REXROTH RD 500 RD42 User manual

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

About this Documentation RD 500 RD42
DOK-RD500*-RD42*******-IB03-EN-P
RD 500 RD42
Power Supply
Operating Guide
DOK-RD500*-RD42*******-IB03-EN-P
120-1950-B314-03/EN
This documentation describes the power supply of the produkt family
RD 500 RD42
•for planning the mechanical control cabinet construction.
•for planning the electrical control cabinet construction.
•for start-up.
•for fault messages and notes to couse and remedy.
Description Release
Date
Notes
DOK-RD500*-RD42*******-IB01-EN-P 12.2000 First edition
DOK-RD500*-RD42*******-IB02-EN-P 01.2003 Warning added
DOK-RD500*-RD42*******-IB03-EN-P 11.2003 Error correction
¤ 2003 Indramat Refu GmbH
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 specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Indramat Refu GmbH
Uracher Strasse 91•D-72555 Metzingen
Telephone [phone] •Fax [phone]
http://www.boschrexroth.de/
Dept. Development ENG (jr)
This document has been printed on chlorine-free bleached paper.
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RD 500 RD42 I
DOK-RD500*-RD42*******-IB03-EN-P
Table of content
1 Description 1-1
1.1 General information....................................................................................................................... 1-1
Operating mode, standby:........................................................................................................ 1-1
Operating mode, run: ............................................................................................................... 1-1
1.2 Dimensioning information ............................................................................................................. 1-1
Dimensioning the power sections ............................................................................................ 1-1
Dimensioning for dynamic regenerative feedback operations................................................. 1-2
1.3 Technical data............................................................................................................................... 1-2
1.4 Block circuit diagram ..................................................................................................................... 1-3
1.5 Type code ..................................................................................................................................... 1-4
2 Mechanical mounting and installation 2-1
2.1 Storage and mounting location ..................................................................................................... 2-1
Storage..................................................................................................................................... 2-1
Minimum requirements at the mounting location..................................................................... 2-1
Installation altitudes above 1000 meters sea level: ................................................................. 2-2
2.2 Mounting the supply modules ....................................................................................................... 2-2
2.3 Dimension drawings...................................................................................................................... 2-3
3 Electrical installation 3-1
3.1 EMC-correct design of drives........................................................................................................ 3-1
3.2 Warnings and information ............................................................................................................. 3-3
3.3 Cable cross-sections..................................................................................................................... 3-4
Alternative fuse types............................................................................................................... 3-4
3.4 Power terminals RD42 .................................................................................................................. 3-5
3.5 Line filter connection ..................................................................................................................... 3-5
3.6 Supply module connection............................................................................................................ 3-6
Power terminal X1.................................................................................................................... 3-6
Power terminal X2.................................................................................................................... 3-6
Power terminal X3.................................................................................................................... 3-6
3.7 Control terminals ........................................................................................................................... 3-7
Terminal diagram ..................................................................................................................... 3-7
Control terminal strip X11 on SN11027 ................................................................................... 3-9
Control terminal strip X52 on NR16236................................................................................. 3-10
3.8 Serial interface ............................................................................................................................ 3-10
Data transfer protocol ............................................................................................................3-10
Connector assignment X16.................................................................................................... 3-11

II Table of content RD 500 RD42
DOK-RD500*-RD42*******-IB03-EN-P
4 Commissioning 4-1
4.1 Connection .................................................................................................................................... 4-1
4.2 Setting the unit configuration ........................................................................................................ 4-1
Setting the display language.................................................................................................... 4-1
Setting the interface address ................................................................................................... 4-1
Powering-up / down the supply module................................................................................... 4-1
4.3 Powering-up .................................................................................................................................. 4-3
4.4 Changing-over the operating mode .............................................................................................. 4-3
4.5 Ready signal ................................................................................................................................. 4-4
4.6 Operating display .......................................................................................................................... 4-4
5 Fault display and fault diagnostics 5-1
5.1 General information....................................................................................................................... 5-1
5.2 Fault signal.................................................................................................................................... 5-1
5.3 Fault acknowledgement ................................................................................................................ 5-1
5.4 Fault display.................................................................................................................................. 5-1
5.5 Fault messages – cause and remedy........................................................................................... 5-2
5.6 Fault display on the regenerative feedback control NR16236...................................................... 5-3
6 Index 6-1
7 Kundenbetreuungsstellen - Sales & Service Facilities 7-1
Indramat Refu .......................................................................................................................... 7-1

RD 500 RD42 Description 1-1
DOK-RD500*-RD42*******-IB03-EN-P
1 Description
1.1 General information
The RD42 supply modules, which are capable of regenerative feedback,
are designed to be connected to inverters with DC connection from the
REFUdrive 500 series. They are suitable for regenerating into the line
supply, for example, when drives are braked.
The three-phase supply is fed-in via a line filter and an uncontrolled three-
phase bridge rectifier. The DC link capacitors are pre-charged via series
resistors and an auxiliary contactor. If faults develop in the power section,
or e.g. if the drive converter is powered-up with a ground fault at the DC
link output, pre-charging is automatically and safely interrupted. When the
system runs-up correctly, the charged capacitors are connected to the
line supply through a diode rectifier using a power contactor, and then the
inverter is enabled.
The supply modules have two operating modes:
Operating mode, standby:
(terminals X52.5 and .6 open-circuit)
The regenerative feedback into the line supply is active. The quiescent
current (if there is no regenerative feedback) is almost zero. The
regenerative power is limited to 50 % of the specified values; refer to the
technical data.
Operating mode, run:
(Terminals X52.5 and .6 closed or there is a significant level of
regenerative feedback)
The regenerative feedback into the line supply is active. The quiescent
current (if there is no regenerative feedback) is approx. 30 % of the rated
current. The regenerative feedback power corresponds to the specified
values, refer to the technical data. The changeover into the run operating
mode can be externally initiated (X52), or is automatically set as a
function of the regenerative feedback power.
1.2 Dimensioning information
Dimensioning the power sections
Two criteria are taken into account when dimensioning the power
sections:
Power consumption
This is the sum of the power drawn from the DC link, taking into account
losses and a coincidence factor. The power which may be drawn from the
DC link is specified under 1.3 Technical data.
Total number of units which can be connected
Capacitors are used in the inverters which are used to smooth the DC link
voltage. When the drive converter is powered-up, these must be charged
using a pre-charging device. If too many inverter modules are connected
to the DC link, then there is a danger that the pre-charging device will be
overloaded.
Every inverter has a power code, which can be taken from the type code
(e.g. RD52.1-7N-022... => power code 22). In order that the pre-charging

1-2 Description RD 500 RD42
DOK-RD500*-RD42*******-IB03-EN-P
device is not overloaded, the sum of the power codes of the connected
inverters may not exceed 200% of the power code of the power supply
module used.
Dimensioning for dynamic regenerative feedback operations
Depending on the dynamic behavior, the following dimensioning should
be considered: For applications, where the DC link power must be
provided within 5 and 15 ms, the peak regenerative feedback power ≤the
rated output of the unit. For applications where the DC link power
increases more slowly (rise time > 30 ms), the unit can be dimensioned
with a peak regenerative power ≤peak power of the unit. Independent of
this, it must be guaranteed, that as an average, the rated output of the
unit is not exceeded.
1.3 Technical data
RD42 power code 026 053 084 105
Line supply 3-ph. 380 V AC ...480 V ±10 %, 50 / 60 Hz
3-ph. 500 V AC ± 10 %, 50 / 60 Hz
Fuse, FF [A] 63 125 200 250
Control voltage supply 3-ph. 380 V AC ... 480 V ± 10 %, 50 / 60 Hz
3-ph. 500 V AC ± 10 %, 50 / 60 Hz
DC link voltage 530 ... 640 V DC ± 10 %
660 V DC ± 10 %
DC side
DC rated current [A] 50 100 160 200
Peak current for 60 s [A] 75 150 240 300
Line supply side
For Vline supply = 400 V
Rated output
Peak output
[kW]
[kW]
26
40
53
80
84
127
105
160
For Vline supply = 480 V
Rated output
Peak output for 60 s
[kW]
[kW]
32
48
64
96
102
154
128
192
For Vline supply = 500 V
Rated output
Peak output for 60 s
[kW]
[kW]
33
50
66
100
105
160
132
200
Line supply rated current
at the rated line supply power
[A] 45 90 150 180
Power factor, line supply Approx. 1
Losses at rated output [kW] 0.8 1.15 1.5 2
Ambient conditions, radio interference suppression level, noise immunity
Cooling airflow requirement m³/s 0.08 0.12 0.2 0.3
Environmental Class 3K3 acc. to DIN IEC 721-3-3 (ambient temperature 0-40 °C)
Radio interference suppression level /
noise immunity
A 1 acc. to EN 55011 / EN 61800-3
Mechanical design
Size Class D E F G
Degree of protection IP 20 acc. to EN 60529
Fig. 1-1: Technical data

RD 500 RD42 Description 1-3
DOK-RD500*-RD42*******-IB03-EN-P
Note: The specified values refer to the “Run”operating mode. In the
“Standby”mode, the regenerative feedback only represents 50
% of the specified values.
1.4 Block circuit diagram
+-
X2
CCD
U1 V1 W1
X1
122121
U1 V1 W1
+
U1 V1 W1 U2 V2 W2
K1K2
33
NF
VL
V
C
PE
D
Checkback signal
line contactor
K1
X3
D
PE
Display
4 V
V
3 x 2A
1 2
X11
3 4 5 6 7 8 9
1
11
12 13 14 15
X16
RS485 / 232
WS
PE
X1 D
C
X2 V2 PEW2 PEPE
M 3~
J
U2
PTC / KTY85+ PTC / KTY85-
SR17000
-
U1' V1' W1'
1 2 3 4 5 6 7 8
46 V
5 V
SV
3 V
23 V
X3
K2
X3
X3
X16
T1
K1
X16
SN
NR
X52
X1 D
X2 V2 PEW2 PE
M 3~
J
U2
PTC / KTY85+ PTC / KTY85-
SR17002
Spee encoder
K1
K1 K1
G
C
Output +24V
ON
Acknowledge
External fault
Output +24V
GND GND
Enable slave
Enable inverter
3 phase power supply
DC - link
Power Supply R 42
Output +24V
ON
Signaling relay
Ready
Changeover standby / run
Inverter REFUdrive 500 RD52
X1
C1 D1
2 A
Inverter REFUdrive 500 RD51
Dig. input Function: "Enable operation" Dig. input Function: " N"
X1
C1 D1
2 A
Checkback signal slave
It is also possible to use an external P24V signal from the PLC = no fault
Output +24V
Dig. input Function: "Enable operation" Dig. input Function: " N"
Output +24V
Fig. 1-2: Block circuit diagram RD42

1-4 Description RD 500 RD42
DOK-RD500*-RD42*******-IB03-EN-P
1.5 Type code
1234 6789
1
05 1234 6789
2
0512346789
3
05 1234 6789
4
05
Example:
Abbrev.
Column
RD42 . 1 - 4R- 026- L
1. Product group
1.1 RD. . . . . . . . . . . . = RD
2. Line
2.1 42. . . . . . . . . . . . . . . . = 42
3. Design
3.1 1 . . . . . . . . . . . . . . . . . . . . . . . = 1
4. Mains connecting voltage
4.1 3 x
AC 380 to 480 V, 10 % . . . . . . . = 4
4.2 3 x AC 500 V, 10 % . . . . . . . . . . . = 5
5. Ba e chopper
5.1 without brake chopper, regenerativ. . . = R
6. DC-bus nominal power at 3 x AC 400 V
6.1 26 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . = 026
6.2 53 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . = 053
6.3 84 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . = 084
6.4 105 kW. . . . . . . . . . . . . . . . . . . . . . . . . . . . = 105
7. Cooling mode
7.1 forced air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . = L
Illustration example: RD42.1
Fig. 1-3: Type code RD42

RD 500 RD42 Mechanical mounting and installation 2-1
DOK-RD500*-RD42*******-IB03-EN-P
2 Mechanical mounting and installation
2.1 Storage and mounting location
Storage
The units must be stored in clean, dry rooms. The storage temperature
must lie between -25°C and +70°C. Temperature fluctuations exceeded
20 K per hour are not permissible. (environmental Class 3K3 according to
DIN IEC 721-3-3)
Hinweis: Supply modules accommodate Al Elko DC link capacitors.
They can be stored for 2 years at a storage temperature of
≤ 40 °C.
Minimum requirements at the mounting location
•The operating room/area should be dust-free. Dust-laden air must be
filtered.
•The ambient temperature must lie in the range 0 ... 40°C.
•The relative air humidity may not exceed 90 %; moisture condensation
is not permissible.
•The air drawn-in may not contain any aggressive or electrically
conductive gases which could have a negative impact on the function
of the equipment.
•The fan airflow may not be restricted. The specified minimum
clearances for air intake and air discharge may not be restricted by
additional mounted components.
•The unit has a certain power loss and heats-up its environment. This
means that it is important that there is sufficient clearance to
temperature-sensitive devices and equipment.

2-2 Mechanical mounting and installation RD 500 RD42
DOK-RD500*-RD42*******-IB03-EN-P
Installation altitudes above 1000 meters sea level:
If the unit is mounted above 1000 meters above sea level, the supply
module utilization must be reduced corresponding to the adjacent
diagram.
It is not permissible to install the unit at altitudes above 2000 meters
above sea level!
1 %
9 %
83 %
8 %
7 %
5 1 15 2 25
Installation altitude in m
above sea level
Utilization
Fig.. 2-1: Derating as a function of the installation altitude
2.2 Mounting the supply modules
•The modules must be mounted vertically onto a flat surface.
•A minimum clearance of 100 mm both above and below the units must
be maintained to ensure that the airflow is not restricted.
•When the units are mounted in a cabinet, the cooling air requirement
of the installed units (refer to Section 1: Technical data) must be
calculated and the cabinet cooling/ventilation appropriately
dimensioned.
•For supply modules, size Classes D to G, the line filter is externally
mounted for space reasons. We recommend that the line filter is
mounted below the unit; refer to the dimension drawings.
•Please refer to the dimension drawings for the mounting dimensions
and the location of the retaining points.
•Use M6x10 Z 2 DIN 7985 screws to mount the units.