REXROTH RD 500 RD42 Operating Manual
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REXROTH RD 500 RD42 Operating Manual

REXROTH RD 500 RD42 Operating Manual

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Industrial
Electric Drives
Hydraulics
and Controls
Rexroth RD 500 RD42
Power Supply
Operating Guide
Linear Motion and
Assembly Technologies
Pneumatics
Service
Mobile
Automation
Hydraulics
R911200190
Edition 03

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Summary of Contents for REXROTH RD 500 RD42

  • Page 1 Industrial Electric Drives Linear Motion and Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth RD 500 RD42 R911200190 Power Supply Edition 03 Operating Guide...
  • Page 2 About this Documentation RD 500 RD42 RD 500 RD42 Title Power Supply Operating Guide Type of Documentation DOK-RD500*-RD42*******-IB03-EN-P Document Typecode 120-1950-B314-03/EN Internal File Reference This documentation describes the power supply of the produkt family Purpose of Documentation RD 500 RD42 •...

  • Page 3: Table Of Contents

    RD 500 RD42 Table of content Description General information........................1-1 Operating mode, standby:......................1-1 Operating mode, run: ....................... 1-1 Dimensioning information ......................1-1 Dimensioning the power sections .................... 1-1 Dimensioning for dynamic regenerative feedback operations..........1-2 Technical data..........................1-2 Block circuit diagram ........................1-3 Type code .............................
  • Page 4 Table of content RD 500 RD42 Commissioning Connection ............................ 4-1 Setting the unit configuration ......................4-1 Setting the display language....................4-1 Setting the interface address ....................4-1 Powering-up / down the supply module................... 4-1 Powering-up ..........................4-3 Changing-over the operating mode ....................4-3 Ready signal ..........................

  • Page 5: Description

    RD 500 RD42 Description Description General information The RD42 supply modules, which are capable of regenerative feedback, are designed to be connected to inverters with DC connection from the REFUdrive 500 series. They are suitable for regenerating into the line supply, for example, when drives are braked.

  • Page 6: Dimensioning For Dynamic Regenerative Feedback Operations

    Description RD 500 RD42 device is not overloaded, the sum of the power codes of the connected inverters may not exceed 200% of the power code of the power supply module used. Dimensioning for dynamic regenerative feedback operations Depending on the dynamic behavior, the following dimensioning should be considered: For applications, where the DC link power must be provided within 5 and 15 ms, the peak regenerative feedback power ≤...

  • Page 7: Block Circuit Diagram

    RD 500 RD42 Description Note: The specified values refer to the “Run” operating mode. In the “Standby” mode, the regenerative feedback only represents 50 % of the specified values. Block circuit diagram Fig. 1-2: Block circuit diagram RD42 DOK-RD500*-RD42*******-IB03-EN-P...

  • Page 8: Type Code

    Description RD 500 RD42 Type code Abbrev. Column 1 2 3 4 6 7 8 9 1 2 3 4 6 7 8 9 1 2 3 4 6 7 8 9 1 2 3 4 6 7 8 9 Example: R D 4 2 .

  • Page 9: Mechanical Mounting And Installation

    RD 500 RD42 Mechanical mounting and installation Mechanical mounting and installation Storage and mounting location Storage The units must be stored in clean, dry rooms. The storage temperature must lie between -25° C and +70° C. Temperature fluctuations exceeded 20 K per hour are not permissible. (environmental Class 3K3 according to DIN IEC 721-3-3) Hinweis: Supply modules accommodate Al Elko DC link capacitors.

  • Page 10: Installation Altitudes Above 1000 Meters Sea Level

    Mechanical mounting and installation RD 500 RD42 Installation altitudes above 1000 meters sea level: If the unit is mounted above 1000 meters above sea level, the supply module utilization must be reduced corresponding to the adjacent diagram. It is not permissible to install the unit at altitudes above 2000 meters...

  • Page 11: Dimension Drawings

    RD 500 RD42 Mechanical mounting and installation Dimension in mm Warm discharged air Min. clearance for cooling RD42 Display REFU High Voltage. Danger of DANGER electrical shock. Do not touch electric alconnectio ns for 5 minutes after switching power off.
  • Page 12 Mechanical mounting and installation RD 500 RD42 Size Dimension in mm Warm discharged Display Display RD42 DANGER DANGER Cooling air M8 Bolt Line filter U1 V1 W1 M8 Bolt U1 V1 W1 Fig. 2-4: Dimension drawing, size Classes F and G...

  • Page 13: Electrical Installation

    RD 500 RD42 Electrical installation Electrical installation EMC-correct design of drives The following 10 rules are the basic guidelines for EMC-correct design of drive systems. Details are provided in separate instructions. Rules 1 to 7 are generally valid. Rules 8 to 10 are especially important to limit noise emission.
  • Page 14 Electrical installation RD 500 RD42 Rule 9 All variable-speed motors must be connected-up using shielded cables. The shields must be connected at both ends to the housings/enclosures through a low-inductance connection (large surface area). The motor cables must also be shielded inside the cabinet or at least shielded using separating sheet metal panels.

  • Page 15: Warnings And Information

    RD 500 RD42 Electrical installation Warnings and information Electric shock which can lead to death as a result of live components at voltage levels more than 50 V! The supply modules are operated with high voltages. Ÿ GEFAHR All work must be carried-out with the equipment in a...

  • Page 16: Cable Cross-Sections

    Electrical installation RD 500 RD42 Information on protective grounding: Due to the discharge currents of the units (>3.5 mA) via the protective conductor (PE), the cable cross-section of the protective conductor to the cabinet must be at least 10mm Cu in accordance with DIN VDE 0160, or a second protective conductor must be routed in parallel (VDE 0160, Section 6.5.2).

  • Page 17: Power Terminals Rd42

    RD 500 RD42 Electrical installation Power terminals RD42 A supply module, size Class G is shown in the terminal layout diagram. The position of the terminals corresponds to the narrower or wider units. X2 DC bus Display REFU drive 500 DANGER High Voltage.

  • Page 18: Supply Module Connection

    Electrical installation RD 500 RD42 Supply module connection Power terminal X1 Terminal Designation Protective conductor Supply connection via the external line filter 3 phases L1, L2, L3 Fig. 3-4: Power terminal X1 Power terminal X2 Terminal Designation DC link connection + (double terminal) DC link connection –...

  • Page 19: Control Terminals

    RD 500 RD42 Electrical installation Control terminals Terminal diagram NR 16236 X52 Control terminals power supply transformer 500 V 460 V DISPLAY 400 V SN 11027 Jumper Fault acknowledgement LEDs red: fault yellow: green: ready not used X16 RS485 / RS232 Control terminals Fig.
  • Page 20 Electrical installation RD 500 RD42 power supply transformer 500 V 460 V 400 V NR16236 X52 Control terminals SN11027 Jumper X11 Control terminals X16 RS485 / RS232 not used Fault acknowledgement LEDs red: fault yellow: green: ready Fig. 3-8: Terminal diagram for size Class G...

  • Page 21: Control Terminal Strip X11 On Sn11027

    RD 500 RD42 Electrical installation Control terminal strip X11 on SN11027 Terminal X11 Designation Digital inputs P24 V output (80 mA load capacity) “ON” control command “Fault acknowledgement” control command (a positive edge is required to acknowledge a fault) Checkback signal, slave for parallel operation; when supplied, there is a jumper between X11.4 –...

  • Page 22: Control Terminal Strip X52 On Nr16236

    3-10 Electrical installation RD 500 RD42 Control terminal strip X52 on NR16236 Terminal Designation Function for the regenerative feedback modules P24V Jumper must always be inserted between 1 and 2 NR_EIN Not inserted If the terminal is jumpered, the “Run” mode is forced;...

  • Page 23: Connector Assignment X16

    3-11 RD 500 RD42 Electrical installation Connector assignment X16 Connector pins X16 RS232 RS485/422 RxD- RxD+ TxD- TxD+ Fig. 3-13: Connector assignment X16 SN11027 Control unit / PC Shield connection Connector housing Fig. 3-14: RS232 SN11027 Control unit TxD+ TxD+ / RxD+...
  • Page 24 3-12 Electrical installation RD 500 RD42 DOK-RD500*-RD42*******-IB03-EN-P...

  • Page 25: Commissioning

    RD 500 RD42 Commissioning Commissioning Connection Warning against hazardous voltages After the line supply voltage has been powered-down, the unit can still have hazardous voltages at the DC link capacitors. As a result of this, the power supply can still DANGER be maintained for some time (the fan runs on).
  • Page 26 Commissioning RD 500 RD42 Terminal strip The power-on command is initiated by connecting a positive voltage at input X11.2. Static operation: +24 V = power-on 0 V = power-off Edge-controlled operation: Edge 0 to +24V = power-on 0 V = power-off...

  • Page 27: Powering-Up

    RD 500 RD42 Commissioning Powering-up The unit is powered-up by connecting P24 V to X11.2. After the power-on command, the DC link capacitors are charged-up via an auxiliary contactor and series resistors. If this operation runs correctly, the charged capacitors are then connected to the line supply via the main contactor and bridge rectifier.

  • Page 28: Ready Signal

    Commissioning RD 500 RD42 Ready signal The “Ready” signal is output when the inverter is enabled (P24V at terminals X11.10). The additional signaling relay, ready (terminals X52.7/8) has a lower priority, and does not have to be evaluated. If a signal is not output, the causes can be as follows:...

  • Page 29: Fault Display And Fault Diagnostics

    RD 500 RD42 Fault display and fault diagnostics Fault display and fault diagnostics General information If a fault occurs, the line contactor is switched-out and the power section goes into a no-voltage condition. The appropriate fault message is displayed. A maximum of ten fault messages can be saved in the SN11027 fault memory;...

  • Page 30: Fault Messages - Cause And Remedy

    Fault display and fault diagnostics RD 500 RD42 Fault messages – cause and remedy Designation Message Cause Remedy / Comment External An H signal is present at terminal strip X11.5 (input, external fault). Slave The master line rectifier/supply unit does not receive a Check the checkback signal cable from X11.10 (slave)

  • Page 31: Fault Display On The Regenerative Feedback Control Nr16236

    RD 500 RD42 Fault display and fault diagnostics Fault display on the regenerative feedback control NR16236 If the unit is shutdown due to a fault, there is a panel with 9 LEDs on the NR16236 regenerative feedback control (also refer to the terminal layout diagram) - information on the fault cause.
  • Page 32 Fault display and fault diagnostics RD 500 RD42 DOK-RD500*-RD42*******-IB03-EN-P...
  • Page 33 RD 500 RD42 Index Index Alternative fuse types 3-4 Block circuit diagram 1-3 Cable cross-sections 3-4 Commissioning 4-1 Connection diagram, supply module 4-3 Control terminals 3-7 Derating 2-2 Dimension drawing, size Classes D and E 2-3 Dimension drawing, size Classes F and G 2-4...
  • Page 34 Index RD 500 RD42 Power terminal X1 3-6 Power terminal X2 3-6 Power terminal X3 3-6 Power terminals RD42 3-5 Powering-up 4-3 Powering-up / down the supply module 4-1 Powering-up the supply module 4-3 Ready signal 4-4 Serial interface 3-10...

  • Page 35: Kundenbetreuungsstellen - Sales & Service Facilities

    RD 500 RD42 Kundenbetreuungsstellen - Sales & Service Facilities Kundenbetreuungsstellen - Sales & Service Facilities Indramat Refu Indramat Refu GmbH Adresse: Uracher Straße 91 72555 Metzingen 72545 Metzingen – Postfach 1554 Postadresse: +49 (0)7123/969-0 Telefon: +49 (0)7123/969-120 Telefax: Kundendienst - Service +49 (0)7123/969-200 (an Werktagen von 8 –...
  • Page 36 Kundenbetreuungsstellen - Sales & Service Facilities RD 500 RD42 Europa (West) - Europe (West) vom Ausland: (0) nach Landeskennziffer weglassen, Italien: 0 nach Landeskennziffer mitwählen from abroad: don’t dial (0) after country code, Italy: dial 0 after country code Austria - Österreich...
  • Page 37 RD 500 RD42 Kundenbetreuungsstellen - Sales & Service Facilities Europa (Ost) - Europe (East) vom Ausland: (0) nach Landeskennziffer weglassen from abroad: don’t dial (0) after country code Czech Republic - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland –...
  • Page 38 Kundenbetreuungsstellen - Sales & Service Facilities RD 500 RD42 Africa, Asia, Australia – incl. Pacific Rim Australia - Australien Australia - Australien China China AIMS - Australian Industrial Bosch Rexroth Pty. Ltd. Shanghai Bosch Rexroth Shanghai Bosch Rexroth Machinery Services Pty. Ltd.
  • Page 39 Canada West - Kanada West Mexico Mexico Bosch Rexroth Canada Corporation Bosch Rexroth Canada Corporation Bosch Rexroth Mexico S.A. de C.V. Bosch Rexroth S.A. de C.V. Burlington Division 5345 Goring St. Calle Neptuno 72 Calle Argentina No 3913 3426 Mainway Drive Burnaby, British Columbia Unidad Ind.
  • Page 40 Kundenbetreuungsstellen - Sales & Service Facilities RD 500 RD42 DOK-RD500*-RD42*******-IB03-EN-P...
  • Page 42 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 93 52-40-50 60 +49 93 52-40-49 4 1 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany R911200190 DOK-RD500*-RD42*******-IB03-EN-P...

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