Product Description:

The HCS04.2E-W1540-N-04-DNNN is a drive controller manufactured by Bosch Rexroth Indramat within the HCS IndraDrive Controllers series. Classified as an HCS drive controller, it converts mains energy into a stabilized DC link and switches that energy to motor phases through IGBT bridges. The device is intended for industrial automation tasks that demand high braking capacity and coordinated motion, such as metal-forming lines, printing presses, and material-handling cells.

The controller’s braking circuit can continuously dissipate 400 kW, while transient deceleration peaks up to 750 kW are accepted for short durations. Operation requires an external resistor between 0.7 Ω and 0.85 Ω, and the lower limit of 0.7 Ω yields the maximum current for emergency stops. A capacitor bank rated at 31.2 mF stabilizes the DC bus so axes draw from a common energy pool. Power is supplied through infeeding or feeder modules, and the line side may deliver fault currents as high as 50 kA, which the internal busbars and protective elements are sized to withstand. Motor current is modulated at a carrier frequency of 4 kHz, providing a compromise between acoustic noise and switching loss. Power cables attach to M12 terminals tightened to 41 Nm to maintain low contact resistance under vibration.

Thermal control is handled by an internal air circuit. The housing offers 20 dm² of open area, and the integrated blower moves 2,400 m3/h when installed in an IP23 cabinet; the flow drops to 660 m3/h if the enclosure is sealed to IP54. The fan drive requires 2,200 VA of supply, and the complete assembly weighs 300 kg, so cabinet mounting must accommodate that static load. The frame tolerates mechanical shocks of 4 g for 11 ms, and normal operation generates a sound pressure level of 75 dB(A). Communication hardware is user selected, and no fixed interface is specified in this variant.