Page 1 Industrial Electric Drives Linear Motion and Service Mobile Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics Rexroth IndraControl VCP 20 Rexroth RD 500 RD51 R911201161 Edition 04 Drive Control Devices V/F Characteristic Control Application Manual...
Page 2 DOK-RD500*-RD51*******-IB04-EN-P 10.2004 revision  Bosch Rexroth AG, 2004 Copyright 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).
Page 3: Table Of Contents
RD 500 RD51 Contents Contents Safety Instructions for Electric Servo Drives and Controls Introduction ........................... 1-1 Explanations ..........................1-1 Hazards due to inappropriate use ....................1-2 General information ........................1-3 Protection against contact with electrical parts................1-4 Protection against electrical shock by protective low voltage (PELV) .......... 1-6 Protection against dangerous movements ...................
Page 4 Contents RD 500 RD51 Technical Data for Size Classes A and B with Pulse Frequency f = 12 kHz (3AC 200 ... 230 V) ............................3-4 Technical Data for Size Classes C, D and E with Pulse Frequency f = 4 kHz......3-5 Technical Data for Size Classes C, D and E with Pulse Frequency f = 8 kHz......
Page 5 RD 500 RD51 Contents Supplementary Fan Transformer ..................3-48 Dimension Drawing, Size Classes G and H, with Cooling Type R........3-50 Mounting Drawing for Devices with External Heat Exchanger for Cabinet Roof Mounting, Size Class G ......................3-51 Mounting Drawing for Devices with External Heat Exchanger for Cabinet Roof Mounting, Size Class H ......................
Page 6 Contents RD 500 RD51 Technical Data SFT Motor inverter for Size Classes A and B with Pulse frequency f kHz / 8 kHz............................ 5-8 Technical Data SFT Motor inverter for Size Classes C, D and E with Pulse frequency f = 4 kHz............................
Page 7 RD 500 RD51 Contents Cable Cross-Sections ........................6-3 Power Terminals RD 51 Size Classes A - E................. 6-4 Terminal Layout Diagram, Size Classes A - B ................ 6-4 Description of Inverter Power Terminals Size Classes A - B ..........6-5 Terminal Layout Diagram Size Classes C, D ................
Page 8 Contents RD 500 RD51 Functions ..........................8-15 Drive setting........................... 8-24 Serial communications ......................8-26 Diagnostics / drive data ......................8-28 Options ..........................8-28 Numerical list ..........................8-28 Commissioning Preparatory Steps for Commissioning..................9-1 Procedure during First Commissioning ..................9-1 Motor optimization / motor evaluation................... 9-3 Motor running under no-load conditions ..................
Page 9: Safety Instructions For Electric Servo Drives And Controls
RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls Safety Instructions for Electric Servo Drives and Controls Introduction Read these instructions before the equipment is used and eliminate the risk of personal injury or property damage. Follow these safety instruc- tions at all times.
Page 10: Hazards Due To Inappropriate Use
Safety Instructions for Electric Servo Drives and Controls RD 500 RD51 Hazards due to inappropriate use High voltage and high discharge current! Dan- ger to life, risk of severe electrical shock and risk of injury! DANGER Dangerous movements! Danger to life and risk of injury or equipment damage by unintentional motor movements! DANGER...
Page 11: General Information
Safety Instructions for Electric Servo Drives and Controls General information • Bosch Rexroth is not liable for damages resulting from failure to ob- serve the warnings given in these documentation. • Read all of the operating, maintenance and safety instructions in your language before starting up the machine.
Page 12: Protection Against Contact With Electrical Parts
Safety Instructions for Electric Servo Drives and Controls RD 500 RD51 European countries: see Directive 89/336/EC (EMC Directive). US.: Refer to the National Electrical Code (NEC), National Electrical Manufacturers Association (NEMA), and local building codes. The user of this equipment must observe the above noted items at all times. •...
Page 13 RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls cured against direct contact. Use appropriate hous- ings, for example a control cabinet. European countries: according to EN 50178/1998, sec- tion 5.3.2.3. US: Refer to the National Electrical Code (NEC), National Electrical Manufacturers Association (NEMA) and local building codes.
Page 14: Protection Against Electrical Shock By Protective Low Voltage (Pelv)
Protection against electrical shock by protective low voltage (PELV) All connections and terminals with voltages between 5 and 50 Volts on Bosch Rexroth products are protective low voltages designed in accor- dance with the following Standards: • International: IEC 60364-4-41 •...
Page 15 RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls Dangerous movements! Danger to life and risk of injury or equipment damage! ⇒ Personnel protection must be secured for the above listed reason by means of superordinate monitors or DANGER measures.
Page 16: Protection Against Magnetic And Electromagnetic Fields During Operations And Mounting
Safety Instructions for Electric Servo Drives and Controls RD 500 RD51 ⇒ Avoid operating high-frequency, remote control and radio equipment near electronic circuits and feeder cables. If use of such equipment cannot be avoided, verify the system and the plant for possible malfunc- tions at all possible positions of normal use before the first start-up.
Page 17: Protection Against Contact With Hot Parts
RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls Protection against contact with hot parts Housing surfaces could be extremely hot! Dan- ger of injury! Danger of burns! ⇒ Do not touch surfaces near the source of heat! Dan- ger of burns! CAUTION ⇒...
Page 18: 1.10 Protection During Handling And Installation
1-10 Safety Instructions for Electric Servo Drives and Controls RD 500 RD51 1.10 Protection during handling and installation Under certain conditions inappropriate handling and installation of parts and components may cause injuries. Risk of injury through incorrect handling! Bod- ily harm caused by crushing, shearing, cutting and mechanical shock! ⇒...
Page 19: 1.12 Protection Against Pressurized Systems
1-11 RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls 1.12 Protection against pressurized systems Certain Motors (ADS, ADM, 1MB etc.) and drives, corresponding to the information in the Project Planning manual, must be provided with various media at a high pressure such as compressed air, hydraulic oil, cooling fluid or coolant.
Page 20 1-12 Safety Instructions for Electric Servo Drives and Controls RD 500 RD51 • Electronic modules/boards and components may only be stored and shipped in conductive packaging (e.g. metalized plastic or metal con- tainers). • If the packaging is not conductive, electronic modules / boards must be wrapped in a conductive material.
Page 21: Description Of Rd51
RD 500 RD51 Description of RD51 Description of RD51 The RD 500 Device Series RD 500 is a state-of-the-art, universal three-phase drive system for various synchronous and induction motors. The modular hardware and software design allows the drive system to be flexibly adapted to the particular drive application.
Page 22: Technical Characteristics Rd 500 Sft
Description of RD51 RD 500 RD51 • Expanded, freely-combinable technology functions ⇒ PID, PI controller, AND, OR, XOR, RS flipflop and D latch ⇒ mathematical function elements ⇒ timers, comparitors, ramp-function generators ⇒ freely-assignable characteristic • Additional signal processor (32-bit floating point) for high-dynamic performance applications, including servo applications ⇒...
Page 23 RD 500 RD51 Description of RD51 Fig.: 2-2 RD51.2 type label (size classes A - B) DOK-RD500*RD51*******-IB04-EN-P...
Page 24: Type Key
Description of RD51 RD 500 RD51 Type Key Basic Device Type Key, Size Classes A – B (RD51.2) Fig.: 2-3 Basic device type key, size classes A - B DOK-RD500*RD51*******-IB04-EN-P...
Page 25: Basic Device Type Key, Size Classes C - H (Rd51.1)
RD 500 RD51 Description of RD51 Basic Device Type Key, Size Classes C - H (RD51.1) £ ³ £ ³ (£ £ ³ ³ ³ Fig.: 2-4 Basic device type key, size classes C - H (page 1) DOK-RD500*RD51*******-IB04-EN-P...
Page 26 Description of RD51 RD 500 RD51 ³ Fig.:2-5 Basic device type key, size classes C - H (page 2) DOK-RD500*RD51*******-IB04-EN-P...
Page 27: Type Key Sft Inverter (Rd51.3)
RD 500 RD51 Description of RD51 Type Key SFT Inverter (RD51.3) Fig.: 2-6 Type Key SFT Inverter (page 1) DOK-RD500*RD51*******-IB04-EN-P...
Page 28 Description of RD51 RD 500 RD51 Fig.: 2-7 Type Key SFT Inverter (page 2) DOK-RD500*RD51*******-IB04-EN-P...
Page 29: Type Key Configuration
RD 500 RD51 Description of RD51 Type Key Configuration Fig.: 2-8 Type key configuration Note: Your local sales center will provide you with information about the versions which are presently available. DOK-RD500*RD51*******-IB04-EN-P...
Page 30: Important Notes Regarding Use
• It must be ensured that the products are installed according to the regulations listed in the documentation. Areas of Use and Application Bosch Rexroth drive control units are designed to control electric motors and to monitor their operation. It may be necessary to connect additional sensors and actuators to control and monitor motors.
Page 31: Improper Use
• are used for applications which have not been clearly released by Bosch Rexroth. In this regard, it is required that you refer to the statements in the general notes regarding safety! DOK-RD500*RD51*******-IB04-EN-P...
Page 32 2-12 Description of RD51 RD 500 RD51 DOK-RD500*RD51*******-IB04-EN-P...
Page 33: Converter Technical Data
RD 500 RD51 Converter Technical Data Converter Technical Data Technical Data for Size Classes A and B with Pulse Frequency f = 4 kHz / 8kHz (3AC 380 ... 480 V) 4 kHz 8 kHz RD51.2 18.5 Rated motor output Supply voltage, 3-phase 380 ...
Page 34: Technical Data For Size Classes A And B With Pulse Frequency F 480 V)
Converter Technical Data RD 500 RD51 4 kHz 8 kHz RD51.2 Performance data of chopper Continuous power kW 1.5 Peak power for t = 1 s kW 10 Ω 60 17.5 17.5 17.5 17.5 Minimum resistance value Max. permissible motor power based on a 4-pin standard induction motor Starting at an output voltage Ua >400 V, the rated current is linearly reduced from 100 % to 83 % for Va = 480 V.
Page 35: Khz / 8 Khz (3Ac 200
RD 500 RD51 Converter Technical Data Technical Data for Size Classes A and B with Pulse Frequency f = 4 kHz / 8 kHz (3AC 200 ... 230 V) 4 kHz 8 kHz RD51.2 Rated motor output Supply voltage, 3-phase 200 ... 230 V AC (±15 %) Output frequency 0 - 250 0 - 500...
Page 36: Technical Data For Size Classes C, D And E With Pulse Frequency F = 4 Khz
Converter Technical Data RD 500 RD51 Technical Data for Size Classes A and B with Pulse Frequency f = 12 kHz (3AC 200 ... 230 V) 12 kHz RD51.2 Supply voltage, 3-phase 200 ... 230 V AC (±15 %) Output frequency 0 - 1400 Rated current Peak current for...
Page 37 RD 500 RD51 Converter Technical Data Technical Data for Size Classes C, D and E with Pulse Frequency f = 4 kHz 4 kHz RD51.1 kW 22 Rated motor output Supply voltage, 3-phase 380 ... 480 V AC (±10 %) Output frequency 0 - 250 Rated current...
Page 38: Technical Data For Size Classes C, D And E With Pulse Frequency F
Converter Technical Data RD 500 RD51 Technical Data for Size Classes C, D and E with Pulse Frequency f = 8 kHz 8 kHz 6 kHz RD51.1 kW 18.5 Rated motor output Supply voltage, 3-phase 380 ... 480 V AC (±10 %) Output frequency 0 - 500 Rated current...
Page 39 RD 500 RD51 Converter Technical Data Technical Data for Size Classes C, D and E with Pulse Frequency f = 12 kHz 12 kHz RD51.1 Supply voltage, 3-phase 380 ... 480 V AC (±10 %) Output frequency 0 - 1400 Rated current A 30 Peak current for...
Page 40: Technical Data For Size Classes G And H With Pulse Frequency F = 4 Khz / 8Khz
Converter Technical Data RD 500 RD51 Technical Data for Size Classes G and H with Pulse Frequency f = 4 kHz / 8kHz 4 kHz 8 kHz RD51.1 kW 132 Rated motor output Supply voltage, 3-phase 380 ... 480 V AC (±10 %) Hz 0 - 250 0 - 150 0 - 500...
Page 41: Technical Data For Size Classes G And H With Pulse Frequency F = 12 Khz
RD 500 RD51 Converter Technical Data 4 kHz 8 kHz RD51.1 Peak power for t = 0.1 s kW 270 2x270 2x370 270 2x270 2x370 Ω 2.2 2x2.2 2x1.6 2x2.2 2x1.6 Minimum resistance value Max. permissible motor power based on 4-pin standard induction motor Starting at an output voltage Ua >400 V, the rated current is linearly reduced from 100 % to 83 % for Va = 480 V.
Page 42: 3.10 Circuit Principle
3-10 Converter Technical Data RD 500 RD51 3.10 Circuit Principle Circuit Principle of Electronics Section Fig.: 3-1 Circuit principle of electronics section Circuit Principle of Power Section, Size Classes A and B DOK-RD500*RD51*******-IB04-EN-P...
Page 43 3-11 RD 500 RD51 Converter Technical Data å Fig.: 3-2 Circuit principle of power section, converter classes A and B DOK-RD500*RD51*******-IB04-EN-P...
Page 44 3-12 Converter Technical Data RD 500 RD51 å Fig.: 3-3 Sample connection of classes A – B, 3AC 380 ... 480 V / 3AC 500 V Note: Optional EMC-filter or line reactor. For 007 and 018 at least one line reactor is required. The separation points on input terminal T –...
Page 45 3-13 RD 500 RD51 Converter Technical Data å Fig.: 3-4 Sample connection of classes A - B, 3AC 200 / 230 V Note: A 570 V DC power supply voltage is required for the switched mode power supply. DOK-RD500*RD51*******-IB04-EN-P...
Page 46: Emc- Filter
3-14 Converter Technical Data RD 500 RD51 EMC- Filter EMC standard EN61800-3 A2 is maintained using the upstream EMC- filter. The devices in device series RD51.2 can be operated with or without a EMC filter / line reactor. Exception Devices with power outputs of 7.5 kW and 18.5 kW must be operated with either a line reactor RND01.1 or a EMC-filter RZE01.2.
Page 47 3-15 RD 500 RD51 Converter Technical Data Type Key Fig.: 3-6 Type key of RZE01.2 EMC-filter with integrated line reactor Technical Data Con- EMC-filter verter RZE01.2... Power Size Max. line Line Fre- Connect- Max. ambient Weight Designation class class voltage current quency able cross-...
Page 48 3-16 Converter Technical Data RD 500 RD51 Type Label Fig.: 3-8 Type label of RZE01.2 EMC-filter with integrated line reactor DOK-RD500*RD51*******-IB04-EN-P...
Page 49: Description Of Emc-Filter Without Commutating Reactor Rze02.1
3-17 RD 500 RD51 Converter Technical Data Description of EMC-filter without commutating reactor RZE02.1 Presentation of Principle Standard configuration: inlaid bridge for TT power supplies Separation point at input terminal T-T1 for IT power supplies Fig.: 3-9 Circuit principle of EMC-filter RZE02.1 without commutating reactor Type Key Fig.: 3-10 Type key of RZE02.1 EMC-filter without commutation reactor...
Page 50 3-18 Converter Technical Data RD 500 RD51 Technical Data Con- EMC-filter verter RZE02.1... Power Size Max. line Line Fre- Connect- Max. ambient Weight Designation class class voltage current quency able cross- temperature section during transport, ² storage and operation, ta °C 50 / 60 Single wire 10 RZE02.1-5-005...
Page 51: Mechanical Assembly Rze01.2 And Rze02.1
3-19 RD 500 RD51 Converter Technical Data Mechanical Assembly RZE01.2 and RZE02.1 Dimension Drawings *: select according to cooling method and foot angle Fig.: 3-13 EMC filter RZE01.2-5-007 / RZE02.1-5-005 *: select according to cooling method and foot angle Fig.: 3-14 EMC filter RZE01.2-5-018 / RZE02.1-5-015 DOK-RD500*RD51*******-IB04-EN-P...
Page 52: Line Reactor
3-20 Converter Technical Data RD 500 RD51 Assembly Example PROG ENTER ST ART ST OP DANGER Fig.: 3-15 Assembly example for RZE01.2 / RZE02.1 Screw M5, which is already present for the PE connection, is used to fasten the line filter and the PE connection of the EMC filter. Line Reactor Description of RND01.1 Line Reactor Presentation of Principle...
Page 53 3-21 RD 500 RD51 Converter Technical Data Type Key Fig.: 3-17 Type key of line reactor RND Technical Data Con- Line reactor verter RND01.1... Power Size Max. line Line Fre- Connect- Max. Weight Designation class class voltage current ductivity quency, able ambient cross-...
Page 54: Mechanical Assembly
3-22 Converter Technical Data RD 500 RD51 Type Label Fig.: 3-19 Type label of line reactor RND Mechanical Assembly Dimension Drawing Fig.: 3-20 Line reactor RND01.1-5-007 / 018 DOK-RD500*RD51*******-IB04-EN-P...
Page 55 3-23 RD 500 RD51 Converter Technical Data Assembly Example PROG ENTER ST ART ST OP DANGER Fig.: 3-21 Assembly example of line reactor RND DOK-RD500*RD51*******-IB04-EN-P...
Page 56: Description Of Ntm02.1 Power Pack Module
3-24 Converter Technical Data RD 500 RD51 Description of NTM02.1 power pack module When converters with a 3AC 200...230V power connection are used, a 570 V DC power supply voltage is required for the switched mode power supply. Using the NTM02.1-200-570-00 power pack module, the 570 V DC power supply voltage can be obtained from a 200 / 230V AC input voltage.
Page 57 3-25 RD 500 RD51 Converter Technical Data Technical Data NTM02.1-200-570-00 power pack module Input voltage V 200 V AC ±10 % 230 V AC ±10 % 260 V AC ±10 % Connection Neutral conductor connection Mains frequency Hz 50 / 60 Mains protection Start-up current A 10...
Page 58: Mechanical Assembly Ntm02.1 Power Pack Module
3-26 Converter Technical Data RD 500 RD51 Type Label Fig.: 3-26 Type label NTM02.1 power pack module Mechanical Assembly NTM02.1 power pack module Dimension Drawing Fig.: 3-27 Dimension Drawing NTM02.1 power pack module DOK-RD500*RD51*******-IB04-EN-P...
Page 59: Circuit Principle Of Power Section, Size Classes C - E
3-27 RD 500 RD51 Converter Technical Data Circuit Principle of Power Section, Size Classes C - E å Fig.: 3-28 Circuit principle of power section, converter classes C - E Note: X155 and X177 may be opened only in the case of additional function Y1 for wide-range voltage devices (3AC380 ...
Page 60: Circuit Principle Of Power Section, Size Classes G - H
3-28 Converter Technical Data RD 500 RD51 Circuit Principle of Power Section, Size Classes G - H Fig.: 3-29 Circuit principle of power section, converter size classes G - H Note: When additional function V1 is used, module SNT is not equipped.
Page 61: 3.11 Mechanical Assembly
3-29 RD 500 RD51 Converter Technical Data 3.11 Mechanical Assembly Storage and Setup Storage The devices must be stored in a clean, dry space. The storage temperature must be between –25 °C and +70 °C. Temperature variations greater than 20 K per hour are not permitted. Note: The converter and supply modules have AL electrolytic capacitors as DC Link capacitors.
Page 62: Setup Elevations Exceeding 1000 Meters Above Sea Level
3-30 Converter Technical Data RD 500 RD51 Degree of utilization at higher ambient temperatures Ambient temperature in °C DG0006F1.FH7 Fig. 3-30: Utilization at a higher ambient temperature Setup Elevations Exceeding 1000 Meters above Sea Level: The utilization of the drive converter must be reduced (derated) according to the diagram below for installation altitudes above 1000 meters above sea level.
Page 63: Dimension Drawing, Size Classes A - B
3-31 RD 500 RD51 Converter Technical Data • When the drive units are mounted in a cabinet, the cooling air requirement of the units must be calculated (refer to Technical data 3.1 to 3.7) and the cabinet ventilation appropriately dimensioned. •...
Page 64 3-32 Converter Technical Data RD 500 RD51 PROG ENTER PROG ENTER ST ART ST OP ST ART ST OP DANGER DANGER Fig.: 3-33 Cooling types, size classes A - B DOK-RD500*RD51*******-IB04-EN-P...
Page 65: Assembly Example Of Several Converters Next To Each Other For Cooling Type P
3-33 RD 500 RD51 Converter Technical Data Assembly Example of Several Converters next to Each Other for Cooling Type P PROG ENTER PROG ENTER PROG ENTER ST ART ST OP ST ART ST OP ST ART ST OP DANGER DANGER DANGER Fig.: 3-34 Arrangement of several converters next to each other for cooling type Dimension Drawing cooling type D Size classes A and B...
Page 66: Minimum Spacing For Cooling For Cooling Type L, P And G
3-34 Converter Technical Data RD 500 RD51 Minimum Spacing for Cooling for Cooling Type L, P and G An assembled converter with forced air-cooling, heat dissipation panel and plug-through cooler, size classes A and B, is shown in the drawing below.
Page 67: Dimension Drawing, Size Classes C, D, E
3-35 RD 500 RD51 Converter Technical Data Dimension Drawing, Size Classes C, D, E ALARM ALARM READY READY PROG PROG ENT ER ENT ER ST ART ST ART ST OP ST OP ALARM ALARM ALARM ALARM READY READY READY READY REFU drive 500 PROG...
Page 68: Dimension Drawing Of Cooling Type L For Size Classes C, D, E
3-36 Converter Technical Data RD 500 RD51 Dimension Drawing of Cooling Type L for Size Classes C, D, E Fig.: 3-38 Dimension sheet for cooling type L, size classes C, D, E Minimum Cooling Spacing for Cooling Type L An assembled converter with forced-air cooling, size classes C, D and E, is shown in the drawing below.
Page 69: Dimension Drawing Of Cooling Type D For Size Classes C, D, E
3-37 RD 500 RD51 Converter Technical Data Dimension Drawing of Cooling Type D for Size Classes C, D, E Fig.: 3-40 Dimension sheet for cooling type D, size classes C, D, E Several Converters next to Each Other with Plug-through cooler size classes A -E Fig.: 3-41 Cut-outs for devices with plug-through cooler...
Page 70: Dimension Drawing Of Cooling Type W For Size Classes C, D, E
3-38 Converter Technical Data RD 500 RD51 Dimension Drawing of Cooling Type W for Size Classes C, D, E ALARM ALARM READY READY PROG PROG ENT ER ENT ER ST ART ST ART ST OP ST OP REFU drive 500 HighVoltage.
Page 71: Working With The Coolant Circulation, Size Classes C, D And E
3-39 RD 500 RD51 Converter Technical Data 3.13 Working with the Coolant Circulation, Size Classes C, D and E Antifreeze is hazardous to health! ⇒ If antifreeze is swallowed, immediately consult a doctor and keep the packaging or label for reference. CAUTION Mixture with other antifreezes! ⇒...
Page 72 3-40 Converter Technical Data RD 500 RD51 Damage to materials due to malfunction in coolant circulation system! ⇒ Ensure fault-free operation of the coolant circulation system WARNING Note: Prevent deposits in the cooling tubes. Note: Pay attention to the change in volume of the coolant due to the temperature differences.
Page 73: Assembly Of Fluid-Cooled Converter, Size Classes C, D And E
3-41 RD 500 RD51 Converter Technical Data Assembly of Fluid-Cooled Converter, Size Classes C, D and E The fluid-cooled devices of size classes C, D and E consist of the device and a copper plate with a brazed-on copper pipe. This is connected to the quick-release couplings by a kink-proof hose.
Page 74 3-42 Converter Technical Data RD 500 RD51 Dynamic Pressure and Coolant Temperature / Volume Flow, Class C Fig.: 3-44 Dynamic pressure and coolant temperature / volume flow, class C DOK-RD500*RD51*******-IB04-EN-P...
Page 75 3-43 RD 500 RD51 Converter Technical Data Dynamic Pressure and Coolant Temperature / Volume Flow, Class D Fig.: 3-45 Dynamic pressure and coolant temperature / volume flow, class D DOK-RD500*RD51*******-IB04-EN-P...
Page 76 3-44 Converter Technical Data RD 500 RD51 Dynamic pressure and coolant temperature / volume flow, Class E Fig.: 3-46 Dynamic pressure and coolant temperature / volume flow, class E DOK-RD500*RD51*******-IB04-EN-P...
Page 77: Assembly Of Converter, Size Classes G And H, With Forced Air Cooling And Integrated Liquid Circulation System (Cooling Type F)
3-45 RD 500 RD51 Converter Technical Data 3.14 Assembly of Converter, Size Classes G and H, with Forced Air Cooling and Integrated Liquid Circulation System (Cooling Type F) Converters of size classes G and H comprise the following elements: line filter, converter and heat exchanger.
Page 78: Dimension Drawing, Size Classes G And H, With Cooling Type F
3-46 Converter Technical Data RD 500 RD51 Dimension Drawing, Size Classes G and H, with Cooling Type F ALARM ALARM READY READY Frontansi PROG ENT ER PROG ENT ER ST ART ST OP ST ART ST OP Fig.: 3-47 Dimension sheet of converter, size classes G and H, with cooling type DOK-RD500*RD51*******-IB04-EN-P...
Page 79: Assembling Liquid-Cooled Converters, Size Classes G And H, With External Heat Exchanger
3-47 RD 500 RD51 Converter Technical Data 3.15 Assembling Liquid-Cooled Converters, Size Classes G and H, with External Heat Exchanger General Notes Regarding Assembly Converters of size classes G and H comprise the following elements: line filter, converter and heat exchanger. The converter, line filter and heat exchanger are each mounted on a separate mounting plate.
Page 80: Supplementary Fan Transformer
3-48 Converter Technical Data RD 500 RD51 Supplementary Fan Transformer • For 200 kW and 400 kW devices, the size of the internal power supply is not adequate for these supplementary fans. An external fan transformer is included to supply power to the fans. •...
Page 81 3-49 RD 500 RD51 Converter Technical Data ALARM READY PROG ENT ER ST ART ST OP Fig.: 3-49 Connection plan for separate fan transformer for size classes G and H with cooling type R DOK-RD500*RD51*******-IB04-EN-P...
Page 82: Dimension Drawing, Size Classes G And H, With Cooling Type R
3-50 Converter Technical Data RD 500 RD51 Dimension Drawing, Size Classes G and H, with Cooling Type R ALARM ALARM READY READY Frontansi PROG ENT ER PROG ENT ER ST ART ST OP ST ART ST OP Fig.: 3-50 Dimension sheet of converter, size classes G and H, with cooling type R DOK-RD500*RD51*******-IB04-EN-P...
Page 83: Mounting Drawing For Devices With External Heat Exchanger For Cabinet Roof Mounting, Size Class G
3-51 RD 500 RD51 Converter Technical Data Mounting Drawing for Devices with External Heat Exchanger for Cabinet Roof Mounting, Size Class G ALARM READY PROG ENT ER ST ART ST OP Fig.: 3-51 Dimension sheet for cabinet roof mounting, size class G DOK-RD500*RD51*******-IB04-EN-P...
Page 84: Mounting Drawing For Devices With External Heat Exchanger For Cabinet Roof Mounting, Size Class H
3-52 Converter Technical Data RD 500 RD51 Mounting Drawing for Devices with External Heat Exchanger for Cabinet Roof Mounting, Size Class H ALARM READY PROG ENT ER ST ART ST OP Fig.: 3-52 Dimension sheet for cabinet roof mounting, size class H DOK-RD500*RD51*******-IB04-EN-P...
Page 85: Mounting Drawing For Devices With External Heat Exchanger For Wall Mounting
3-53 RD 500 RD51 Converter Technical Data Mounting Drawing for Devices with External Heat Exchanger for Wall Mounting Fig.: 3-53 Dimension sheet for wall mounting, size class H 3.16 Working on the Coolant Circulation System Size Classes G and H Both versions of the liquid-cooled drive units, with integrated and external heat exchanger, are supplied filled with liquid.
Page 86 3-54 Converter Technical Data RD 500 RD51 Damage to materials due to condensation! ⇒ In temperate climate zones (up to 40 °C and 70 % humidity), the inlet temperature of the coolant must lie max. 5 K below the interior switch cabinet WARNING temperature! Note:...
Page 87: Mounting Extension Hoses For External Heat Exchanger
3-55 RD 500 RD51 Converter Technical Data Destruction of device due to short-circuit! ⇒ Collect drip water during assembly DANGER Mounting Extension Hoses for External Heat Exchanger For devices with external heat exchangers, all of the parts required for the hose extensions (hoses, connectors, couplings, clamps, coolant, etc.) are supplied according to the customer’s specification when ordering.
Page 88: Servicing The Coolant Circulation System
3-56 Converter Technical Data RD 500 RD51 Servicing the Coolant Circulation System The coolant circulation system is a closed cooling system that does not require either servicing or inspection. If the “Device excess temperature” fault occurs during operation, it should be checked whether the coolant level is at the center of the compensation tank.
Page 89: Electrical Installation Of Converter
RD 500 RD51 Electrical Installation of Converter Electrical Installation of Converter 10 Rules for Installation of Drives According to EMC The following 10 rules are the basics for designing drive systems in compliance with EMC. Rules 1 to 7 are generally valid. Rules 8 to 10 are especially important to limit noise emission.
Page 90: Warnings And Notes
Electrical Installation of Converter RD 500 RD51 All variable-speed motors should be connected using shielded cables, Rule 9 whereby the shield is connected at both ends to the housings through the largest possible surface area to minimize the inductance. The motor feeder cables should also be shielded outside the cabinet, or at least screened using barriers.
Page 91: Cable Cross-Sections
RD 500 RD51 Electrical Installation of Converter Damage to the devices as a result of an incorrect supply voltage! ⇒ RD 500 devices are designed for various supply voltages! This is the reason why supply voltages are CAUTION not specified in the drawings and tables for the terminal strips.
Page 92: Power Terminals Rd51 Size Classes A - E
Electrical Installation of Converter RD 500 RD51 Power Terminals RD51 Size Classes A - E Terminal Layout Diagram Size Classes A - B PROG ENTER ST ART ST OP DANGER 24 V Stand-by power supply, starting lock-out and filter current feedback 24 V Stand-by power supply and starting lock-out Fig.: 4-1...
Page 93: Description Of Converter Power Terminals, Size Classes A - B
RD 500 RD51 Electrical Installation of Converter Description of Converter Power Terminals, Size Classes A - B X1, Power supply connection and Dc link connection Execution RD51.2-x- Type pole number Execution Sub-unit Plug on device Sub-unit Plug on device Sub-unit Plug on device Sub-unit Plug on device...
Page 94 Electrical Installation of Converter RD 500 RD51 X1, SNT supply Execution RD51.2-x- Type pole number Execution plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device Tab.
Page 95 RD 500 RD51 Electrical Installation of Converter X2, Motor connection Execution RD51.2-x- Type pole number Execution plug-in connection 3 Plug on device plug-in connection 3 Plug on device plug-in connection 3 Plug on device plug-in connection 3 Plug on device plug-in connection 3 Plug on device Tab.
Page 96 Plug on device plug Plug on device Tab. 4-11 Execution Identification single connection Identification signification Operation possible only with the original Bosch Rexroth filter Tab. 4-12 Identification single connection Connection cross-section RD52.2-x- Cable cross- section which can be connected mm²...
Page 97 RD 500 RD51 Electrical Installation of Converter X80 Starting lock-out (only in A1 and A2) Execution RD51.2-x- Type pole number Execution plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device Tab.
Page 98 4-10 Electrical Installation of Converter RD 500 RD51 X83, 24 V Stand-by power supply for the electronics (only in A1 and A2) Execution RD51.2-x- Type pole number Execution plug Plug on device plug Plug on device plug Plug on device plug Plug on device plug...
Page 99: Terminal Layout Diagram, Size Classes C, D
4-11 RD 500 RD51 Electrical Installation of Converter Terminal Layout Diagram, Size Classes C, D A converter, size C (270 mm wide) is illustrated in the terminal layout diagram. The position of the terminals is essentially the same for the narrower or wider drive units.
Page 100: Terminal Layout Diagram, Size Class E
4-12 Electrical Installation of Converter RD 500 RD51 Terminal Layout Diagram, Size Class E Note: The additional function 24 V Stand-by power supply (terminal X83) is only mounted if it was actually ordered. ALARM ALARM READY READY PROG PROG ENT ER ENT ER ST ART ST ART...
Page 101: Description Of Converter Power Terminals, Size Classes C - E
4-13 RD 500 RD51 Electrical Installation of Converter Description of Converter Power Terminals, Size Classes C - E X1, Line supply Execution RD5!.1-x- Type number Execution High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal...
Page 102 4-14 Electrical Installation of Converter RD 500 RD51 X1, DC link Execution RD51.1-x- Type Num- Execution Universal terminal With mounting foot Universal terminal With mounting foot Universal terminal With mounting foot Universal terminal With mounting foot Universal terminal With mounting foot Universal terminal With mounting foot High current bushing terminal 3...
Page 103 4-15 RD 500 RD51 Electrical Installation of Converter X1, C1 and D1 (connection idle) Execution RD51.1-x- Type number Execution Universal terminal Screw terminal Universal terminal Screw terminal Universal terminal Screw terminal Universal terminal Screw terminal Universal terminal Screw terminal Universal terminal Screw terminal High current bushing terminal Screw terminal...
Page 104 4-16 Electrical Installation of Converter RD 500 RD51 Fuses Converter Size class C, D and E Fuses RD51.1-x- Maximum series fuse, type gL, A 1) Safety values are provided for the 3AC 400 V input voltage and for the rated output X1 of the device. If the input voltage differs, the safety value must be changed.
Page 105 4-17 RD 500 RD51 Electrical Installation of Converter X2, Motor connection Execution RD51.1-x- Type number Execution High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail...
Page 106 4-18 Electrical Installation of Converter RD 500 RD51 X2, cable damping L1 Execution RD51.1-x- Type number Execution High current bushing terminal Screw terminal High current bushing terminal Screw terminal High current bushing terminal Screw terminal High current bushing terminal Screw terminal High current bushing terminal Screw terminal High current bushing terminal...
Page 107 Screw terminal High current bushing terminal Screw terminal Tab. 4-38 Execution Identification single connection Identification signification Operation possible only with the original Bosch Rexroth filter Tab. 4-39 Identification single connection Connection cross-section RD52.1-x- Cable cross- Torque section which can be connected, mm²...
Page 108 4-20 Electrical Installation of Converter RD 500 RD51 X80, Starting lock-out Execution RD51.1-x- Type pole number Execution plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection...
Page 109 4-21 RD 500 RD51 Electrical Installation of Converter X83, 24 V Stand-by power supply for the electronics (only in A1 and A2) Execution RD51.1-x- Type pole number Execution plug Plug on device plug Plug on device plug Plug on device plug Plug on device plug...
Page 110 4-22 Electrical Installation of Converter RD 500 RD51 X81 additional function CF / DF Identification single connection Identification signification Connection RZC01.x... Only for internal use Tab. 4-47 Identification single connection Note: Depending on the national regulations at the setup location, an external fuse and / or a short-circuit-proof layout may also be required.
Page 111: Power Terminals Rd51 Size Classes G - H
4-23 RD 500 RD51 Electrical Installation of Converter Power Terminals RD51 Size Classes G - H After the device has been mounted, the electrical connections between the line filter and drive converter must be established: • Bolt the busbars provided between the main contactor of the line filter and the converter.
Page 112: Terminal Layout Diagram Converter Size Class H
4-24 Electrical Installation of Converter RD 500 RD51 Terminal Layout Diagram Converter Size Class H ALARM READY PROG ENT ER ST ART ST OP Fig.:4-5 Terminal layout diagram, converter size class H DOK-RD500*RD51*******-IB04-EN-P...
Page 113: Description Of Power Terminals, Converter Size Classes G - H
4-25 RD 500 RD51 Electrical Installation of Converter Description of Power Terminals, Converter Size Classes G - H X1, Line supply connection Execution RD51.1-x- Type number Execution High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail Stud connection...
Page 114 4-26 Electrical Installation of Converter RD 500 RD51 X1, 121 per 124 Execution RD51.1-x- Type Pole Execution number Terminal strip Slip-on terminal Terminal strip Slip-on terminal Terminal strip Slip-on terminal Terminal strip Slip-on terminal Terminal strip Slip-on terminal Tab. 4-51 Execution Identification single connection Identification signification...
Page 115 4-27 RD 500 RD51 Electrical Installation of Converter Fuses Converter Size class G and H Fuses RD51.1-x- Maximum series fuse, type gL, A 1) 1000 Safety values are provided for the 3AC 400 V input voltage and for the rated output X1 of the device. If the input voltage differs, the safety value must be changed.
Page 116 4-28 Electrical Installation of Converter RD 500 RD51 X2, DC link Size class G Execution RD51.1-x- number Execution feed-through terminal terminal block feed-through terminal terminal block feed-through terminal terminal block Tab. 4-55 Execution Identification single connection Identification signification DC link terminal L+ DC link terminal L - Internal brake resistor connected in the heat exchanger between C and F...
Page 117 4-29 RD 500 RD51 Electrical Installation of Converter X2, DC link Size class H Execution RD51.1-x- number Execution feed-through terminal 2 + 4 terminal block feed-through terminal 2 + 4 terminal block Tab. 4-59 Execution Identification single connection Identification signification DC link terminal L+ DC link terminal L - Tab.
Page 118 4-30 Electrical Installation of Converter RD 500 RD51 X2, Motor connection Execution RD51.1-x- Type number Execution High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail Stud connection rail Stud connection rail Tab.
Page 119 4-31 RD 500 RD51 Electrical Installation of Converter X2, line supply isolation Execution RD51.1-x- Type number Execution feed-through terminal double level terminal feed-through terminal double level terminal feed-through terminal double level terminal feed-through terminal double level terminal feed-through terminal double level terminal Tab.
Page 120 4-32 Electrical Installation of Converter RD 500 RD51 X2, Connection fan Execution RD51.1-x- Type number Execution feed-through terminal terminal block feed-through terminal terminal block feed-through terminal terminal block feed-through terminal double level terminal feed-through terminal double level terminal Tab. 4-70 Execution Identification single connection Identification signification...
Page 121 4-33 RD 500 RD51 Electrical Installation of Converter X5, Control voltage for the line filter Execution RD51.1-x- Type Pole- Execution number plug With Srew flange plug With Srew flange plug With Srew flange plug With Srew flange plug With Srew flange Tab.
Page 122 4-34 Electrical Installation of Converter RD 500 RD51 X2, cable damping L1 Execution RD51.1-x- Type Number Execution Universal terminal Terminal on mounting rail Universal terminal Terminal on mounting rail Universal terminal Terminal on mounting rail Universal terminal Terminal on mounting rail Universal terminal Terminal on mounting rail Tab.
Page 123 4-35 RD 500 RD51 Electrical Installation of Converter X2, Filter current feedback Execution RD51.1-x- Type number Execution High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail...
Page 124 4-36 Electrical Installation of Converter RD 500 RD51 X80, Starting lock-out Execution RD51.1-x- Type pole number Execution plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device Tab.
Page 125: Control Transformer T1
4-37 RD 500 RD51 Electrical Installation of Converter X83, 24 V Power Supply for the electronics (only in A1 and A2) Execution RD51.1-x- Type pole number Execution plug Plug on device plug Plug on device plug Plug on device plug Plug on device plug Plug on device...
Page 126: Dimension Drawing Of Control Transformer
4-38 Electrical Installation of Converter RD 500 RD51 Note: If the line supply voltage that is used and the current setting do not agree, the correct setting is to be made by switching terminals on the control transformer. Material damage due to overload of the component! ⇒...
Page 127: Connection Diagram
4-39 RD 500 RD51 Electrical Installation of Converter Connection Diagram Depending on the encoder used, the conductors for the temperature sensor are routed in the encoder cable or are connected using a separate cable on connector X15. Fig.: 4-7 Connection diagram for converter size classes A - E DOK-RD500*RD51*******-IB04-EN-P...
Page 128 4-40 Electrical Installation of Converter RD 500 RD51 Depending on the encoder used, the conductors for the temperature sensor are routed in the encoder cable or are connected using a separate cable on connector X15. Fig.:4-8 Connection diagram for converter size classes G - H DOK-RD500*RD51*******-IB04-EN-P...
Page 129: Control Terminals
4-41 RD 500 RD51 Electrical Installation of Converter Control Terminals Terminal Layout Diagram SR17000 Size classes A - B DANGER Fig.:4-9 Control terminals on the SR17000 logic and control board DOK-RD500*RD51*******-IB04-EN-P...
Page 130: Terminal Layout Diagram Sr17000 Size Class C - H
4-42 Electrical Installation of Converter RD 500 RD51 Terminal Layout Diagram SR17000 Size class C - H ALARM READY Fig.:4-10 Control terminals on the SR17000 logic and control board DOK-RD500*RD51*******-IB04-EN-P...
Page 131: Description Of Control Terminals
4-43 RD 500 RD51 Electrical Installation of Converter Description of Control Terminals Terminal Designation Comment Service interface R x D RS232 service interface; To plug in the operator panel T x D To connect a PC with the RDwin user interface Ground RS485 interface R x D+ / T x D +...
Page 132: Providing The Reference Potential When Operating Serveral Rd 500S
Description of control terminals on SR17000 Providing the Reference Potential when Operating Serveral RD 500s If devices of the RD 500 series are potentially connected with each other and / or to an external control, a central connection must be established between the reference ground and the PE.
Page 133: Incremental Encoder Connection
4-45 RD 500 RD51 Electrical Installation of Converter Fig.:4-12 Central Connection reference ground to PE If there is no potential control connection between the devices (e.g. coupling using fiber optic cabler), the reference ground is directly connected to the PE on each device. Note: When delivered, RD 500 devices have a direct connection between the reference ground and the PE via the X14.7 cable...
Page 134 4-46 Electrical Installation of Converter RD 500 RD51 Note: The maximum cable length between the encoder and evaluation electronics depends on the encoder! Please observe the limit frequency of the evaluation electronics as well as that of the encoder. Connection Limit frequency Connection without inverted tracks 150 Hz...
Page 135 4-47 RD 500 RD51 Electrical Installation of Converter Parameter Name Description / explanation Factory setting Pass- No.: of the selectable options min ... max values word 0137 Freq.normalization ext. 50.0 Hz 5.0 ... 1500.0 Hz 0138 IGR measuring time D1800 1 ...
Page 136: Service Interface Rs 232 (X11)
Service Interface RS 232 (X11) This interface is used to connect the user panel or a PC with RDwin. A preassembled standard extension cable can be obtained from Bosch Rexroth to connect the devices (Order No.: R911200239, length 5 m). ALARM READY...
Page 137 4-49 RD 500 RD51 Electrical Installation of Converter Parameterizing Service Interface RS232 The service interface also operates with the USS protocol. However, the protocol type is fixed (4 / 6 words, even parity, 1 stop bit). See function description: DOK-RD500-RD51*xxVRS*-FKxx-EN-P. The baud rate can be selected using P0499.
Page 138: Standard Interface Rs485 (X12)
4-50 Electrical Installation of Converter RD 500 RD51 Standard Interface RS485 (X12) The RS485 interface supports the USS protocol, which is used to control the converter from a PLC. The USS protocol for a universal serial interface defines an access technique according to the master-slave principle for communication via a serial bus.
Page 139 4-51 RD 500 RD51 Electrical Installation of Converter Fig.: 4-22 Connection, standard interface When using this interface, it should be ensured that the same interface configuration is set for each bus node. Exception: "SS1 slave address"; in this case, each bus node (station) has its own address.
Page 140: Parameterizing The Converter
4-52 Electrical Installation of Converter RD 500 RD51 Parameterizing the Converter The configuration of the standard RS485 interface should be set using parameters P0500 to P0506. The parameters are accessed as follows via the menu: PARAMETERIZATION/PROMPTEDPARAMETR/SER. COMMUNICATION Parameterizing the Standard RS485 Interface Parameter Name Description / explanation...
Page 141: Inverter Technical Data
RD 500 RD51 Inverter Technical Data Inverter Technical Data Technical Data for Size Classes A and B with Pulse frequency f = 4 kHz / 8 kHz 4 kHz 8 kHz RD51.2 18.5 Rated motor output Supply voltage DC 530 ... 670 V (±10 %) Output frequency 0 - 250 0 - 500...
Page 142: Technical Data For Size Classes A And B With Pulse Frequency F
Inverter Technical Data RD 500 RD51 Technical Data for Size Classes A and B with Pulse Frequency f = 12 kHz 12 kHz RD51.2 Supply voltage DC 530 ... 670 V (± 20 %) Output frequency 0 - 1400 Rated current Peak current for t = 60 s A 5.2...
Page 143: Technical Data For Size Classes C, D And E With Pulse Frequency F
RD 500 RD51 Inverter Technical Data Technical Data for Size Classes C, D and E with Pulse Frequency f = 4 kHz 4 kHz RD51.1 kW 22 Rated motor output Supply voltage DC 530 ... 670 V (±10 %) Output frequency 0 - 250 Rated current A 43...
Page 144: Technical Data For Size Classes C, D And E With Pulse Frequency F
Inverter Technical Data RD 500 RD51 Technical Data for Size Classes C, D and E with Pulse Frequency f = 8 kHz 8 kHz 6 kHz RD51 kW 18.5 Rated motor output Supply voltage DC 530 ... 670 V (±10 %) Output frequency 0 - 500 Rated current...
Page 145 RD 500 RD51 Inverter Technical Data Technical Data for Size Classes C, D and E with Pulse Frequency f = 12 kHz 12 kHz RD51.1 Supply voltage DC 530 ... 670 V (±10 %) Output frequency 0 - 1400 Rated current A 30 Peak current for t = 60 s...
Page 146: Technical Data For Size Classes G With Pulse Frequency F = 4 Khz / 8Khz
Inverter Technical Data RD 500 RD51 Technical Data for Size Classes G with Pulse Frequency f = 4 kHz / 8kHz 4 kHz 8 kHz RD51.1 Rated motor output Supply voltage DC 530 ... 670 V (±10 %) 0 - 250 0 - 150 0 - 500 0 - 250...
Page 147: Technical Data For Size Classes G With Pulse Frequency F = 12 Khz
RD 500 RD51 Inverter Technical Data Technical Data for Size Classes G with Pulse Frequency f = 12 kHz 12 kHz RD51.1 Supply voltage DC 530 ... 670 V (±10 %) 0 - 1000 0 - 500 Output frequency Rated current A 140 Peak current for t = 60 s...
Page 148: Technical Data Sft Motor Inverter For Size Classes A And B With Pulse Frequency F
Inverter Technical Data RD 500 RD51 Technical Data SFT Motor inverter for Size Classes A and B with Pulse frequency f = 4 kHz / 8 kHz 4 kHz 8 kHz RD51.3 18.5 Rated motor output Supply voltage DC 750 V (-15 % +5 %) Output frequency 0 - 250 0 - 500...
Page 149: Technical Data Sft Motor Inverter For Size Classes C, D And E With Pulse Frequency F
RD 500 RD51 Inverter Technical Data Technical Data SFT Motor inverter for Size Classes C, D and E with Pulse frequency f = 4 kHz 4 kHz RD51.3 kW 30 Rated motor output Supply voltage DC 750 V (-15 % +5 %) Output frequency 0 - 250 Rated current...
Page 150: Technical Data Sft Motor Inverter For Size Classes C, D And E With Pulse Frequency F
5-10 Inverter Technical Data RD 500 RD51 5.10 Technical Data SFT Motor inverter for Size Classes C, D and E with Pulse frequency f = 8 kHz 8 kHz RD51.3 kW 22 Rated motor output Supply voltage DC 750 V (-15 % +5 %) Output frequency 0 - 500 Rated current...
Page 151: Technical Data Sft Motor Inverter For Size Class G With Pulse Frequency F
5-11 RD 500 RD51 Inverter Technical Data 5.11 Technical Data SFT Motor inverter for Size Class G with Pulse frequency f = 4 kHz / 8 kHz 4 kHz 8 kHz RD51.3 kW 160 Rated motor output Supply voltage DC 750 V (-15 % +5 %) 0 - 150 0 - 250 Output frequency...
Page 152: 5.12 Circuit Principle
5-12 Inverter Technical Data RD 500 RD51 5.12 Circuit Principle Circuit Principle of Electronics Section Fig.: 5-1 Circuit principle of electronics section DOK-RD500*RD51*******-IB04-EN-P...
Page 153: Circuit Principle Of Power Section, Size Classes A And B
5-13 RD 500 RD51 Inverter Technical Data Circuit Principle of Power Section, Size Classes A and B å Fig.: 5-2 Sample connection of classes A – B when using inverter Note: Connections C1 - C and D1 - D absolutely must be made. Note: The leakage current compared to PE is greater than 3.5 mA.
Page 154: Circuit Principle Of Power Section, Size Classes C - E
5-14 Inverter Technical Data RD 500 RD51 Circuit Principle of Power Section, Size Classes C - E å Fig.: 5-3 Circuit principle of power section, inverter classes C - E Note: The connection (inherently short circuit proof) between C1 – C and D1 - D can be made .
Page 155: Circuit Principle Of Power Section, Size Class G (Without Sft)
5-15 RD 500 RD51 Inverter Technical Data Circuit Principle of Power Section, Size Class G (without SFT) å only for cooling type F Fig.: 5-4 Circuit principle of power section, inverter size class G Note: When additional function V1 is used, module SNT is not equipped.
Page 156: Circuit Principle Of Power Section, Inverter Sft Size Class G
5-16 Inverter Technical Data RD 500 RD51 Circuit Principle of Power Section, Inverter SFT Size Class G å P1): pump is not equipped at cooling type W heat exchanger is not equipped at cooling type R and W Fig.: 5-5 Circuit principle of power section, inverter SFT size class G DOK-RD500*RD51*******-IB04-EN-P...
Page 157: 5.13 Mechanical Assembly
5-17 RD 500 RD51 Inverter Technical Data 5.13 Mechanical Assembly Storage and Setup Storage The devices must be stored in a clean, dry space. The storage temperature must be between –25 °C and +70 °C. Temperature variations greater than 20 K per hour are not permitted. Note: The converter and supply modules have AL electrolytic capacitors as DC link capacitors.
Page 158: Setup Elevations Exceeding 1000 Meters Above Sea Level
5-18 Inverter Technical Data RD 500 RD51 Degree of utilization at higher ambient temperatures Ambient temperature in °C DG0006F1.FH7 Fig. 5-6: Utilization at a higher ambient temperature Setup Elevations Exceeding 1000 Meters above Sea Level: The utilization of the inverter must be reduced (derated) corresponding to the diagram below for installation altitudes above 1000 meters above sea level.
Page 159: Dimension Drawing, Size Classes A - B
5-19 RD 500 RD51 Inverter Technical Data • When the drive units are mounted in a cabinet, the cooling air requirement of the units must be calculated (refer to Technical data 5.1 to 5.5) and the cabinet ventilation appropriately dimensioned. •...
Page 160 5-20 Inverter Technical Data RD 500 RD51 PROG ENTER PROG ENTER ST ART ST OP ST ART ST OP DANGER DANGER Fig.: 5-9 Cooling types, size classes A - B DOK-RD500*RD51*******-IB04-EN-P...
Page 161: Assembly Example Of Several Devices Next To Each Other For Cooling Type P
5-21 RD 500 RD51 Inverter Technical Data Assembly Example of Several Devices next to Each Other for Cooling Type P PROG ENTER PROG ENTER PROG ENTER ST ART ST OP ST ART ST OP ST ART ST OP DANGER DANGER DANGER Fig.: 5-10 Arrangement of several devices next to each other for cooling type P Dimension Drawings for Cooling Types D for Size Classes A - B...
Page 162 5-22 Inverter Technical Data RD 500 RD51 Fig.: 5-12 Minimum spacing for assembly DOK-RD500*RD51*******-IB04-EN-P...
Page 163: Dimension Drawing, Size Classes C, D, E
5-23 RD 500 RD51 Inverter Technical Data Dimension Drawing, Size Classes C, D, E ALARM ALARM READY READY ALARM ALARM READY READY PROG PROG ENT ER ENT ER ST ART ST ART ST OP ST OP PROG ENT ER PROG ENT ER ST ART ST OP...
Page 164: Dimension Drawing Of Cooling Type L For Size Classes C, D, E
5-24 Inverter Technical Data RD 500 RD51 Dimension Drawing of Cooling Type L for Size Classes C, D, E Fig.: 5-14 Dimension sheet for cooling type L, size classes C, D, E Minimum Cooling Spacing for Cooling Type L An assembled inverter with forced-air cooling, size classes C, D and E, is shown in the drawing below.
Page 165: Dimension Drawing Of Cooling Type D For Size Classes C, D, E
5-25 RD 500 RD51 Inverter Technical Data Dimension Drawing of Cooling Type D for Size Classes C, D, E Fig.: 5-16 Dimension sheet for cooling type D, size classes C, D, E Several Inverters next to Each Other with Through-Hole Cooling Fig.: 5-17 Cut-outs for devices with plug - through cooler Note:...
Page 166: Assembly Of Inverter, Size Classes G With Forced Air Cooling And Integrated Liquid Circulation System (Cooling Type F)
5-26 Inverter Technical Data RD 500 RD51 5.15 Assembly of Inverter, Size Classes G with Forced Air Cooling and Integrated Liquid Circulation System (Cooling Type F) Inverters of size class G comprise the following elements: inverter and heat exchanger. The inverter and heat exchanger are mounted on a common mounting plate and are fully connected.
Page 167: Assembling Liquid-Cooled Inverters, Size Class G With External Heat Exchanger
5-27 RD 500 RD51 Inverter Technical Data 5.16 Assembling Liquid-Cooled Inverters, Size Class G with External Heat Exchanger General Notes Regarding Assembly Inverters of size class G comprise the following elements: inverter and heat exchanger. In externally assembled heat exchangers, the inverter is not cooled by the air flow of the heat exchanger.
Page 168: Supplementary Fan Transformer
5-28 Inverter Technical Data RD 500 RD51 Supplementary Fan Transformer For 200 kW device, the size of the internal power supply is not adequate for these additional fans. An external fan transformer is included to supply power to the fans. The fan transformer to connect the inverter fans must be mounted at a suitable location in the cabinet.
Page 169: Dimension Drawing, Size Classes G With Cooling Type R
5-29 RD 500 RD51 Inverter Technical Data ALARM READY PROG ENT ER ST ART ST OP Fig.: 5-20 Connection plan for separate fan transformer for size class G with cooling type R Dimension Drawing, Size Classes G with Cooling Type R ALARM READY PROG...
Page 170: Mounting Drawing For Devices With External Heat Exchanger For Cabinet Roof Mounting, Size Class G
5-30 Inverter Technical Data RD 500 RD51 Mounting Drawing for Devices with External Heat Exchanger for Cabinet Roof Mounting, Size Class G ALARM READY PROG ENT ER ST ART ST OP Fig.: 5-22 Dimension sheet for cabinet roof mounting, size class G Mounting Drawing for Devices with External Heat Exchanger for Wall Mounting Fig.: 5-23 Dimension sheet for wall mounting, size class G...
Page 171: 5.17 Working On The Coolant Circulation System Size Class G
5-31 RD 500 RD51 Inverter Technical Data 5.17 Working on the Coolant Circulation System Size Class G Both versions of the liquid-cooled drive units, with integrated and external heat exchanger, are supplied filled with liquid. The coolant comprises tap water and antifreeze, type Antifrogen N (Clariant). It is mixed in the ratio 1 : 1.
Page 172 5-32 Inverter Technical Data RD 500 RD51 Damage to materials due to malfunction in coolant circulation system! ⇒ Ensure fault-free operation of the coolant circulation system WARNING Note: Prevent deposits in the cooling tubes. Note: Pay attention to the change in volume of the coolant due to the temperature differences.
Page 173: Mounting Extension Hoses For External Heat Exchanger
5-33 RD 500 RD51 Inverter Technical Data Mounting Extension Hoses for External Heat Exchanger For devices with external heat exchangers, all of the parts required for the hose extensions (hoses, connectors, couplings, clamps, coolant, etc.) are supplied according to the customer’s specifications when ordering. Customers must assemble the extension hoses themselves, as described below: 1.
Page 174 5-34 Inverter Technical Data RD 500 RD51 DOK-RD500*RD51*******-IB04-EN-P...
Page 175: Electrical Installation Of Inverter
RD 500 RD51 Electrical Installation of Inverter Electrical Installation of Inverter 10 Rules for Installation of Drives According to EMC The following 10 rules are the basics for designing drive systems in compliance with EMC. Rules 1 to 7 are generally valid. Rules 8 to 10 are especially important to limit noise emission.
Page 176: Warnings And Notes
Electrical Installation of Inverter RD 500 RD51 All variable-speed motors should be connected using shielded cables, Rule 9 whereby the shield is connected at both ends to the housings through the largest possible surface area to minimize the inductance. The motor feeder cables should also be shielded outside the cabinet, or at least screened using barriers.
Page 177: Cable Cross-Sections
RD 500 RD51 Electrical Installation of Inverter Damage to the devices as a result of an incorrect supply voltage! ⇒ RD 500 devices are designed for various supply voltages! This is the reason why supply voltages are CAUTION not specified in the drawings and tables for the terminal strips.
Page 178: Power Terminals Rd 51 Size Classes A - E
Electrical Installation of Inverter RD 500 RD51 Power Terminals RD 51 Size Classes A - E Terminal Layout Diagram, Size Classes A - B X1 U1 V1 W1 D D C C F only for additional function CF / DF D1 C1 X1 PROG ENTER...
Page 179: Description Of Inverter Power Terminals Size Classes A - B
RD 500 RD51 Electrical Installation of Inverter Description of Inverter Power Terminals Size Classes A - B X1, Line supply, DC link connection Execution RD51.2-xx- Type pole number Execution RD51.3-xx- Sub-unit Plug on device Sub-unit Plug on device Sub-unit Plug on device Sub-unit Plug on device Sub-unit...
Page 180 Electrical Installation of Inverter RD 500 RD51 X1, DC link connection Execution RD51.2-xx- Type pole number Execution RD51.3-xx- plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device Tab.
Page 181 RD 500 RD51 Electrical Installation of Inverter Fuses Motor Inverter SFT Size Classes A and B Fuses RD51.3-xx- Maximum series fuse, type gL, A 1) or AC-fuses with min. 750 V at L / R = 20 ms. Tab. 6-8 Series fuse X2, Motor connection Execution...
Page 182 Electrical Installation of Inverter RD 500 RD51 X80 Starting lock-out (only in A1 and A2) Execution RD51.2-xx- Type pole number Execution RD51.3-xx- plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device Tab.
Page 183 RD 500 RD51 Electrical Installation of Inverter X83, 24 V Stand-by power supply for the electronics (only in A1 and A2) Execution RD51.2-xx- Type pole number Execution RD51.3-xx- plug Plug on device plug Plug on device plug Plug on device plug Plug on device plug...
Page 184 6-10 Electrical Installation of Inverter RD 500 RD51 X2, Filter current feedback F1 (only in A1) Execution RD51.2-xx- Type pole number Execution RD51.3-xx- plug Plug on device plug Plug on device plug Plug on device plug Plug on device plug Plug on device Tab.
Page 185: Terminal Layout Diagram Size Classes C, D
6-11 RD 500 RD51 Electrical Installation of Inverter Terminal Layout Diagram Size Classes C, D An inverter of size class C is illustrated in the terminal layout diagram. The position of the terminals is essentially the same for the narrower or wider drive units.
Page 186: Terminal Layout Diagram Size Class E
6-12 Electrical Installation of Inverter RD 500 RD51 Terminal Layout Diagram Size Class E Note: The additional function 24 V Stand by power supply (terminal X83) is only mounted if it was actually ordered. DC link connection C1 D1 ALARM ALARM READY READY...
Page 187: Description Of Inverter Power Terminals Size Classes C - E
6-13 RD 500 RD51 Electrical Installation of Inverter Description of Inverter Power Terminals Size Classes C - E X1 DC link connection Execution RD51.1-xx- Type number Execution RD51.3-xx- High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal...
Page 188 6-14 Electrical Installation of Inverter RD 500 RD51 X1, SNT supply Execution RD51.1-xx- Type Num- Execution RD51.3-xx- Universal terminal With mounting foot Universal terminal With mounting foot Universal terminal With mounting foot Universal terminal With mounting foot Universal terminal With mounting foot Universal terminal With mounting foot High current bushing terminal 2...
Page 189 6-15 RD 500 RD51 Electrical Installation of Inverter Fuses Inverter Size classes C, D and E Fuses RD51.1-xx- Maximum series fuse, type gL, A 1) Safety values are provided for the DC 560 V input voltage and for the rated output X1 of the device. If the input voltage differs, the safety value must be changed.
Page 190 6-16 Electrical Installation of Inverter RD 500 RD51 X2, Motor connection Execution RD51.1-xx- Type Number Execution RD51.3-xx- High current bushing terminal Screw connection High current bushing terminal Screw connection High current bushing terminal Screw connection High current bushing terminal Screw connection High current bushing terminal Screw connection High current bushing terminal...
Page 191 6-17 RD 500 RD51 Electrical Installation of Inverter X2, cable damping L1 Execution RD51.1-xx- Type Number Execution RD51.3-xx- High current bushing terminal Screw connection High current bushing terminal Screw connection High current bushing terminal Screw connection High current bushing terminal Screw connection High current bushing terminal Screw connection...
Page 192 High current bushing terminal Screw connection High current bushing terminal Screw connection Tab. 6-37 Execution Identification single connection Identification signification Operation possible only with the original Bosch Rexroth filter Tab. 6-38 Identification single connection Connection cross-section RD51.1-xx- Cable cross- Torque RD51.3-xx- section which can be connected, mm²...
Page 193 6-19 RD 500 RD51 Electrical Installation of Inverter X80, Starting lock-out Execution RD51.1-xx- Type pole number Execution RD51.3-xx- plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device plug-in connection Plug on device...
Page 194 6-20 Electrical Installation of Inverter RD 500 RD51 X83, 24 V Stand-by power supply for the electronics (only in A1 and A2) Execution RD51.1-xx- Type pole number Execution RD51.3-xx- plug Plug on device plug Plug on device plug Plug on device plug Plug on device plug...
Page 195 6-21 RD 500 RD51 Electrical Installation of Inverter X81, additional function CF / DF Identification single connection Identification signification connection RZC01.x... only for internal use Abb. 6-4: Identification single connection Note: Depending on the national regulations at the setup location, an external fuse and / or a short-circuit-proof layout may also be required.
Page 196: Power Terminals Rd51 Size Class G
6-22 Electrical Installation of Inverter RD 500 RD51 Power Terminals RD51 Size Class G After the device has been mounted, the electrical connections must be established: Terminal Layout Diagram Inverter Size Class G Heat exchanger ALARM READY PROG ENT ER ST ART ST OP Inverter...
Page 197: Description Of Power Terminals Inverter Size Class G
6-23 RD 500 RD51 Electrical Installation of Inverter Description of Power Terminals Inverter Size Class G X1, DC link connection Execution RD51.1-xx- Type number Execution Stud connection rail Stud connection rail Stud connection rail Tab. 6-6: Execution Identification single connection Identification signification DC link connection L+...
Page 198 6-24 Electrical Installation of Inverter RD 500 RD51 X2, DC link, control terminal Execution RD51.1-xx- Type number Execution RD51.3-xx- feed-through terminal 2 + 1* terminal block feed-through terminal 2 + 1* terminal block feed-through terminal 2 + 1* terminal block at additional function Brake resistor Tab.
Page 199 6-25 RD 500 RD51 Electrical Installation of Inverter Fuses inverter Size class G fuses RD51.1-xx- Maximum series fuse, type gL, A 1) Safety values are provided for the DC 560 V input voltage and for the rated output X1 of the device. If the input voltage differs, the safety value must be changed.
Page 200 6-26 Electrical Installation of Inverter RD 500 RD51 X5, control voltage Execution RD51.1-xx- Type Pole- Execution number plug Plug on device plug Plug on device plug Plug on device Tab. 6-23: Execution Identification single connection Identification signification Supply voltage Voltage class 7: AC 400 V 50 / 60 Hz Supply voltage Voltage class 8:...
Page 201 6-27 RD 500 RD51 Electrical Installation of Inverter X2, L1 cable damping (additional function) Execution RD51.1-xx- Type number Execution RD51.3-xx- Universal terminal Terminal on mounting rail Universal terminal Terminal on mounting rail Universal terminal Terminal on mounting rail Tab. 6-29: Execution Identification single connection Identification signification...
Page 202 6-28 Electrical Installation of Inverter RD 500 RD51 X2, W1 95 mm² terminal C and F (additional function) Execution RD51.1-xx- Type number Execution High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail High current terminal Terminal on mounting rail Tab.
Page 203: Control Transformer T1
6-29 RD 500 RD51 Electrical Installation of Inverter X83, 24 V power supply for the electronics Execution RD51.1-xx- Type Pol number Execution RD51.3-xx- plug Plug on device plug Plug on device plug Plug on device Tab. 6-41: Execution Identification single connection Identification signification P24 V 24 V DC –15 / +20 %, ripple, max 5 % (VDE0411 /...
Page 204 6-30 Electrical Installation of Inverter RD 500 RD51 Dimension in mm 300V control transformer Connection line ( eligible ) 460V 440V 400V 230V MB520023EN00.FH9 415V 380V Fig.: 6-44 Control Transformer T1 DOK-RD500*RD51*******-IB04-EN-P...
Page 205: Connection Diagram
6-31 RD 500 RD51 Electrical Installation of Inverter Connection Diagram Connection Diagram Inverter Size class A - E DC link SNT -power supply L+ L- C1 D1 SR 17000 Operating panel X11 Service Interface RDwin Ser. Communication X12 RS485 Interface via USS-protocoll Commands, X14 Standard terminal...
Page 206: Connection Diagram Inverter Size Class G (Rd51.1)
6-32 Electrical Installation of Inverter RD 500 RD51 Connection Diagram Inverter Size class G (RD51.1) L+ L- X1 C D X5 1 SR 17000 Operating panel X11 Service Interface RDwin Ser. Communication X12 RS485 Interface viaUSS-protocoll Commands, X14 Standard terminal Setpoints, actual values Reference voltage Analog input+...
Page 207: Connection Diagram Inverter Sft Size Class G (Rd51.3)
6-33 RD 500 RD51 Electrical Installation of Inverter Connection Diagram Inverter SFT Size class G (RD51.3) L+ L- X1 C D X5 7 SR 17000 Operating panel X11 Service Interface RDwin Ser. Communication X12 RS485 Interface viaUSS-protocoll Commands, X14 Standard terminal Setpoints, actual values Reference voltage Analog input+...
Page 208: Control Terminals See Chapter 4.7
6-34 Electrical Installation of Inverter RD 500 RD51 Control terminals see Chapter 4.7 Service Interface (RS232) see Chapter 4.9 Standard Interface (RS482) see Chapter 4.10 DOK-RD500*RD51*******-IB04-EN-P...
Page 209: Operator Control And Visualization
RD 500 RD51 Operator Control and Visualization Operator Control and Visualization Possibilities of Operator Control The user panel (option), the RDwin PC user interface and several other interfaces are available to operate, visualize and parameterize RD 500 units. Serial interfaces RS232 and RS485 are installed as standard on the logic and control board.
Page 210: Operation With The Operator Panel
Operator Control and Visualization RD 500 RD51 Operation with the operator panel When supplied (standard values of the basic parameterization are set), the start / stop key and the plus / minus key (for the motorized potentiometer function) are active. Function Conditions Starts the drive...
Page 211: Fast Parameterization Using Key Combinations
RD 500 RD51 Operator Control and Visualization Fast Parameterization using Key Combinations Response If these keys are simultaneously pressed: – the complete parameter number is set to zero (numerical list). – the complete parameter value is set to zero (for numerical parameters).
Page 212: Fault Messages When Parameterizing
Operator Control and Visualization RD 500 RD51 Damage caused by parameterizing errors! ⇒ The filter or motor could be damaged if the pulse frequency (P0026) is incorrectly selected. CAUTION Fault Messages when Parameterizing Error message Cause Solution Parameter is not Parameter numbers which are not Only pre-defined parameters are available in the accessible in the...
Page 213: Copy Function
RD 500 RD51 Operator Control and Visualization Copy Function A copy function is integrated in the user panel. This allows a parameter set to be saved in the user panel (P0733) and then transferred quickly into another unit (P0732). In this case, only those parameters which are accessible with the selected password level are transferred to the unit.
Page 214: Visualization
Operator Control and Visualization RD 500 RD51 Visualization Monitor Monitor Structure Fig.: 7-9 Monitor program structure DOK-RD500*RD51*******-IB04-EN-P...
Page 215: Operating Display
RD 500 RD51 Operator Control and Visualization Monitor Functions Four selectable parameters are simultaneously displayed. The parameter Parameter monitor can be used to support commissioning, e.g. the speed setpoint route can be tracked using the parameterizable functions of the converter. In this case, use the D parameters from the function charts.
Page 216: Fault Display
Operator Control and Visualization RD 500 RD51 Fault Display If an operating condition which initiates a fault occurs, the fault display replaces the operating display. Fig.: 7-12 Fault display LED Display LED display Meaning No LED lit Operating condition, power-on inhibitor not ready to power-up Operating condition, ready to power-up Green LED lit...
Page 217: Parameter Value Assignment
Parameter Value Assignment Parameter Value Assignment Parameterization The RD 500 series can be parameterized with two possibilities: 1. Basic parameterization: The operator has pre-defined parameters in the "basic parameterization". It is menu-prompted, and it allows many applications to be quickly set in a user-friendly fashion. It is selected in the condition when supplied from the factory.
Page 218 Parameter Value Assignment RD 500 RD51 Fig. 8-1: Parameterization menu structure DOK-RD500*RD51*******-IB04-EN-P...
Page 219: Overview
RD 500 RD51 Parameter Value Assignment Overview Fig. 8-2: Menu overview DOK-RD500*RD51*******-IB04-EN-P...
Page 220: Password Levels
Parameter Value Assignment RD 500 RD51 Password Levels The parameters are located at various access levels. A password is required to change parameters. If several parameters are changed in the parameterization, the password has to be entered only the first time. The required password level can be taken from the parameter table.
Page 221 RD 500 RD51 Parameter Value Assignment Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0106.00 cos-phi ASM 0.50 ... 0.98 cos-phi from the motor rating plate. 0112.00 Rated current SM 0.5 A ... P0033 Rated current from the motor rating plate.
Page 222 Parameter Value Assignment RD 500 RD51 Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0280.XX Ramp-up time Refer to Fig. 8-4: Up- and down-ramps 5.000 s Ramp-up time of the ramp-function generator. The 0.000 ...
Page 223: Guided Parameterization
RD 500 RD51 Parameter Value Assignment Guided parameterization Drive control / setpoints Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0870 On / off for NORMAL Terminal dynamic 1 Enters On / off for NORMAL operation 0...13 0 = Term.
Page 224 Parameter Value Assignment RD 500 RD51 Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0196 Mot. pot. mode Supplementary parameter for “motor Start f set, expon. 1 potentiometer”. 0 ... 3 For Start f set, the motor potentiometer setpoint, which was set the last after the off command, is approached.
Page 225 RD 500 RD51 Parameter Value Assignment Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0284 Analog window STD Supplementary parameter for “analog input”. 0.50 % The analog setpoint smoothing is specified in a 0.00 ...
Page 226: Standard Terminal Assignment
8-10 Parameter Value Assignment RD 500 RD51 Standard terminal assignment Para- Name Description / explanation Factory Pass- meter setting word selectable options No.: min ... max values 0875 Dig. input, I no function output1 Combined digital input and output 0...98 0 = I no function (I = input) 2 = I...
Page 227 8-11 RD 500 RD51 Parameter Value Assignment Para- Name Description / explanation Factory Pass- meter setting word selectable options No.: min ... max values 52 = IT no alarm. ext. (IT = input which is only active in the “TEST” mode) 53 = IT no fault ext.
Page 228 8-12 Parameter Value Assignment RD 500 RD51 Para- Name Description / explanation Factory Pass- meter setting word selectable options No.: min ... max values 0461 Mode dig. In- Supplementary parameter for output signals output1 Mode dig.output1 Terminal X14.2 3 ... 4 3 = direct 4 = inverted 0463...
Page 229 8-13 RD 500 RD51 Parameter Value Assignment Para- Name Description / explanation Factory Pass- meter setting word selectable options No.: min ... max values 0759.01 Hysteresis x:xs Supplementary parameter for “O motor rotating 2”. 1.00 % Hysteresis for current 0.00 ... 100.00 % 0731.01 Fixed value for...
Page 230 8-14 Parameter Value Assignment RD 500 RD51 Para- Name Description / explanation Factory Pass- meter setting word selectable options No.: min ... max values 0411 Output-block Supplementary parameter for “analog output”. direct signal Defines how a signal is transferred. 0...3 0 = direct 1 = absolute value 2 = inverted...
Page 231: Functions
8-15 RD 500 RD51 Parameter Value Assignment Functions • Controller setting • Start / stop function • Thermal motor protection • V / Hz control (open loop) Controller setting Para- Name Description / explanation Factory setting Pass- meter word selectable options min ...
Page 232 8-16 Parameter Value Assignment RD 500 RD51 Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0546 DC braking current Supplementary parameter for “braking 5.00 % operation” from P0043 and P0044: 100 % corresponds to the contents of parameter 1.00 ...
Page 233 8-17 RD 500 RD51 Parameter Value Assignment Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0388 PTC evaluation Supplementary parameter for PTC in P0385 Fault The following options can be selected when the 0 / 1 selected PTC switching value (P389) is reached: 0 = alarm (alarm, motor temperature)
Page 234 8-18 Parameter Value Assignment RD 500 RD51 Fig. 8-5: Emulation of the thermal overload release The overload protection is switched-in and switched-out using P0565 and Overload protection the response type, either alarm or fault, is selected. The response threshold of the overload protection (P0566) can be set between 0.5 A and the peak current P0025.
Page 235 8-19 RD 500 RD51 Parameter Value Assignment V / Hz control Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0181.00 V/f characteristic fa Refer to Fig. 8-6: V / Hz characteristic diagram The V / Hz characteristic data is calculated by the 0.0 ...
Page 236 8-20 Parameter Value Assignment RD 500 RD51 V / f characteristic The values of the V / f characteristic (P0181 – P0188) are calculated from the rating plate data (P0181 – P0188). The unit calculates the characteristic data after you have entered the data on the rating plate of your motor.
Page 237 8-21 RD 500 RD51 Parameter Value Assignment Default calculation of the characteristic data from the rating plate data: Square-law V/f characteristic × 0120 0117 0181 slip × × slip 0185 − 0182 − × 0186 − 0183 − × 0187 0184 0188 Fig.
Page 238 8-22 Parameter Value Assignment RD 500 RD51 Additional functions Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0282.00 Rounding ramp up 0.000 s Rounding-off times UP for the ramp-function 0.000 ... 800.00 s generator.
Page 239 8-23 RD 500 RD51 Parameter Value Assignment For arithmetic positive setpoints changes, the RFG UP times are effective, for arithmetic negative setpoints changes, the RFG DOWN times are effective. Abb. 8-9: Ramp-up and ramp-down with direction of rotation reversal For absolute setpoints increases, the RFG UP are effective, for absolute setpoint decreases, the RFG DOWN times are effective Abb.
Page 240: Drive Setting
8-24 Parameter Value Assignment RD 500 RD51 Drive setting Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0071 Load factorySetting No action 0 = no action 0 ... 4 1 = basic, standard values are loaded Parameters, with a password level less than or the same as the entered password level are set to the standard value of the basic parameterization.
Page 241 8-25 RD 500 RD51 Parameter Value Assignment Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0037.00 Display, lines 1,2,3 f actual Selects the operating display for line 1. 0 ... 9 0 = status (drive status message) 1 = actual speed (electrical) 2 = output effective current...
Page 242: Serial Communications
8-26 Parameter Value Assignment RD 500 RD51 Serial communications Sub-menu to set standard RS485 interfaces. Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0499 RS232 baud rate 9600 baud 0 = 1200 baud 0 ...
Page 243 8-27 RD 500 RD51 Parameter Value Assignment Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 1270 SI6 baud rate X13 4 = 125 kbaud 4 ... 7 5 = 250 kbaud 6 = 500 kbaud 1 Mbaud 1271.XX...
Page 244: Diagnostics / Drive Data
8-28 Parameter Value Assignment RD 500 RD51 Diagnostics / drive data Para- Name Description / explanation Factory setting Pass- meter word selectable options min ... max values No.: 0028 Operating hours Operating hours with the inverter enabled. 0 ... 2147483647 h 0029 Operating minutes Operating minutes with the inverter enabled.
Page 245: Commissioning
RD 500 RD51 Commissioning Commissioning Preparatory Steps for Commissioning The power terminals for the converters should be connected as specified in section 4.4, 4.5 and the control terminals as specified in section 4.7 The power terminals for the inverters should be connected as specified in sections 6.4, 6.5 and the control terminals as specified in section 4.7 .
Page 246 Commissioning RD 500 RD51 Fig. 9-1: Flow diagram, commissioning DOK-RD500*RD51*******-IB04-EN-P...
Page 247: Motor Optimization / Motor Evaluation
RD 500 RD51 Commissioning Motor optimization / motor evaluation Motor running under no-load conditions In the steady-state condition, the drive converter current should be approx. 1/3 of the rated motor current. If a significant deviation is identified, then the motor data, which was entered in Quick-Setup, can be checked to ensure that it is correct, and the mechanical load can be checked to ensure that it moves freely.
Page 248 Commissioning RD 500 RD51 DOK-RD500*RD51*******-IB04-EN-P...
Page 249: Basic Functions
10.1 Starting lock-out for RD 500 Size Classes A - H Description Devices in the RD 500 series are equipped with a start inhibitor function. Using this function, the “Protection against accidental starting” requirement, in compliance with EN 60 204-1, can be implemented.
Page 250 10-2 Basic Functions RD 500 RD51 If the line supply is not connected and the “Standby” additional function is selected, the “Starting lock out” warning message is not displayed. Furthermore, the starting lock out cannot be used (alone) in the following cases: •...
Page 251: Optional Device Functions
11-1 RD 500 RD51 Optional Device Functions Optional Device Functions 11.1 Additional function 24 V Stand-by Power Supply General The additional function standby allows the control electronics to operate without any line supply voltage connected to the converter. A 24 V DC control power supply voltage is required.
Page 252 11-2 Optional Device Functions RD 500 RD51 Note: Size classes A to E, the additional function is a stand-by power supply of the control electronics, as the drive is out. After „drive ON“: DC-link supplies the control electronics. Size classes G and H, the 24 V power supply is complete power supply and during operation permanently required.
Page 253: Troubleshooting
12-1 RD 500 RD51 Troubleshooting Troubleshooting 12.1 Self-Test Error Messages After the initialization routine, the system carries out a self-test. Here, the individual parts of the microcomputer system, such as the EEPROM, are checked and data are read in from the power control board. 12.2 Warnings If a warning occurs, the warning message is displayed alternatingly with the programmed operating display.
Page 254: 12.4 List Of Warning And Fault Messages
12-2 Troubleshooting RD 500 RD51 12.4 List of Warning and Fault Messages Messages Warning Fault External DC link voltage too high DC link voltage too low Device excess temperature Braking resistor Main contactor Pre-charge New EEPROM Clock1 <==> Clock2 Power section Inverter Power supply Excess speed...
Page 255: Warning And Fault Messages-Cause And Remedy / Comments
12-3 RD 500 RD51 Troubleshooting 12.5 Warning and Fault Messages– Cause and Remedy / Comments Designation Message Cause Remedy / comments External Warning / fault If the function “no external fault” is assigned to a Determine and eliminate the cause of signal loss in the digital input and if there is no 24 V signal at the digital system.
Page 256: Precharge
12-4 Troubleshooting RD 500 RD51 Designation Message Cause Remedy / comments Precharge Fault After startup, the temporal sequence of charging the Check: DC link voltage is checked. If inadmissible variances if the power supply is available occur here, precharging is terminated. if there is a short-circuit between terminals C and D Short-circuit between terminals C and D (DC link or C-PE / D-PE.
Page 257: Ground Fault
12-5 RD 500 RD51 Troubleshooting Designation Message Cause Remedy / comments Ground fault Fault Ground fault at the inverter output terminals (U2, V2, W2) or excessive capacitance with respect to ground as a result of long motor cables. EEPROM data Warning / fault The appropriate parameter numbers can be viewed Cause in the parameterization:...
Page 258: Ss2 Function
12-6 Troubleshooting RD 500 RD51 Designation Message Cause Remedy / comments SS2 function Warning / fault Only for option interface cards at option slot 1. Check that the PPO type (protocol type), baud rate, The drive converter detects a physical fault on the parity, stop bit and slave address are correct.
Page 259: Sr Output Level
12-7 RD 500 RD51 Troubleshooting Designation Message Cause Remedy / comments SR output level? Fault The control card and the firmware (Flash Eprom) do Please call customer service. not match. BR overload Warning / fault For the parameterized brake resistor, the drive converter computes a temperature image.
Page 260: Overcurrent
12-8 Troubleshooting RD 500 RD51 Designation Message Cause Remedy / comments Overcurrent Fault Current limiting is active for a time which is longer Check the setting of P0574! than that parameterized. The time duration of the uninterrupted current limiting (D1678 = 1) can be set between 1 second and 100 seconds in 11 steps using P0574.
Page 261: On For Starting Lock-Out
12-9 RD 500 RD51 Troubleshooting Designation Message Cause Remedy / comments On for starting lock-out Fault The message only occurs when the start inhibit option is installed. Sizes A to E: Contacts X80.1 and 2 were opened during operation, or an on command was output with the terminal open.
Page 262: Starting Lock-Out Active
12-10 Troubleshooting RD 500 RD51 Designation Message Cause Remedy / comments Starting lock-out active Warning Only for the start inhibit option: The start inhibit was activated, while the drive converter was not operational. Module overtemperature Warning / fault The measured module temperature of the power Example of incorrectly set air control in P0034: transistor or of the mains rectifier is too high.
Page 263: Service & Support
13-1 RD 500 RD51 Service & Support Service & Support 13.1 Helpdesk Unser Kundendienst-Helpdesk im Hauptwerk Lohr Our service helpdesk at our headquarters in Lohr am am Main steht Ihnen mit Rat und Tat zur Seite. Main, Germany can assist you in all kinds of inquiries. Sie erreichen uns Contact us +49 (0) 9352 40 50 60...
Page 264: 13.5 Kundenbetreuungsstellen
C A L L E N T R Y C E N T E R ERSATZTEILE / SPARES Rexroth Indramat GmbH H e l p d e s k H O T L I N E 2 4 / 7 / 3 6 5 verlängerte Ansprechzeit...
Page 265 - Italien Netherlands - Niederlande/Holland Netherlands – Niederlande/Holland Bosch Rexroth S.p.A. Bosch Rexroth S.p.A. Bosch Rexroth Services B.V. Bosch Rexroth B.V. Via del Progresso, 16 (Zona Ind.) Via Isonzo, 61 Technical Services Kruisbroeksestraat 1 35020 Padova 40033 Casalecchio di Reno (Bo) Kruisbroeksestraat 1 (P.O.
Page 266 - Tschechien Czech Republic - Tschechien Hungary - Ungarn Poland – Polen DEL a.s. Bosch -Rexroth, spol.s.r.o. Bosch Rexroth Kft. Bosch Rexroth Sp.zo.o. Strojírenská 38 Hviezdoslavova 5 Angol utca 34 ul. Staszica 1 591 01 Zdar nad Sázavou 627 00 Brno 1149 Budapest 05-800 Pruszków...
Page 267 Australia - Australien Australia - Australien China China AIMS - Australian Industrial Bosch Rexroth Pty. Ltd. Shanghai Bosch Rexroth Shanghai Bosch Rexroth Machinery Services Pty. Ltd. No. 7, Endeavour Way Hydraulics & Automation Ltd. Hydraulics & Automation Ltd. 28 Westside Drive...
Page 268 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 269: Index
14-1 RD 500 RD51 Index Index Ambient temperature 3-30, 5-17 Analog input 4-43 Analog output 4-43 Antifreeze 3-42, 3-54, 5-31 Assembling Liquid-Cooled Converters, Size Classes G and H, with External Heat Exchanger 3-48 Assembly of Converter size classes A to E 3-31 Assembly of Converter, Size Classes G and H, with Forced Air Cooling and Integrated Liquid Circulation System 3-46 Assembly of Inverter, Size Classes G with Forced Air Cooling and Integrated...
Page 270 14-2 Index RD 500 RD51 Fault acknowledgement 7-5 Fault Acknowledgement 12-1 Fault display 7-8 Fault message Safety Off (NAMUR) 12-8 Fault message BR overload 12-7 Braking resistor 12-3 DC link voltage too high 12-3 DC link voltage too low 12-3 Device excess temperature 12-3 EEPROM data 12-5 External 12-3...
Page 271 14-3 RD 500 RD51 Index Key functions of the user panel in monitor mode 7-1 Line supply feeder cables 4-3, 6-3 List of warning and fault messages 12-2 Load standard parameters 7-3 Load standard values 7-3 Menu overview 8-3 Minimum spacing for cooling 3-35 Monitor functions 7-7 Monitor program structure 7-6 Motor feeder cables 4-3, 6-3...
Page 272 14-4 Index RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls 1-1 Self-test error messages 12-1 Service interface 4-48 Servicing the coolant circulation system 3-57, 5-33 Setup elevations 3-31, 5-18 Square-law characteristic diagram 8-21 Standard interface 4-50 Standby 11-1 Starting lock out 10-1 Storage 3-30, 5-17 Storage temperature 3-30, 5-17...
Page 273 14-5 RD 500 RD51 Index Type key of RZE01.2 EMC-filter with integrated line reactor 3-16 Type label of line reactor RND 3-23 Type label of RZE01.2 EMC-filter with integrated line reactor 3-17 Use See Proper use and see Improper use USS protocol 4-50 Utilization 3-30, 5-17 Warning and Fault Messages–...
Page 274 14-6 Index RD 500 RD51 DOK-RD500*RD51*******-IB04-EN-P...
Page 276 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 +49 (0)93 52-40-49 41 service.svc@boschrexroth.de www.boschrexroth.com Printed in Germany R911201161 DOK-RD500*RD51*******-IB04-EN-P...

This manual is also suitable for:

Rd 500 sft series Rd51.1 Rd51 series Rd51.2 Rd51.3

REXROTH RD 500 Series Applications Manual

Table of Contents

1 Safety Instructions for Electric Servo Drives and Controls

2 Description of RD51

3 Converter Technical Data

4 Electrical Installation of Converter

5 Inverter Technical Data

6 Electrical Installation of Inverter

7 Operator Control and Visualization

8 Parameter Value Assignment

9 Commissioning

10 Basic Functions

11 Optional Device Functions

12 Troubleshooting

12.4 List of Warning and Fault Messages

13 Service & Support

14 Index

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Summary of Contents for REXROTH RD 500 Series