Frameless torque motors MRT/MST synchronous torque motors with torque ratings up to 13,800 Nm Maximum speeds up to 2,000 RPM liquid cooled (thermal encapsulation)71 039 AE-0409 A5.qxd06.10.20049:40 UhrSeite 15Bosch Rexroth CorporationElectric Drives and Controls5150 Prairie Stone ParkwayHoffman Estates, IL 60192-3707Telephone (847) 645-3600Facsimile (847) 645-6201www.boschrexroth-us.comPrinted in the United States71039AE09/04International offices:Asia:China RussiaIndia SingaporeJapan South KoreaMalaysiaAustraliaEurope:AustriaNetherlandsBelgiumNorwayBulgariaPolandCzech RepublicPortugalDenmarkRomaniaFinlandSlovakiaFranceSpainGermanySwedenGreeceSwitzerlandHungaryTurkeyItalyUkraineUnited KingdomNorth America:CanadaUnited StatesMexicoSouth America:ArgentinaVenezuelaBrazilU.S. business unit offices:Bosch Rexroth CorporationIndustrial Hydraulics2315 City Line RoadBethlehem, PA 18017-2131Telephone (610) 694-8300Facsimile (610) 694-8467Bosch Rexroth CorporationCorporate Headquarters5150 Prairie Stone ParkwayHoffman Estates, IL 60192-3707Telephone (847) 645-3600Facsimile (847) 645-6201Bosch Rexroth CorporationLinear Motion andAssembly Technologies816 E. Third StreetBuchanan, MI 49107Telephone (269) 695-0151Facsimile (269) 695-536314001 South Lakes DriveCharlotte, NC 28273Telephone (800) 438-5983Facsimile (704) 583-0523Bosch Rexroth CorporationPneumatics1953 Mercer RoadLexington, KY 40511-1021Telephone (859) 254-8031Facsimile (859) 281-3491Bosch Rexroth CorporationService Automation5150 Prairie Stone ParkwayHoffman Estates, IL 60192-3707Telephone (847) 645-3600Facsimile (847) 645-08042315 City Line RoadBethlehem, PA 18017-2131Telephone (610) 694-8300Facsimile (610) 694-8467Bosch Rexroth CorporationMobile Hydraulics1700 Old Mansfield RoadWooster, OH 44691-039499 Rainbow RoadTelephone (330) 263-3300Facsimile (330) 263-3333Factory AutomationRegional sales offices:CentralBosch Rexroth CorporationElectric Drives and Controls2150 Point Boulevard, Suite 800Elgin, IL 60123Telephone (224) 293-3552Facsimile (847) 551-9812Great LakesBosch Rexroth CorporationElectric Drives and Controls1701 Harmon RoadAuburn Hills, MI 48326-1549Telephone (248) 393-3330Facsimile (248) 393-2893NortheastBosch Rexroth CorporationElectric Drives and Controls99 Rainbow RoadEast Grandby, CT 06026-0000Telephone (860) 844-8377Facsimile (860) 844-8595SoutheastBosch Rexroth CorporationElectric Drives and Controls2810 Premiere ParkwayDuluth, GA 30097Telephone (678) 583-4338Facsimile (678) 417-6637WestBosch Rexroth CorporationElectric Drives and Controls7901 Stoneridge DrivePleasanton, CA 94588Telephone (925) 227-1084Facsimile (925) 227-10812003 Bosch Rexroth Corporation