REXROTH RD 500 Series Instructions for use

Rexroth IndraControl VCP 20
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
Rexroth RD 500 RD51
Drive Control Devices
V/F Characteristic Control
R911201161
Edition 04
Application Manual

Over this documentation RD 500 RD51
DOK-RD500*RD51*******-IB04-EN-P
Rexroth RD 500 RD51
Drive Control Devices
V/F Characteristic Control
Application Manual
DOK-RD500*RD51*******-IB04-EN-P
Document Number: 120-1950-B305-04/EN
This documentation explains the frequency converters of the drive series
RD 500 RD51. It provides information.
•for planing the mechanical control cabinet construction.
•for planing the electrical control cabinet construction.
•for commissioning the drive controls.
•for basic parameterization of the drive controls.
to fault messages and notes to cause and remedy.
Description Release
Date Notes
DOK-RD500*-RD51*******-IB01-EN-P 01.2000 First edition
DOK-RD500*-RD51*******-IB02-EN-P 03.2003 revision
DOK-RD500*-RD51*******-IB03-EN-P 11.2003 revision
DOK-RD500*-RD51*******-IB04-EN-P 10.2004 revision
Bosch Rexroth AG, 2004
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).
The data specified above only serve to describe the product. No
statements concerning a certain condition or suitablility for a certain
application can be derived from our information. The given information
does not release the user from the obligation of own judgement and
verification. It must be remembered that our products are subject to a
natural process of wear and aging.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str.2 •D-97816 Lohr a. Main
Telefon [phone] / 40-0 •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.de/
Dpt. ENG (mi)
This document has been printed on chlorine-free bleached paper..
Title
Type of Documentation
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Internal File Reference
Purpose of Documentation
Record of Revisions
Copyright
Validity
Published by
Note

RD 500 RD51 Contents I
DOK-RD500*RD51*******-IB04-EN-P
Contents
1 Safety Instructions for Electric Servo Drives and Controls 1-1
1.1 Introduction................................................................................................................................... 1-1
1.2 Explanations................................................................................................................................. 1-1
1.3 Hazards due to inappropriate use ................................................................................................ 1-2
1.4 General information...................................................................................................................... 1-3
1.5 Protection against contact with electrical parts.............................................................................1-4
1.6 Protection against electrical shock by protective low voltage (PELV).......................................... 1-6
1.7 Protection against dangerous movements................................................................................... 1-6
1.8 Protection against magnetic and electromagnetic fields during operations and mounting.......... 1-8
1.9 Protection against contact with hot parts...................................................................................... 1-9
1.10 Protection during handling and installation.................................................................................1-10
1.11 Battery safety.............................................................................................................................. 1-10
1.12 Protection against pressurized systems..................................................................................... 1-11
1.13 Precautionary measures when handling components which can be destroyed by
electrostatic discharge (ESDS)................................................................................................... 1-11
2 Description of RD51 2-1
2.1 The RD 500 Device Series........................................................................................................... 2-1
Handling................................................................................................................................... 2-1
Electromagnetic Compatibility................................................................................................. 2-1
Technical Characteristics ........................................................................................................ 2-1
Technical Characteristics RD 500 SFT ................................................................................... 2-2
2.2 Type Label.................................................................................................................................... 2-2
2.3 Type Key....................................................................................................................................... 2-4
Basic Device Type Key, Size Classes A – B (RD51.2)........................................................... 2-4
Basic Device Type Key, Size Classes C - H (RD51.1)............................................................ 2-5
Type Key SFT Inverter (RD51.3)............................................................................................. 2-7
Type Key Configuration........................................................................................................... 2-9
2.4 Important Notes Regarding Use................................................................................................. 2-10
Proper Use............................................................................................................................. 2-10
Improper use.......................................................................................................................... 2-11
3 Converter Technical Data 3-1
3.1 Technical Data for Size Classes A and B with Pulse Frequency fp= 4 kHz / 8kHz (3AC
380 ... 480 V) ................................................................................................................................ 3-1
3.2 Technical Data for Size Classes A and B with Pulse Frequency fp= 12 kHz (3AC 380 ...
480 V) ........................................................................................................................................... 3-2
3.3 Technical Data for Size Classes A and B with Pulse Frequency fp= 4 kHz / 8 kHz (3AC
200 ... 230 V) ................................................................................................................................ 3-3

II Contents RD 500 RD51
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3.4 Technical Data for Size Classes A and B with Pulse Frequency fp= 12 kHz (3AC 200 ...
230 V) ........................................................................................................................................... 3-4
3.5 Technical Data for Size Classes C, D and E with Pulse Frequency fp= 4 kHz............................ 3-5
3.6 Technical Data for Size Classes C, D and E with Pulse Frequency fp= 8 kHz............................ 3-6
3.7 Technical Data for Size Classes C, D and E with Pulse Frequency fp= 12 kHz.......................... 3-7
3.8 Technical Data for Size Classes G and H with Pulse Frequency fp= 4 kHz / 8kHz..................... 3-8
3.9 Technical Data for Size Classes G and H with Pulse Frequency fp= 12 kHz.............................. 3-9
3.10 Circuit Principle........................................................................................................................... 3-10
Circuit Principle of Electronics Section.................................................................................. 3-10
Circuit Principle of Power Section, Size Classes A and B..................................................... 3-10
EMC- Filter............................................................................................................................. 3-14
Description of EMC-filter with integrated line reactor RZE01.2............................................. 3-14
Description of EMC-filter without commutating reactor RZE02.1.......................................... 3-17
Mechanical Assembly RZE01.2 and RZE02.1...................................................................... 3-19
Line Reactor .......................................................................................................................... 3-20
Description of RND01.1 Line Reactor ................................................................................... 3-20
Mechanical Assembly............................................................................................................ 3-22
Description of NTM02.1 power pack module ........................................................................ 3-24
Mechanical Assembly NTM02.1 power pack module............................................................ 3-26
Circuit Principle of Power Section, Size Classes C - E......................................................... 3-27
Circuit Principle of Power Section, Size Classes G - H......................................................... 3-28
3.11 Mechanical Assembly................................................................................................................. 3-29
Storage and Setup................................................................................................................. 3-29
Minimum Requirements at the Installation Location.............................................................. 3-29
Utilization ............................................................................................................................... 3-29
Setup Elevations Exceeding 1000 Meters above Sea Level:................................................ 3-30
3.12 Assembly of Converter Size Classes A to E............................................................................... 3-30
Dimension Drawing, Size Classes A - B ............................................................................... 3-31
Dimension Drawings for Cooling Types L and P for Size Classes A - B............................... 3-31
Assembly Example of Several Converters next to Each Other for Cooling Type P.............. 3-33
Dimension Drawing cooling type D Size classes A and B..................................................... 3-33
Minimum Spacing for Cooling for Cooling Type L, P and G.................................................. 3-34
Dimension Drawing, Size Classes C, D, E............................................................................ 3-35
Dimension Drawing of Cooling Type L for Size Classes C, D, E.......................................... 3-36
Minimum Cooling Spacing for Cooling Type L...................................................................... 3-36
Dimension Drawing of Cooling Type D for Size Classes C, D, E.......................................... 3-37
Several Converters next to Each Other with Plug-through cooler size classes A -E............ 3-37
Dimension Drawing of Cooling Type W for Size Classes C, D, E......................................... 3-38
3.13 Working with the Coolant Circulation, Size Classes C, D and E................................................ 3-39
Assembly of Fluid-Cooled Converter, Size Classes C, D and E........................................... 3-41
Technical Data of Coolant Circulation System, Size Classes C, D and E ............................ 3-41
3.14 Assembly of Converter, Size Classes G and H, with Forced Air Cooling and Integrated
Liquid Circulation System (Cooling Type F)............................................................................... 3-45
Dimension Drawing, Size Classes G and H, with Cooling Type F........................................ 3-46
3.15 Assembling Liquid-Cooled Converters, Size Classes G and H, with External Heat
Exchanger................................................................................................................................... 3-47
General Notes Regarding Assembly..................................................................................... 3-47

RD 500 RD51 Contents III
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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......................................................................................................... 3-52
Mounting Drawing for Devices with External Heat Exchanger for Wall Mounting................. 3-53
3.16 Working on the Coolant Circulation System Size Classes G and H........................................... 3-53
Mounting Extension Hoses for External Heat Exchanger ..................................................... 3-55
Servicing the Coolant Circulation System ............................................................................. 3-56
Technical Data of Coolant Circulation System, Size Classes G and H................................. 3-56
4 Electrical Installation of Converter 4-1
4.1 10 Rules for Installation of Drives According to EMC................................................................... 4-1
4.2 Warnings and Notes..................................................................................................................... 4-2
4.3 Cable Cross-Sections................................................................................................................... 4-3
4.4 Power Terminals RD51 Size Classes A - E.................................................................................. 4-4
Terminal Layout Diagram Size Classes A - B......................................................................... 4-4
Description of Converter Power Terminals, Size Classes A - B.............................................. 4-5
Terminal Layout Diagram, Size Classes C, D....................................................................... 4-11
Terminal Layout Diagram, Size Class E................................................................................ 4-12
Description of Converter Power Terminals, Size Classes C - E ........................................... 4-13
4.5 Power Terminals RD51 Size Classes G - H............................................................................... 4-23
Terminal Layout Diagram Converter Size Class G ............................................................... 4-23
Terminal Layout Diagram Converter Size Class H................................................................ 4-24
Description of Power Terminals, Converter Size Classes G - H........................................... 4-25
Control Transformer T1......................................................................................................... 4-37
Dimension Drawing of Control Transformer.......................................................................... 4-38
4.6 Connection Diagram................................................................................................................... 4-39
4.7 Control Terminals ....................................................................................................................... 4-41
Terminal Layout Diagram SR17000 Size classes A - B........................................................ 4-41
Terminal Layout Diagram SR17000 Size class C - H ........................................................... 4-42
Description of Control Terminals........................................................................................... 4-43
Providing the Reference Potential when Operating Serveral RD 500s................................. 4-44
Incremental encoder connection ........................................................................................... 4-45
4.8 Service Interface RS 232 (X11).................................................................................................. 4-48
4.9 Standard Interface RS485 (X12) ................................................................................................ 4-50
Parameterizing the Converter................................................................................................ 4-52
5 Inverter Technical Data 5-1
5.1 Technical Data for Size Classes A and B with Pulse frequency fp= 4 kHz / 8 kHz..................... 5-1
5.2 Technical Data for Size Classes A and B with Pulse Frequency fp= 12 kHz .............................. 5-2
5.3 Technical Data for Size Classes C, D and E with Pulse Frequency fp= 4 kHz............................ 5-3
5.4 Technical Data for Size Classes C, D and E with Pulse Frequency fp= 8 kHz............................ 5-4
5.5 Technical Data for Size Classes C, D and E with Pulse Frequency fp= 12 kHz.......................... 5-5
5.6 Technical Data for Size Classes G with Pulse Frequency fp= 4 kHz / 8kHz............................... 5-6
5.7 Technical Data for Size Classes G with Pulse Frequency fp= 12 kHz ........................................ 5-7

IV Contents RD 500 RD51
DOK-RD500*RD51*******-IB04-EN-P
5.8 Technical Data SFT Motor inverter for Size Classes A and B with Pulse frequency fp= 4
kHz / 8 kHz.................................................................................................................................... 5-8
5.9 Technical Data SFT Motor inverter for Size Classes C, D and E with Pulse frequency fp
= 4 kHz.......................................................................................................................................... 5-9
5.10 Technical Data SFT Motor inverter for Size Classes C, D and E with Pulse frequency fp
= 8 kHz........................................................................................................................................ 5-10
5.11 Technical Data SFT Motor inverter for Size Class G with Pulse frequency fp= 4 kHz / 8
kHz.............................................................................................................................................. 5-11
5.12 Circuit Principle........................................................................................................................... 5-12
Circuit Principle of Electronics Section.................................................................................. 5-12
Circuit Principle of Power Section, Size Classes A and B..................................................... 5-13
Circuit Principle of Power Section, Size Classes C - E......................................................... 5-14
Circuit Principle of Power Section, Size Class G (without SFT)............................................ 5-15
Circuit Principle of Power Section, Inverter SFT Size Class G............................................. 5-16
5.13 Mechanical Assembly................................................................................................................. 5-17
Storage and Setup................................................................................................................. 5-17
Minimum Requirements at the Installation Location.............................................................. 5-17
Utilization ............................................................................................................................... 5-17
Setup Elevations Exceeding 1000 Meters above Sea Level:................................................ 5-18
5.14 Mounting Inverter Size Classes A to E.......................................................................................5-18
Dimension Drawing, Size Classes A - B ............................................................................... 5-19
Dimension Drawings for Cooling Types L and P for Size Classes A - B............................... 5-19
Assembly Example of Several Devices next to Each Other for Cooling Type P................... 5-21
Dimension Drawings for Cooling Types D for Size Classes A - B ........................................ 5-21
Minimum Cooling Spacing for Cooling Type L, P and D....................................................... 5-21
Dimension Drawing, Size Classes C, D, E............................................................................ 5-23
Dimension Drawing of Cooling Type L for Size Classes C, D, E.......................................... 5-24
Minimum Cooling Spacing for Cooling Type L...................................................................... 5-24
Dimension Drawing of Cooling Type D for Size Classes C, D, E.......................................... 5-25
Several Inverters next to Each Other with Through-Hole Cooling ........................................ 5-25
5.15 Assembly of Inverter, Size Classes G with Forced Air Cooling and Integrated Liquid
Circulation System (Cooling Type F).......................................................................................... 5-26
Dimension Drawing, Size Class G with Cooling Type F........................................................ 5-26
5.16 Assembling Liquid-Cooled Inverters, Size Class G with External Heat Exchanger................... 5-27
General Notes Regarding Assembly..................................................................................... 5-27
Supplementary Fan Transformer .......................................................................................... 5-28
Dimension Drawing, Size Classes G with Cooling Type R ................................................... 5-29
Mounting Drawing for Devices with External Heat Exchanger for Cabinet Roof
Mounting, Size Class G......................................................................................................... 5-30
Mounting Drawing for Devices with External Heat Exchanger for Wall Mounting................. 5-30
5.17 Working on the Coolant Circulation System Size Class G......................................................... 5-31
Mounting Extension Hoses for External Heat Exchanger ..................................................... 5-33
Servicing the Coolant Circulation System ............................................................................. 5-33
Technical Data of Coolant Circulation System, Size Class G............................................... 5-33
6 Electrical Installation of Inverter 6-1
6.1 10 Rules for Installation of Drives According to EMC................................................................... 6-1
6.2 Warnings and Notes..................................................................................................................... 6-2

RD 500 RD51 Contents V
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6.3 Cable Cross-Sections................................................................................................................... 6-3
6.4 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........................................................................ 6-11
Terminal Layout Diagram Size Class E................................................................................. 6-12
Description of Inverter Power Terminals Size Classes C - E................................................ 6-13
6.5 Power Terminals RD51 Size Class G......................................................................................... 6-22
Terminal Layout Diagram Inverter Size Class G................................................................... 6-22
Description of Power Terminals Inverter Size Class G......................................................... 6-23
Control Transformer T1......................................................................................................... 6-29
6.6 Connection Diagram................................................................................................................... 6-31
Connection Diagram Inverter Size class A - E...................................................................... 6-31
Connection Diagram Inverter Size class G (RD51.1)............................................................ 6-32
Connection Diagram Inverter SFT Size class G (RD51.3).................................................... 6-33
6.7 Control terminals see Chapter 4.7.............................................................................................. 6-34
6.8 Service Interface (RS232) see Chapter 4.9................................................................................ 6-34
6.9 Standard Interface (RS482) see Chapter 4.10........................................................................... 6-34
7 Operator Control and Visualization 7-1
7.1 Possibilities of Operator Control................................................................................................... 7-1
7.2 Operator Control with the User Panel........................................................................................... 7-1
Visualization (Monitor) with the User Panel............................................................................. 7-1
Operation with the operator panel........................................................................................... 7-2
Parameterization Using the User Panel.................................................................................. 7-2
Fast Parameterization using Key Combinations ..................................................................... 7-3
Load Standard Values............................................................................................................. 7-3
Fault Messages when Parameterizing .................................................................................... 7-4
Copy Function.......................................................................................................................... 7-5
Fault Acknowledgement.......................................................................................................... 7-5
7.3 Visualization.................................................................................................................................. 7-6
Monitor..................................................................................................................................... 7-6
Operating Display.................................................................................................................... 7-7
Warning Display....................................................................................................................... 7-7
Fault Display............................................................................................................................ 7-8
LED Display............................................................................................................................. 7-8
8 Parameter Value Assignment 8-1
8.1 Parameterization........................................................................................................................... 8-1
Parameterization Structure......................................................................................................8-1
Overview.................................................................................................................................. 8-3
8.2 Password Levels........................................................................................................................... 8-4
8.3 Quick Setup .................................................................................................................................. 8-4
8.4 Guided parameterization .............................................................................................................. 8-7
Drive control / setpoints........................................................................................................... 8-7
Standard terminal assignment............................................................................................... 8-10

VI Contents RD 500 RD51
DOK-RD500*RD51*******-IB04-EN-P
Functions............................................................................................................................... 8-15
Drive setting........................................................................................................................... 8-24
Serial communications .......................................................................................................... 8-26
Diagnostics / drive data ......................................................................................................... 8-28
Options .................................................................................................................................. 8-28
8.5 Numerical list .............................................................................................................................. 8-28
9 Commissioning 9-1
9.1 Preparatory Steps for Commissioning..........................................................................................9-1
9.2 Procedure during First Commissioning ........................................................................................ 9-1
9.3 Motor optimization / motor evaluation........................................................................................... 9-3
Motor running under no-load conditions.................................................................................. 9-3
Running-up / accelerating under load ..................................................................................... 9-3
9.4 General Information...................................................................................................................... 9-3
10 Basic Functions 10-1
10.1 Starting lock-out for RD 500 Size Classes A - H........................................................................ 10-1
Description............................................................................................................................. 10-1
Mode of Operation................................................................................................................. 10-1
Application Information.......................................................................................................... 10-1
11 Optional Device Functions 11-1
11.1 Additional function 24 V Stand-by Power Supply....................................................................... 11-1
General.................................................................................................................................. 11-1
Technical Data....................................................................................................................... 11-1
12 Troubleshooting 12-1
12.1 Self-Test Error Messages........................................................................................................... 12-1
12.2 Warnings..................................................................................................................................... 12-1
12.3 Faults.......................................................................................................................................... 12-1
Fault Acknowledgement........................................................................................................ 12-1
12.4 List of Warning and Fault Messages .......................................................................................... 12-2
12.5 Warning and Fault Messages–Cause and Remedy / Comments............................................ 12-3
13 Service & Support 13-1
13.1 Helpdesk..................................................................................................................................... 13-1
13.2 Service-Hotline ........................................................................................................................... 13-1
13.3 Internet........................................................................................................................................ 13-1
13.4 Vor der Kontaktaufnahme... - Before contacting us... ................................................................ 13-1
13.5 Kundenbetreuungsstellen - Sales & Service Facilities............................................................... 13-2
14 Index 14-1

RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls 1-1
DOK-RD500*RD51*******-IB04-EN-P
1 Safety Instructions for Electric Servo Drives and
Controls
1.1 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.
Do not attempt to install, use or service this equipment without first read-
ing all of the documentation provided with the product. Read and under-
stand these safety instructions and all user documentation of the equip-
ment prior to working with the equipment at any time. If you do not have
the user documentation for your equipment contact your local Bosch Rex-
roth representative to send this documentation immediately to the person
or persons responsible for the safe operation of this equipment.
If the product is resold, rented, transferred or passed on to others, then
these safety instructions must be delivered with the product.
WARNING
Inappropriate use of this equipment, failure to
follow the safety instructions in this document
or tampering with the product, including dis-
abling of safety devices, may result in product
damage, personal injury, severe electrical shock
or death!
1.2 Explanations
The safety warnings in this documentation describe individual degrees of
hazard seriousness in compliance with ANSI:
Warning symbol with text Degree of hazard seriousness
The degree of hazard seriousness describes
the consequences resulting from non-
compliance with the safety guidelines:
DANGER
Bodily harm or product damage will occur.
WARNING
Death or severe bodily harm may occur.
CAUTION
Death or severe bodily harm may occur.
Fig. 1-1:Classes of danger according to ANSI

1-2 Safety Instructions for Electric Servo Drives and Controls RD 500 RD51
DOK-RD500*RD51*******-IB04-EN-P
1.3 Hazards due to inappropriate use
DANGER
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!
WARNING
High electrical voltage due to wrong connec-
tions! Danger to life, severe electrical shock and
severe bodily injury!
WARNING
Health hazard for persons with heart pacemak-
ers, metal implants and hearing aids in proxim-
ity to electrical equipment!
CAUTION
Surface of machine housing could be extremely
hot! Danger of injury! Danger of burns!
CAUTION
Risk of injury due to inappropriate handling!
Bodily injury caused by crushing, shearing, cut-
ting and mechanical shock or improper han-
dling of pressurized systems!
CAUTION
Risk of injury due to inappropriate handling of
batteries!

RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls 1-3
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1.4 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. If you find that due to a
translation error you can not completely understand the documentation
for your product, please ask your supplier to clarify.
•Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for opti-
mal and safe operation of this equipment.
•Trained and qualified personnel in electrical equipment:
Only trained and qualified personnel may work on this equipment or in
its proximity. Personnel are qualified if they have sufficient knowledge
of the assembly, installation and operation of the product as well as an
understanding of all warnings and precautionary measures noted in
these instructions.
Furthermore, they should be trained, instructed and qualified to switch
electrical circuits and equipment on and off, to ground them and to
mark them according to the requirements of safe work practices and
common sense. They must have adequate safety equipment and be
trained in first aid.
•Only use spare parts and accessories approved by the manufacturer.
•Follow all safety regulations and requirements for the specific applica-
tion as practiced in the country of use.
•The equipment is designed for installation on commercial machinery.
European countries: see directive 89/392/EC (Machinery Directive)
•The ambient conditions specified in the product documentation must
be observed.
•Use only safety features that are clearly and explicitly approved in the
Project Planning manual.
For example, the following areas of use are not allowed: Cranes and
hoisting equipment, elevators used for people or freight, devices and
vehicles to transport people, medical applications, refinery plants, the
transport of hazardous goods, radioactive or nuclear applications, ap-
plications sensitive to high frequency, mining, control of protection
equipment (also in a machine).
•Start-up is only permitted once it is ensured that the machine, in which
the product is installed, complies with the requirements of national
safety regulations and safety specifications of the application.
•Operation is only permitted if the national EMC regulations for the ap-
plication are met.
The machine builder is responsible for compliance with the limiting
values as prescribed in the national regulations and specific EMC
regulations for the application.

1-4 Safety Instructions for Electric Servo Drives and Controls RD 500 RD51
DOK-RD500*RD51*******-IB04-EN-P
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.
•Technical data, connections and operational conditions are specified in
the product documentation and must be followed at all times.
1.5 Protection against contact with electrical parts
Note: This section refers to equipment with voltages above 50 Volts.
Making contact with parts at voltages above 50 Volts could be dangerous
to personnel and cause an electrical shock. When operating electrical
equipment, it is unavoidable that some parts of the unit conduct danger-
ous voltages.
DANGER
High electrical voltage! Danger to life, severe
electrical shock and severe bodily injury!
⇒Only those trained and qualified to work with or on
electrical equipment are permitted to operate, main-
tain or repair this equipment.
⇒Follow general construction and safety regulations
when working on electrical installations.
⇒Before powering-up, the productive conductor must
be permanently connected to all electrical units ac-
cording to the connection diagram.
⇒Do not operate electrical equipment at any time if the
protective conductor is not permanently connected,
even for brief measurements or tests.
⇒Before working with electrical parts with voltage po-
tentials higher than 50 V, the equipment must be
disconnected from the line supply or power supply.
⇒The following should be observed with electrical
drives, power supplies, and filter components:
Wait five (30) minutes after switching off power to
allow capacitors to discharge before beginning work.
Measure the voltage at the capacitors before begin-
ning work to make sure that the equipment is safe to
touch.
⇒Never touch the electrical connection points of a
component while power is turned on.
⇒Install the covers and guards provided with the
equipment properly before switching the equipment
on. Prevent contact with live parts at any time.
⇒A residual-current-operated protective device (r.c.d.)
must not be used on an electric drive! Indirect con-
tact may be prevented by other means, for example,
by an overcurrent protective device.
⇒Equipment that is built into machines must be se-

RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls 1-5
DOK-RD500*RD51*******-IB04-EN-P
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. The user of this equipment must observe
the above noted instructions at all times.
To be observed for electric drives and filter components:
DANGER
High voltage! High leakage current! Danger to
life, danger of injury and bodily harm from elec-
trical shock!
⇒Before powering-up all housings and motors must be
permanently grounded according to the connection
diagram. This applies even for brief tests.
⇒The protective conductor of the electrical equipment
must be permanently connected to the line supply.
The leakage current is greater than 3.5 mA.
⇒Use a copper conductor with at least 10 mm²cross
section over its entire course for this protective con-
nection!
⇒Prior to startups, even for brief tests, always connect
the protective conductor or connect with ground wire.
High voltage levels can occur on the housing that
could lead to severe electrical shock and personal
injury.
European countries: EN 50178 / 1998, Section 5.3.2.1.
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 instructions at all times.

1-6 Safety Instructions for Electric Servo Drives and Controls RD 500 RD51
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1.6 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
•EU countries: Refer to EN 50178/1998, Section 5.2.8.1.
WARNING
High voltage due to wrong connections! Danger
to life, severe electrical shock and severe bodily
injury!
⇒Only equipment, electrical components and cables of
the protective low voltage type (PELV = Protective
Extra Low Voltage) may be connected to all termi-
nals and connections with 0 to 50 Volts.
⇒Only safely isolated voltages and electrical circuits
may be connected. Safe isolation is achieved, for
example, with an isolating transformer, a safe opto-
electronic coupler or when battery-operated.
1.7 Protection against dangerous movements
Dangerous movements can be caused by faulty control or the connected
motors. There are various causes:
•unclean or wrong wiring of cable connections
•inappropriate or wrong operation of equipment
•malfunction of sensors, encoders and monitoring circuits
•defective components
•software errors
Dangerous movements can occur immediately after equipment has been
powered-up or even after an unspecified time of trouble-free operation.
The monitors in the drive components make faulty operation almost im-
possible. Regarding personnel safety, especially the danger of bodily
harm and property damage, this alone should not be relied upon to en-
sure complete safety. Until the built-in monitors become active and effec-
tive, it must be assumed in any case that some faulty drive movements
will occur. The extent of these faulty drive movements depends on the
type of control and the state of operation.

RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls 1-7
DOK-RD500*RD51*******-IB04-EN-P
DANGER
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
measures.
These are implemented in accordance with the spe-
cific situation of the plant/system and a danger and
fault analysis conducted by the manufacturer of the
plant/system. All the safety regulations that apply to
this plant/system are included. By switching off, cir-
cumventing or if safety devices have simply not been
activated, then random machine movements or other
types of faults can occur.
Avoiding accidents, injury or property damage:
⇒Keep free and clear of the machine’s range of mo-
tion and moving parts. Prevent people from acci-
dentally entering the machine’s range of movement:
- use protective fences
- use protective railings
- install protective coverings
- install light curtains or light barriers
⇒Fences must be strong enough to withstand maxi-
mum possible momentum.
⇒Mount the emergency stop switch (E-stop) in the
immediate reach of the operator. Verify that the
emergency stop works before startup. Don’t operate
the machine if the emergency stop is not working.
⇒Isolate the drive power connection by means of an
emergency stop circuit or use a start-inhibit system
to prevent unintentional start-up.
⇒Make sure that the drives are brought to standstill
before accessing or entering the danger zone.
⇒Secure vertical axes against falling or slipping after
switching off the motor power by, for example:
- Mechanically securing the vertical axes
- Adding an external brake / clamping mechanism
- Balancing and thus compensating for the vertical
axes weight and the gravitational force
The standard equipment motor brake or an external
brake controlled directly by the servo drive are not
sufficient to guarantee the safety of personnel!
⇒Disconnect electrical power to the equipment using a
master switch and lock-out the switch against reclo-
sure:
- for maintenance and repair work
- for cleaning of equipment
- if the equipment is not used for long periods of time

1-8 Safety Instructions for Electric Servo Drives and Controls RD 500 RD51
DOK-RD500*RD51*******-IB04-EN-P
⇒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. If necessary, perform a special
electromagnetic compatibility (EMC) test on the
plant.
1.8 Protection against magnetic and electromagnetic fields
during operations and mounting
Magnetic and electromagnetic fields generated by current-carrying con-
ductors and permanent magnets in motors represent a serious health
hazard to persons with heart pacemakers, metal implants and hearing
aids.
WARNING
Health hazard for persons with heart pacemak-
ers, metal implants and hearing aids in proxim-
ity to electrical equipment!
⇒Persons with pacemakers, metal implants and hear-
ing aids are not permitted to enter following areas:
- Areas in which electrical equipment and parts are
mounted, being operated or started up.
- Areas in which parts of motors with permanent
magnets are being stored, operated, repaired or
mounted.
⇒If it is necessary for a person with a pacemaker to
enter such an area, then a physician must be con-
sulted prior to doing so. Pacemakers, that are al-
ready implanted or will be implanted in the future,
have a considerable deviation in their immunity to
interference. Due to the unpredictable behavior there
are no generally valid rules.
⇒Persons with hearing aids, metal implants or metal
pieces must consult a doctor before they enter the
areas described above. Otherwise health hazards
will occur.

RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls 1-9
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1.9 Protection against contact with hot parts
CAUTION
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!
⇒Wait ten (10) minutes before you access any hot
unit. Allow the unit to cool down.
⇒Do not touch hot parts of the equipment, such as
housings, heatsinks or resistors. Danger of burns!

1-10 Safety Instructions for Electric Servo Drives and Controls RD 500 RD51
DOK-RD500*RD51*******-IB04-EN-P
1.10 Protection during handling and installation
Under certain conditions inappropriate handling and installation of parts
and components may cause injuries.
CAUTION
Risk of injury through incorrect handling! Bod-
ily harm caused by crushing, shearing, cutting
and mechanical shock!
⇒Observe general instructions and safety regulations
during handling installation.
⇒Use only appropriate lifting or moving equipment.
⇒Take precautions to avoid pinching and crushing.
⇒Use only appropriate tools. If specified by the product
documentation, special tools must be used.
⇒Use lifting devices and tools correctly and safely.
⇒Wear appropriate protective clothing, e.g. safety
glasses, safety shoes and safety gloves.
⇒Never stay under suspended loads.
⇒Clean up liquids from the floor immediately to pre-
vent personnel from slipping.
1.11 Battery safety Batteries contain reactive chemicals in a solid housing. Inappropriate
handling may result in injuries or equipment damage.
CAUTION
Risk of injury through incorrect handling!
⇒Do not attempt to re-activate discharged batteries by
heating or other methods (danger of explosion and
corrosion).
⇒Never charge batteries (danger from leakage and
explosion).
⇒Never throw batteries into a fire.
⇒Do not dismantle batteries.
⇒Handle with care. Incorrect withdrawal or installation
of a battery can damage equipment.
Note: Environmental protection and disposal! The batteries con-
tained in the product should be considered as hazardous ma-
terial for land, air and sea transport in the sense of the legal
requirements (danger of explosion). Dispose of batteries sepa-
rately from other refuse. Observe the legal requirements given
in the country of installation.

RD 500 RD51 Safety Instructions for Electric Servo Drives and Controls 1-11
DOK-RD500*RD51*******-IB04-EN-P
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. In these cases, improper handling of the supply of the
pressurized systems or connections of the fluid or air under pressure can
lead to injuries or accidents.
CAUTION
Danger of injury when pressurized systems are
handled by untrained personnel!
⇒Do not attempt to disassemble, to open or to cut a
pressurized system.
⇒Observe the operation restrictions of the respective
manufacturer.
⇒Before the disassembly of pressurized systems,
lower pressure and drain off the fluid or gas.
⇒Use suitable protective clothing (for example protec-
tive eyewear, safety shoes and gloves)
⇒Remove any fluid that has leaked out onto the floor
immediately.
Note: Environmental protection and disposal! The fluids used in the
operation of the pressurized system equipment is not envi-
ronmentally compatible. Fluid that is damaging to the envi-
ronment must be disposed of separately from normal waste.
Observe the national specifications of the country of installa-
tion.
1.13 Precautionary measures when handling components
which can be destroyed by electrostatic discharge
(ESDS)
The drive units contain components and parts which can be destroyed by
electrostatic discharge. Please observe the following when working with
electronic modules and boards:
•Electronic modules and boards should only be touched if absolutely
necessary.
•Before touching an electronic module/board, the human body must
first be electrically discharged.
•Electronic modules / boards may not come into contact with highly-
insulating materials (e.g. plastic foils, insulating work surfaces, articles
of clothing manufactured from man-made fiber).
•Electronic modules / boards may only be placed on conductive sur-
faces.
•The soldering iron tip must be grounded when carrying-out soldering
work on electronic modules/boards.

1-12 Safety Instructions for Electric Servo Drives and Controls RD 500 RD51
DOK-RD500*RD51*******-IB04-EN-P
•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. In this case, e.g. conductive
foam rubber or household aluminum foil can be used.
The necessary ESDS protective measures are clearly shown in the fol-
lowing diagram:
a
bed
ff f
d
a
c
ed
f f
b
ca
When seated When standing When sitting/standing
a: Conductive floor
b: ESDS table
c: ESDS shoes
d: ESDS overall
e: ESDS bracelet
f: Grounding connection of the cabinets
Fig. 1-2: ESDS protective measures