Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies
Pneumatics
Service
Automation
Mobile
Hydraulics
RD500
Rexroth’s Frequency Converters for
Individual Solutions
Flexible, fast and modular
2
Table of Contents
Description of the RD500 product series
4
Device selection RD51/RD52/RS51
6
RD51/RD52 frequency converters, inverters
8
Type code
General technical data
Derating with high pulse frequencies
8
9
10
RD51 control unit block diagram
11
RD52 control unit block diagram
12
Power module block diagrams for 3 to 18.5 kW
13
Power module block diagrams for 22 to 110 kW
14
Power module block diagrams for 132 to 400 kW
15
Frequency converter/inverter technical data for 3 to 18.5 kW
16
Frequency converter technical data for 22 to 110 kW
17
Frequency converter technical data for 132 to 400 kW
18
Inverter technical data for 22 to 110 kW
20
Inverter technical data for 132 to 400 kW
21
RD41 unregulated power supply modules 12.5 to 100 kW
22
RD42 regenerative power supply modules 26 to 105 kW
23
RS51 frequency converters up to 3000 Hz
24
Control unit block diagram
24
Power module block diagram
25
Frequency converter technical data for 3 to 50 kVA
26
General technical data
27
Accessories
28
Firmware FWA and software tool RDwin
28
Operator panel
29
Options modules, configuration of module slots 1 and 2
30
Motor filters up to 200 Hz
32
Sinusoidal filters up to 200 Hz
33
Radio interference suppression filter B
34
Standard braking resistors for RD51/RD52
35
Description of reinforced braking resistors
37
Reinforced braking resistors IP20
38
Reinforced braking resistors IP23
40
Chemistry module
42
Heat exchangers
44
Accessories for water-cooled devices
45
3
Rexroth Frequency Converters
Our Know-how for Your Drive Solution
If you are looking for a partner to help you achieve an optimal drive solution, you have come to the right place.
The added value of a partnership with us comes from the fact that we immerse ourselves in your application –
and thus release a multitude of extra drive functions. You save on hardware and also increase application performance. Over 35 years of experience in the field of frequency converter technology as well as the flexibility
and openness of our devices are just some of our greatest strengths. Our extensive know-how in applications
and sales combined with high product quality are the ideal foundation for all your needs. Working closely together, we will be able to make perfect solutions a reality
Traditionally Innovative
Innovation is our driving factor.
Since 1965, we have continuously
set milestones in drive technology,
which have later become “state of
the art”. Our aim has been, and
still is, to develop new applications
for frequency converters in connection with synchronous and induction motors. This is tradition
in our company: During four
decades of experience in frequency
converters, we have repeatedly
proven our technological leadership in a variety of applications.
For example, we were the first to
introduce IGBT technology and
flux vector control.
We are nowadays setting new
standards with the modularconstructed RD500 product series.
Our solutions are tailored to fit your applications. Rexroth frequency converters are also
available in protection types that correspond to
use in the chemical industry.
In the Spotlight –
Your Application
One of Rexroth‘s specialties is
consistent concentration on your
application. The openness and
flexibility of our frequency converter series are the foundation for
solutions that are optimized for
your requirements. Our goal is to
always integrate increased functionality, to ensure you the technological advantage.
Rexroth offers a complete line of compact,
modular, and technologically refined frequency
converters, which are suitable for complex test
stands, for example.
4
Modular and Communicative Flexibility –
from CANopen to SERCOS Interface
Rexroth offers you a complete frequency converter program that fulfills every need. The modular structure of
hardware and software guarantees optimal tailoring to your particular drive requirements.
With the compact RD51/52 plug-in units and high-speed RS51 frequency converters, the right solution is always available.
PLC Inside
Many technology functions for
your drive requirements are easy
to realize with the Rexroth frequency converter. You save on
expensive hardware by using the
freely-switchable function blocks
for simple PLC requirements. For
the easiest implementation, a function library with pre-defined application modules is available.
More Intelligence for Your
Solution
Simple operation provides nearly
plug-and-play capability, for example, automatic motor adjustment
using parameter identification, directed initial start-up via a control
panel with a graphics display and
the powerful software tool RDwin.
More Technology for More
Power
Rexroth frequency converters are
impressive because of their superior control performance; flux vector control without an encoder,
even for synchronous motors and
variable cooling technology. In addition, there are advantages like an
Precise positioning and load-dependent speed
control are typical characteristics of Rexroth‘s
frequency converters when used for lifting and
conveying applications.
integrated curve calculator,
master/slave mode and angle synchronization functionality.
Better Connection to Master
Controls
Rexroth offers the first frequency
converters on the market that have
the only digital SERCOS drive interface normed for worldwide
use – in addition to the Profibus
DP, Interbus S and CANopen field
bus interfaces. They integrate into
open-architecture systems and allow decentralized drive structures.
5
As Individual as Your Needs –
Our Drive Solutions
Compact RD51/RD52 Devices –
Flexible and Cost-Effective
With the RD51/52 compact devices, we offer you a particularly
flexible and economical solution
with a standardized and modular
system structure in the 3 to 400
kW range.
This series includes frequency converters in different variations
(with/without braking chopper,
mains contactor, etc.), power inverter modules for DC connection
and power supply modules in regenerative power or supply-only
variations.
Besides “classic” air cooling, models with liquid cooling and internal
or external heat exchangers are
available – for the highest degree of
flexibility.
These devices are available as
stand-alone units, or in combination and completely wired in CEtested control cabinets.
Tailored Drive Performance
Both the VFC (voltage frequency
control) and FVC (flux vector control) control methods are perfectly
suited to cover a range of requirements, from simple, economical
pump drives to highly dynamic
test stands.
The compact RD51/52 devices are
the right solution for any taste –
for individual or group drives, as
well as synchronous or induction
motors.
Sturdy and High-Powered –
RD500 for the Chemical
Industry
Based on the RD500 standard
frequency converter series,
Rexroth offers drive solutions that
are tailor-made for the chemical
industry.
Examples include a standardized
option to control the frequency
converter with analog or digital
signals via the NAMUR terminal
strip or field buses and the possibility to operate the motors using
motor cables of up to 400 meters
with standardized optional filters.
For typical grinding applications,
a high-resolution gap eliminator is
integrated in the frequency converters – expensive external components are therefore a thing of
the past.
An integrated braking resistor and
a flying restart circuit to synchronize to a running machine are further significant advantages of this
unique drive system.
RS51 – High Speed for
Spindle Drives
With the RS51 series of frequency
converters, Rexroth offers you the
perfect drive solution for highspeed spindle drives with up to
180,000 rpm.
The optimized VFSC (voltage frequency synchro control) control
method and the integrated sinusoidal filter provide excellent
efficiency and minimal rotor
heating – and therefore ensure
long service life and the highest
machining precision.
Rexroth frequency converters are suitable for
all processes which require especially high
drive rotary speeds, such as grinding and
milling.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
6
fU = 0…1500 Hz
Technical Requirements
Necess ary device
charact erist ics
R D51 VFC
R D52 FVC
Volt age Frequency
Cont rol
Flux Vect or Cont rol
w/o encoder
w/o encoder
w/ encoder
Speed control
–
yes
yes
Speed range
1:20
1:20
1:30,000
2%
with slippage
compens ation
0.6%
0.003%
at a high
encoder
resolution ( E R N )
no
yes
yes
5% MN
2% MN
Synchronous
motor:
0.5% MN
Induction motor:
1% MN
Torque rise time
–
0.5 msec
0.3 msec
Full holding torque at
rot . speed 0
no
no
yes
Frequency precision
0.01%
–
–
Motor identification
–
yes
yes
Electric line shaft
–
–
yes
Positioning
–
–
yes
Position control
–
–
yes
Speed precision
Torque control
Torque ripple
Decide which unit
RD51 or RD52
Determine the necessary motor current for
your individual drive tasks.
RD51: VfU -max = power voltage
RD52: VfU -max = 0.95 x power voltage
Do you need individual drives or drives
with common circuits and energy alignment and which:
mains supply voltage/
intermediate circuit voltage?
Is braking operation necessary?
Which cooling type?
How is the frequency converter controlled?
Are the standard terminal strips sufficient
for controlling the drive?
Is an output filter required? e. g.
with long motor cable lengths of more than
75 m or with motors with insufficient voltage for modernization tasks.
Software tool RDwin?
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
7
Device selection
fU = 0…3000 Hz
RS51 page 24
Applications
Device applic at ions
Recommendations
R D51 VFC
R D52 FVC
Volt age Frequency
Cont rol
Flux Vect or Cont rol
w/o encoder
Ventilator and pump drives
●
Warehousing technology
¡
C onveyor belts
●
Test stand technology
w/o
encoder
w/
encoder
●
¡
¡
¡
●
Agit ators
●
¡
Ex truders
¡
●
¡
Group drives (multiple motors running
parallel on one frequency converter)
●
Roller t ables
●
Presses
¡
¡
●
Order a frequency converter with braking chopper
Wire drawing systems
¡
●
¡
Braking resistors pages 35-36
Winding drives
( sheet metal , paper, cloth )
¡
●
Winch drives
¡
●
Paper machines
¡
●
Frequency converters pages 16-18
Power supply modules pages 22-23
Inverters pages 16, 20-21
Reinforced braking resistors pages 37-41
Use regenerative power supply module
page 23, unregulated power supply modules are
always equipped with a braking chopper.
Pages 16, 17, 19, 20, 21
External heat exchanger page 44
Flying shears
Crane technology
– Hoisting/pulling gear
– Moving gear
– Slewing gear
●
Stage technology
Via operator panel page 29
C ableways / elevators
¡
Via field buses from page 30
Textile technology
– C ontinuous machine
– Spinning machine
– C ontinuous spinning systems
¡
●
Grinding machines u
– Drilling drives
– Milling spindles / machines
●
●
¡
Via terminal strips page 11, 12
No: terminal strip expansion page 31
Motor filter page 32
Sinusoidal filter page 33
Page 28
● Main recommended applications
! Possible use conceivable
" See also RS51, page 24
¡
●
¡
●
¡
●
●
¡
●
¡
¡
¡
●
●
●
¡
●
8
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Type Code
R D 5 1.1
4 N
0 2 2
L
V 1
F W
Note: See pages 28 and 30 for firmware type codes
and configuration of options modules.
Product Group
Device Options
Additional Functions
RD Standard
frequency converters
B Frequency converter with
integrated braking chopper
NN Not occupied
N No option
F1 Feedback of filter current
Series
L1 Feedback of cable damping
Motor filter 500 V 108 and 130 A
Frequency converters/inverters
Power Code
51 VFC voltage frequency control
003 3 to 9.5 kW
52 FVC flux vector control
018 10 to 400 kW e.g. 18.5 kW = 018
Version
Cooling Type
1 Power range 22 to 400 kW
L Forced air cooling
for devices up to 110 kW
2 Power range 3 to 18.5 kW
Device Type and Supply Voltages
2 Frequency converter
3 AC 200 to 230 V ± 15%, 50/60 Hz
e.g.
3 kW = 003
D Through-connection cooler
for devices from 22 to 110 kW
P Heat exchanger plate
for devices up to 18.5 kW
4 Frequency converter
3 AC 380 to 480 V ± 10%, 50 / 60 Hz
F Forced air cooling with
internal liquid circuit
for devices starting from 132 kW
5 Frequency converter
3 AC 500 V ± 10%, 50 / 60 Hz
R Liquid cooling with internal pump
for devices starting from 132 kW
7 Inverter
DC 530 to 670 V ± 10%
W Liquid cooling
– Device type and supply voltage
“4, 5”, power 22 to 110 kW
– Device type and supply voltage
“7, 8”, power 55 to 110 kW
8 Inverter
DC 700 V ± 10 %
V1 24 V stand-by power supply
M1 Power code >
— 132 kW and
output frequency > 150 Hz
W1 Power code >
— 132 kW and
brake resistor terminals 95 mm2
Z1 Power code >
— 132 kW and
DC-link terminals 95 mm2
Y1 IT network capable, 3 AC 400 V ± 15%
A1 24 V stand-by power supply,
start inhibit and feedback of filter current
for devices up to 18.5 kW
A2 24 V stand-by power supply and start
inhibit for devices up to 18.5 kW
Combinations of additional functions available
upon request.
Firmware
FW Firmware type code
see page 28
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
9
Technical Data
3-phase AC 380 V to 500 V (± 10%) 50/60 Hz
in different ranges. The devices are suitable for
connection to an IT network.
Cooling Methods
Ra
[kWted m
] ( o to
[H r o
P ] ut
LF
)
pu
t
or
ce
da
i
D
rc
T
oo
co hro
lin
ole ug
g
r h-c
on
ne
P
He
cti
on
at
di s
ch
FF
ar
ge
i nt o r c e
pla
er d
na ai
te
l li r c
R
q
o
uid ol
Liq
i
n
i nt u i
er d c circ g w
na o
u ith
o
l
pu lin it
W
g
m
L
p wi
ex i q u
th
ter id
na c o
l c o li
i rc ng
ui t ,
Power supply
Power range
for 3 to 400 kW (4 to 544 HP) rated motor output
Overload ability
130% for 60 sec; 170% for 1 sec;
200% for 0.5 sec (up to 110 kW)
Output voltage
3-phase AC 0 V to power supply (VFC devices)
3-phase AC 0 V to 0.95 x power supply (FVC devices)
Output frequency
0 to 200 Hz, optionally to 1,400 Hz
Efficiency at nominal point
0.97 to 0.98 (depending on output range)
Power factor
λL >0.9 inductive; cos ϕ>0.96
Protection type
IP 20 according to EN 60529
Cooling type
see graph on the right
Installation height
1,000 m (3,300 ft) above sea level up to max.
2,000 m (6,600 ft); starting at 1,000 m (3,300 ft)
power reduction 1.7% per 100 m (330 ft)
Ambient temperature
0 to +40°C (32 to 104°F) operation,
up to 50°C (122°F) power reduction of 2.5% per deg.;
-25 to +70 °C (-13°F to 158°F) storage
18.5
(25)
Environmental class
3K3 according to DIN IEC 721-3-3
(ambient temperature 0 to +40°C (32 to 104°F))
22
(30)
Perm. air humidity
<85% at 28°C (82°F); non-condensing
Radio interference
degree/noise immunity
A1 according to EN 55011/EN 61800-3
Devices 22 to 400 kW (30 to 544 HP) with integrated filter
Devices 3 to18.5 kW (4 to 25 HP) with external RZE filter
Electromagnetic
Compatibility (EMC)
per EMC product standards for electric drives
EN 61800-3, IEC 1800-3
Contamination level
level 2 per DIN VDE 0110
CE label
EC low voltage guideline 73/23 (EWG)
per EN 50178
Min. operation frequency
with/without encoder 0 Hz/2 Hz
Connectable Motor Types
Induction, synchronous, standard and specialized motors
Connectable Encoders, RD52 Series – Flux Vector Control
Incremental encoder
TTL V = 5 V, TTL V = 9 to 30 V (version R),
HTL V = 9 to 30 V
Sine/cosine encoder
V = 5 V, 1 Vpp
with or without rotor positioning sensor
Gear encoder
V = 5 V, 1 Vpp
Resolver
Ve = 7 Vrms 8 kHz, TR = 0.5, p = 2, 4, 6 to 64
Absolute encoder
Stegmann Hiperface
3
(4)
110
(150)
132
(165)
400
(500)
External Heat Exchanger
10
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Derating
With High Pulse Frequencies
M
ai
3 - ns s
p u
48 ha s ppl
0 eA yv
V C ol
± 3 t ag
10 80 e
% 1 to
Po
we
rc
od
e
M
a
3 - ins s
p
u
48 ha s ppl
0 eA yv
V C ol
± 3 ta
M
ai
10 8 ge
3- ns s % 10 to
ph up
± as pl
10 e A y v
M % C 5 olta
ain
0 0 ge
3- s s
V
ph u
48 as ppl
0 e A yv
V
± C olt
M
ain 10 38 age
s
3 - s % 1 0 to
p u
± ha s ppl
10 e A y v
% C ol
50 t ag
0 e
V
M
ain
3- s s
p u
48 ha s ppl
0 eA yv
V C ol
t
±
10 380 age
% 1 to
Operation at a pulse Operation at a pulse Operation at a pulse Operation at a pulse
frequency of 4 kHz frequency of 8 kHz frequency of 10 kHz frequency of 12 kHz
Output frequency Output frequency Output frequency Output frequency
up to 400 Hz
up to 800 Hz
up to 1000 Hz
up to 1400 Hz
Rated current [ A ]
003
1
7,5
6
5, 8
4,5
4,9
4
8,5
7
005
13
10
10
8
007
18
14
13
10
12
10
015
30
24
25
20
22
18
018
35
28
30
24
26
22
022
43
34
35
28
33
30
030
56
45
43
34
39
35
037
68
54
56
45
48
40
045
82
66
68
55
60
52
055
99
80
82
66
75
68
075
135
108
99
80
90
80
090
165
130
135
108
108
80
110
195
160
135
108
108
80
132
230
190
195
160
168
140
160
290
240
230
190
200
170
200
350
280
280
240
245
210
315
540
432
400
345
355
310
400
680
550
540
432
468
395
The rated current is linearly reduced starting at an output voltage Vout > 400 V from 100% to 83%
at Vout = 480 V.
The permissible continuous
currents of the drive converter/inverter are reduced
when operating with higher
pulse frequencies.
For all pulse frequencies, the
short-term overload capacities apply:
Devices up to 110 kW:
1.3 times for 60 sec;
1.7 times for 1 sec;
2 times for 0.5 sec
Devices starting from
132 kW:
1.3 times for 60 sec;
1.7 times for 1 sec
Devices from 132 to 400 kW
have an integrated motor filter for operation with output
frequencies up to 150 Hz
when fp=4 kHz and 250 Hz
when fp=8 kHz. The M1 additional function, i.e. without integrated motor filter,
must be selected in the type
code for higher output frequencies and pulse frequencies over 8 kHz.
See accessories on page 32
for external moter filters, or
upon request.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
11
RD51 VFC Voltage Frequency Control
Control Unit Block Diagram
Voltage Frequency Control
RDwin
To power module
Voltage frequency control
drives offer an economical
drive solution for applications that do not need servo
characteristics such as
pumps, fans, moving gears,
extruders, agitators, and
conveyor belts. The drive
works on a frequencycontrolled basis, that is, the
set value determines the
output frequency. The output voltage is adjusted proportionally to the frequency.
To improve the drive’s qualities, I x R and slipping compensation are integrated as
well as a rise in voltage
(boost) in the lower frequency range. A square
characteristic curve can be
selected for pump and fan
applications.
Removable Operator
Panel
•
•
•
•
Operate
Monitor
Parameterize
Copy parameter sets and
transfer them to other
devices
Standard Control Terminal
Strips
• 3 digital inputs or outputs
(as desired)
• 2 digital inputs
Level: inputs and outputs
P24V PLC-compatible
• 1 analog input ± 10 V,
resolution ± 9 bit or
0/4 to 20 mA,
res. 10 bit
• 1 encoder input for HTL
incremental encoder,
altern. 3 digital inputs
• 1 analog output ± 10 V,
5 mA, short-circuit-proof,
resolution ± 8 bit,
reference as selected + 10 V,
- 10 V
• 1 relay output
250 V AC, 7 A or
30 V DC, 7 A
• RS 232
• RS 485
Interfaces for Module
Slots 1 and 2
•
•
•
•
•
SERCOS interface
INTERBUS S remote bus
PROFIBUS DP slave
CANopen
Peer-to-peer coupling
with fiber-optic cable
• Control terminal strip
extension
12
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
RD52 FVC Flux Vector Control
Control Unit Block Diagram
Flux vector control is employed in the most challenging, highly-dynamic drive
tasks. The RD52 can be
operated both with an encoder (incremental encoder,
resolver, sin/cos encoder,
Hiperface) as well as without an encoder. Three phase
induction motors and synchronous motors can be operated with the RD52. The
drive can control rotary
speed or torque. The stator
current is divided into two
components: the magnetization current and the active
current via the motor model.
With the patented multivariable control system, the
vectors of both component
currents are adjusted so exactly in accordance with the
dialog, that the highest possible utilization of the motor
and drive converter combination is guaranteed.
Patent document: 44 18 997
from 2.6.99, German Patent
and Trademark Office,
Munich
Removable Operator
Panel
•
•
•
•
Operate
Monitor
Parameterize
Copy parameter sets and
transfer them to other
devices
To power module
Flux Vector Control
Standard Control Terminal
Strips
• 3 digital inputs or outputs
(as desired)
• 2 digital inputs
Level: inputs and outputs
P24V PLC-compatible
• 1 analog input ± 10 V,
resolution ± 11 bit or
0/4 to 20 mA,
resolution 12 bit
• 1 analog output ± 10 V,
5 mA, short-circuit-proof,
resolution ± 8 bit, reference as selected +10 V, -10 V
• 1 relay output 250 V AC,
7 A or 30 V DC, 7 A
• RS 232, RS 485
Interfaces for Module
Slots 1 and 2
• SERCOS interface
•
•
•
•
INTERBUS S remote bus
PROFIBUS DP slave
CANopen
SynchroLink for fast communication between multiple drives
• Peer-to-peer coupling
with fiber-optic cable
• Control terminal strip
extension
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Frequency Converter/Inverter 3 to 18.5 kW
Power Module Block Diagrams
Inverter
From
control unit
From
control unit
Frequency Converter
* Open the isolation point on the T-T1 input terminal for operation with an IT network.
** Frequency converters which are 2B devices or have 2B mains supply voltage
must have an external distribution voltage of DC 530 to 670 V ± 10%.
EW
GL
K1
K2
NF
SE
SNT
VL
Ground fault transducer
Rectifier
Main contactor
Pre-charging relay
Mains filter
Current sensing
Switch-mode power supply
Pre-charging
WS
WR
BC
Inverter control
Inverter
Braking chopper
Accessories
RZW Braking resistor
RZM Motor filter
RZS Sinusoidal filter
A1
A2
Additional fuctions
24 V stand-by power supply,
start inhibit and feedback of
filter current
24 V stand-by power supply
and start inhibit
13
14
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Frequency Converter/Inverter
22 to 110 kW
Power Module Block Diagrams
EW
GL
K1
K2
NF
SE
SNT
VL
WS
WR
X80
Ground fault transducer
Rectifier
Main contactor
Pre-charging relay
Mains filter
Current sensing
Switch-mode power supply
Pre-charging
Inverter control
Inverter
Start inhibit
From
control unit
Inverter
From
control unit
Frequency Converter
B
Equipment version
Frequency converter with integrated
braking chopper
Accessories
RZW Braking resistor
RZM Motor filter
V1
Additional function
24 V stand-by power supply
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
15
Frequency Converter/Inverter
132 to 400 kW
Power Module Block Diagrams
BC
BW
E1
EW
GL
K1
K2
From
control unit
Inverter
From
control unit
Frequency Converter
Braking chopper
Internal braking resistor
Fan
Ground fault transducer
Rectifier
Main contactor
Pre-charging contactor
P1
SE
SNT
VL
WS
WR
X80
Cooling circuit pump
Current sensing
Switched-mode power supply
Pre-charging
Inverter control
Inverter
Start inhibit
Accessories
RZM Motor filter
V1
Additional function
24 V power supply
* Distribution voltage for inverter with
mains supply voltage
DC 530 to 670 V:
AC 400 V 50/60 Hz
DC 700 V:
AC 500 V 50/60 Hz
16
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Frequency Converter/Inverter 3 to 18.5 kW
Technical Data and Dimensions
2 3-phase AC 200 to 230 V ± 15% 3
4 3-phase AC 380 to 480 V ± 10%
5 3-phase AC 500 V ± 10%
Power code
0 0 3
L
Note: See page 8 for the complete type code.
Mains supply
volt age
Peak current
Mains supply
volt age
3
4
1.5
003
5.5
7.5
3
005
13
10
4
007
15
20
5.5
18.5
25
7.5
7.5
1
7.5
Peak current
[A]
A
6
17
22
26
10
18
23
31
36
015
30
39
51
018
35
46
60
2
B
c
c
se
c
.5
7.8
ze
r0
Peak current
[A]
Si
se
0
r6
fo
±
AC
5
10 00 V
%
15
3
Size
Rated current
[A]
13
Maximum permitted motor output referring to a 4-pole
standard motor.
9.8
3
AC
48 3 8
0 0 to
V
±
10
%
fo
r6
0
se
c
fo r
1
se
c
fo
r0
.5
se
c
Rated current
[ A ]2
Rated motor output
Size
5
3
[ kW
]1
[ kW at 4
] 1a 00
t5 V
00
V
[H
P] 1
at
46
0
V
[ kW
]a
t2
00
V3
Po
we
rc
od
e
4
Peak current
se
Rated motor output
fo
4 B
r1
R D 5 2.2
L Forced air cooling
P Heat discharge plate
fo
51 VFC Voltage Frequency Control
52 FVC Flux Vector Control
Size
10
12
A
13
17
20
A
14
18
24
28
A
60
24
31
41
48
B
70
28
36
48
56
B
The rated current is linearly reduced starting at an output voltage
Vout > 400 V from 100% to 83% at Vout = 480 V.
External distribution voltage of DC 600 V ± 20% necessary.
Forced air cooling
A (15 kg/33 lb)
B (18 kg/40 lb)
Heat discharge plate
A (10 kg/22 lb)
B (12 kg/26 lb)
An RND01.1-5-007 or -018
line choke or an
RZE01.1-5-007 or -018 filter
is necessary to operate devices with power code 007
and 018.
Line chokes and filters must
be ordered separately.
A radio interference degree/
noise immunity of A1 according to EN 55011/
EN61800-3 is attained with
an external RZE filter or a
central filter in the system.
Minimum clearance for cooling above and below is 100 mm (4”)
Cooling type P: Minimum clearance between frequency converters installed next to each other is 15 mm (0.6”)
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
17
Frequency Converter 22 to 110 kW
Technical Data and Dimensions
B Frequency converter with
integrated braking chopper
N No option
4 3 AC 380 to 480 V ± 10%
5 3 AC 500 V ± 10%
51 VFC Voltage Frequency Control
52 FVC Flux Vector Control
R D
Power code
5 2.1
4 B
0 2 2
D
Mains supply
volt age
Rated motor output
D Through-connection cooler
L Forced air cooling
W Liquid cooling
Note: See page 8 for the complete type code.
Mains supply
volt age
Peak current
Size
5
Peak current
[A]
Rated current
[A]
c
Peak current
[A]
ze
Si
fo
fo r
r1
0.
5
se
c
se
c
se
0
r6
fo
3
±
c
fo
fo r
1
r0
.5
se
c
se
c
se
0
r6
fo
AC
5
10 00 V
%
80
AC
3
10 80 t
% o4
±
Rated current
[ A ]2
Rated motor output
1
3
[ kW
]1
[ kW at 4
] 1a 00
t5 V
00
V
[H
P] 1
at
46
0
V
Po
we
rc
od
e
V
4
Peak current
Size
22
30
022
43
56
73
86
34
44
58
68
C
30
40
030
56
73
95
112
45
59
77
90
C
37
50
037
68
88
116
136
54
70
92
108
C
45
60
045
82
107
139
164
66
86
112
132
C
55
75
055
99
129
168
198
80
104
136
160
D
75
100
075
135
176
230
270
108
140
184
216
D
90
125
090
165
215
281
330
130
169
221
260
E
110
150
110
195
254
332
390
160
208
272
320
E
Maximum permitted motor output referring to a 4-pole standard motor.
Size
C
2
The rated current is linearly reduced starting at an
output voltage Vout > 400 V from 100% to 83% at
Vout = 480 V.
Forced air cooling
D
E
Minimum clearance for cooling above and below is 100 mm (4”)
The frequency converters
22 to 110 kW have an integrated line choke to reduce
harmonic feedback and a
mains filter to maintain class
A1 according to EN 55011.
C (36 kg/79 lb)
D (52 kg/114 lb)
E (74 kg/163 lb)
Through-connection
cooler
C (33 kg/73 lb)
D (49 kg/108 lb)
E (77 kg/169 lb)
Liquid cooling
C (28 kg/62 lb)
D (42 kg/92 lb)
E (57 kg/125 lb)
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
18
Frequency Converter 132 to 400 kW
Technical Data
B Frequency converter with
integrated braking chopper
N No option
4 3-phase AC 380 to 480 V ± 10%
5 3-phase AC 500 V ± 10%
51 VFC Voltage Frequency Control
52 FVC Flux Vector Control
F Forced air cooling with
internal liquid circuit
R Liquid cooling with
internal pump
Power code
R D 5 2.1
Rated motor
output
4 B
1 3 2
Mains supply
volt age
F
Peak current
Mains supply
volt age
Peak current
[W]
[ kW]
[ kW ]
Size
5
1
Rated current
[ A ]2
er
Si
ze
i nu
nt
Co
r0
.1
se
ou
c
nt
r re
cu
fo
ak
Pe
I nt
.b
ra
se
r1
sp
ow
sis
re
g
k in
c
c
se
fo
0
c
r1
se
se
0
r6
fo
r6
Rated current
[A]
fo
Peak current
[A]
c
3
AC
± 50
10 0
% V
Rated motor
output
fo
[ kW
1
[ kW ] at
] 1a 400
t5 V
[H
00
P] 1
V
at
46
0
Po
V
we
rc
od
e
3
AC
48 3 8
0
V 0 to
±
10
%
to
r
4
Note: See page 8 for the complete type code.
Peak current
[A]
[W]
[ kW]
[ kW]
Size
132
165
132
230
299
391
190
247
323
2.2
270
2
G1
160
200
160
290
377
493
240
312
408
2.2
270
2
G1
200
250
200
350
455
595
280
364
476
1.6
370
2.5
G2
315
400
315
540
702
918
432
562
734
2 x 2.2
2 x 270
2x2
H1
400
500
400
680
884
1156
550
715
935
2 x 1.6
2 x 370
2 x 2.5
H2
Maximum permitted motor output referring to a 4-pole standard motor.
The frequency converters for
the 132 to 400 kW power
range are “all inclusive”,
complete units to be installed in cabinets by the
customer.
The frequency converters
consist of:
• Mains rectifier, capacitor
link and
• IGBT inverter bridge
• Optional braking chopper
with integrated braking
resistor
• Line choke for reducing
harmonic feedback
• Mains contactor for electrical isolation
• Mains filter to maintain
class A1 according to
EN 55011
2
The rated current is linearly reduced starting at an
output voltage Vout > 400 V from 100% to 83% at
Vout = 480 V.
• A motor filter designed for
a 50 m motor cable. The
M1 additional function,
i.e. without integrated motor filter, must be selected
in the type code for operation with output frequencies >150 Hz (fp=4 kHz).
See accessories on page 32
for external moter filters.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Cooling type F
Forced air cooling
with internal liquid circuit
Cooling type R
Liquid cooling
with internal pump
Size G (180 kg/397 lb)
Size G (157 kg/346 lb)
Size H (358 kg/789 lb)
Size H (312 kg/688 lb)
Minimum clearance for cooling above and below is 200 mm (8”)
Minimum clearance for cooling above and below is 200 mm (8”)
19
20
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Inverters 22 to 110 kW
Technical Data and Dimensions
7 DC 530 to 670 V ± 10%
8 DC 700 V ± 10%
Power code
L Forced air cooling
W Liquid cooling
D Through-connection cooler
Mains supply
volt age
8
Rated current
[ A ]2
Rated motor output
1
Peak current
[A]
Peak current
[A]
Si
ze
r0
.5
se
c
se
c
Rated current
[A]
Size
22
30
022
43
56
73
86
34
44
58
68
C
30
40
030
56
73
95
112
45
59
77
90
C
37
50
037
68
88
116
136
54
70
92
108
C
45
60
045
82
107
139
164
66
86
112
132
C
55
75
055
99
129
168
198
80
104
136
160
D
75
100
075
135
176
230
270
108
140
184
216
D
90
125
090
165
215
281
330
130
169
221
260
E
110
150
110
195
254
332
390
160
208
272
320
E
Maximum permitted motor output referring to a 4-pole
standard motor.
2
The rated current is linearly reduced starting at an output voltage
Vout > 400 V from 100% to 83% at Vout = 480 V.
Size
C
D
Size
c
Peak current
fo
[ kW
]1
[ kW at 4
0
] 1a 0 V
t5
00
V
[H
P] 1
at
46
0
V
Po
we
rc
od
e
DC
5
± 30
10 t
to % o 6
p (c 70
3 - o we o r r e V
ph r
s
to ase sup pon
48 A ply ds
0 C
V 38
±
10 0
%
fo
)
r6
0
se
c
fo
r1
se
c
fo
r0
.5
se
c
DC
(c 700
or
V
po re s p ±
we on 10
3- r s ds %
p
u
t
50 ha se p p ly o
0
A
V) C
Peak current
r1
Mains supply
volt age
7
Rated motor output
Note: See page 8 for the complete type code.
See page 16 for inverters 3 to 18.5 kW.
se
L
fo
0 2 2
0
7 N
r6
R D 5 1.1
fo
51 VFC Voltage Frequency Control
52 FVC Flux Vector Control
Forced air cooling
Through-connection Liquid cooling
cooler
C (22 kg/48 lb)
D (32 kg/70 lb)
E (44 kg/97 lb)
C (20 kg/44 lb)
D (30 kg/66 lb)
E (42 kg/92 lb)
E
Minimum clearance for cooling above and below is 100 mm (4”)
D (25 kg/55 lb)
E (36 kg/79 lb)
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
21
Inverters 132 to 400 kW
Technical Data and Dimensions
51 VFC Voltage Frequency Control
52 FVC Flux Vector Control
Power code
F Forced air cooling with
7 DC 530 to 670 V ± 10%
internal liquid circuit
8 DC 700 V ± 10%
R Liquid cooling with internal pump
F
Rated motor output
1
Rated current [ A ]2
Peak current [ A ]
Mains supply
volt age
8
Rated current [ A ]
Peak current [ A ]
ze
Size
132
165
132
230
299
391
190
247
323
G1
160
200
160
290
377
493
240
312
408
G1
200
250
200
350
455
595
280
364
476
G2
315
400
3153
540
702
918
432
562
734
H1
400
500
400
680
884
1156
550
715
935
H2
3
Maximum permitted motor output referring to a 4-pole
standard motor.
2
3
Cooling type F
Forced air cooling with internal liquid circuit
Size G
H
Size
c
Peak current
Si
fo r
[ kW
1
se
c
]1
[ kW at 4
0
] 1a 0 V
t5
00
V
[H
P] 1
at
46
0
V
Po
we
rc
od
e
DC
5
± 30
10 to
to % 2 67
0
p (
3 - ow c o r r V
ph er es
a
s
to se up pon
48 A p d
0 C 3 ly s
V± 8
10 0
%
)
fo
r6
0
se
c
Peak current
se
Mains supply
volt age
7
Rated motor output
Note: See page 8 for the complete type code.
1
1 3 2
fo r
7 N
DC
(c 700
or
po re s p V ±
w o 1
3 - er s nds 0 %
ph u
t
50 a s e p p ly o
0
A
V C
±
10
%
)
fo r
60
se
c
R D 5 1.1
The rated current is linearly reduced starting at an output
voltage Vout > 400 V from 100% to 83% at Vout = 480 V.
Currently in development
G (128 kg/280 lb)
H (252 kg/556 lb)
Cooling type R
Liquid cooling
G
H
G (104 kg/229 lb)
H (206 kg/454 lb)
Minimum clearance for cooling above and below is 200 mm (8”)
The inverters for the 132 to
400 kW power range are designed with an integrated
motor filter for a 50 m mo-
tor cable. The M1 additional
function, i.e. without integrated motor filter, must be
selected in the type code for
operation with output
frequencies >150 Hz
(fp=4 kHz).
See accessories on page 32
for external moter filters.
22
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Unregulated Power Supply Modules
12.5 to 100 kW
Technical Data and Dimensions
B With braking chopper
6 3-phase AC 400V ± 15%
rc
we
Po
0 1 2
L
od
e
Ra
te
in d c
D C ur
r
l i n e nt
k* [A
]
[ kW
ut
tp
ou
d
te
Ra
012
25
25
025
50
50
050
100
100
12.5
6 B
]
Co
n
re ne c
sis ta
to ble
rR b
ra
mi
n [
W ] k ing
Re
le
r e va n
sis t
to bra
r* * ki
* ng
M
ax
i nv . c o
. w nn
i th e c
ou tab
t R le
ZL
Si
ze
**
R D 4 1.1
Power code
L Forced air cooling
20
011
3
A
7.5
030
3
A
100
5
055
3
B
200
3.75
075
6
C
* Overload capacity 1.5 times for 60 sec
** The indicated number of inverters is an estimated standard value that has to be determined for
every application. The number of inverters can be increased with the RZL03.1-300 load amplifier.
*** See pages 38 to 40
power supply module. This
is calculated from the power
difference of drives working
as a motor and a generator at
Selection
The net power consumption
of the connected drives is
used for selecting a suitable
Size
A
B
Size A and B with integrated mains filter
Size C dimensions and weight with
the external mains filter
Minimum clearance for cooling
above and below is 100 mm (4”)
C
the same time plus the
power loss of all drives.
A (22 kg/49 lb)
B (36 kg/79 lb)
C (58 kg/128 lb)
Power Modules to
Connect to Inverters
It is economical to supply
multiple inverter modules
from one common power
supply module with drives
that work in one common
technological group. Via the
inverter coupling in the DC
link, there is a power cancellation between drives working as a motor and a generator at the same time. Only
the power difference and the
heat loss is taken from the
incoming three-phase supply network. The power supply module and other power
supply devices such as transformers, switches, contactors, etc., only need to be designed with the power necessary for the network. This
can conserve a considerable
amount of power, for example with wrappers.
If the power fed back regeneratively in the DC link
overbalances e.g. when shut
down, it is transformed into
heat via a braking resistor
unit connected to the power
supply module.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
23
Regenerative Power Supply Modules
26 to 105 kW
Technical Data and Dimensions
4 3-phase AC 380 V to 480 V ± 10%
5 3-phase AC 500 V ± 10%
4 R
0 2 6
L
Ra
te
at d o
3 - ut
ph pu
as t [
e A kW
C ]
Ra
50
te
0
d
in
V
D C cur
r
l i n e nt
k* [A
]
ma
x
i nv . c o
. w nn
i th e c t
ou ab
t R le
ZL
**
Si
ze
Ra
te
at d o
3 - ut
40 pha put
0 se [ k
V
AC W ]
Po
we
rc
od
e
R D 4 2.1
R Regenerative
Power code
L Forced air cooling
26
026
33
50
3
D
53
053
66
100
3
E
84
084
105
160
6
F
105
105
132
200
6
G
Regenerative Power
Supply Modules to
Connect to Inverters
The use of regenerative
power supply modules is
recommended with
predominantly generatorbased operations or on those
with large power demands.
The devices from the RD42
series work with unregulated DC link and block current.
* Overload capacity 1.5 times for 60 sec
** The indicated number of inverters is an estimated standard value that has
to be determined for every application. The number of inverters can be
increased with the RZL03.1-300 load amplifier.
Size
D
E
Dimensions and weight with
the external mains filter
Minimum clearance for cooling above and below is 100 mm (4”)
F
G
Selection
The net power consumption
of the connected drives is
used for selecting a suitable
power supply module. This
is calculated from the power
difference of drives working
as a motor and a generator at
the same time plus the
power loss of all drives.
D (46 kg/101 lb)
E (83 kg/183 lb)
F (88 kg/194 lb)
G (98 kg/216 lb)
24
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
RS51 VFSC Voltage Frequency Synchro Control
Control Unit Block Diagram
All in One
To power module
All of the necessary function
modules for controlling
spindle motors have been
integrated in the RS51:
• Start inhibit
• Braking resistor
• Sinusoidal filter
• Gap eliminator
• 32 pre-programmed
spindle parameter sets
VFSC (Voltage Frequency
Synchro Control)
Although induction pulse
methods are typically used
for standard applications
with frequency converters,
RS51 uses a synchronous
PWM. Only these VFSCs
enable a high output frequency of 3,000 Hz.
Removable Operator
Panel
•
•
•
•
Operate
Monitor
Parameterize
Copy parameter sets and
transfer them to other
devices.
Gap Eliminator Function
The optional “gap eliminator” function can detect
whether the grinding machine is touching the workpiece by the smallest
changes to the active load
current signal. The grinding
process cycle times can thus
Example of a typical parallel interface configuration
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
25
RS51 VFSC Voltage Frequency Synchro Control
Power Module Block Diagram
from
controller
be substantially reduced
without any expensive additional circuits. The proportional torque speed active load current signal can
also be used to monitor and
control the load on the
spindle.
Standard Control Terminal
Strip
• 3 digital inputs or outputs
(as desired)
• 8 digital inputs
Level: inputs and outputs
P24V PLC-compatible
• 1 analog input ± 10 V,
resolution ± 9 bit
0/4 to 20 mA,
resolution 10 bit
• 1 analog output ± 10 V,
5 mA, short-circuit-proof,
resolution ± 8 bit,
reference as selected
+ 10 V, - 10 V
EW
GL
K1
K2
NF
SE
SNT
VL
WS
WR
SF
X80
BC
BW
Ground fault transducer
Rectifier
Main contactor
Pre-charging relay
Mains filter
Current sensing
Switch-mode power supply
Pre-charging
Inverter control
Inverter
Sinusoidal filter
Start inhibit
Braking chopper
Internal braking resistor
• 1 relay output 250 V AC,
7 A or 30 V DC, 7 A
• RS 232
• RS 485
Interfaces
• SERCOS interface
• INTERBUS S slave
remote bus
• PROFIBUS DP slave
• CANopen
• Peer-to-peer coupling
• Control terminal strip
extension
Accessories
RZW External braking resistor
V1
Additional Function
24 V stand-by power supply
26
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Frequency Converters 3 to 50 kVA S6
Output Frequencies up to 3000 Hz, Technical Data
Power code
G Integrated braking chopper and resistor
L Forced air cooling
4 3-phase AC 380 V to 480 V ± 10%
R S 5 1.1
NN Not occupied
V1 24 V stand-by power supply
4 G 0 0 3
L
N N F W
Note: See pages 28 and 30 for the firmware type code and
configuration of the optional modules.
Output frequency 0 – 3000 Hz
S1
co
nt
i nu
ou
sp
S6
ow
er
6 0 r ate
% dp
E D ow
T= er
12
M
0
ax
se
6 0 . ou
c
s e tpu
c tf
or
S1
cu con
r r e ti n
nt u o u
s
S6
6 0 r a te
% dc
ED ur r
T = e nt
12
Pe
0
a
se
60 k cu
c
r
se re
c nt
fo
r
Fr
eq
po ue n
we c y
r c co
o d nv
e er
S1
te
r
co
p o nt
we i n u
r ou
s
S6
E D r a te
T= d po
12 we
0
se r 60
c
M
%
ax
6 0 . ou
s e tpu
c tf
or
S1
cu con
r r e ti n
nt u o u
s
S6
E D r a te
T= d po
12 we
0
se r 60
Pe
c
%
ak
60 cu
r
r
se en
c
tf
or
Si
ze
Output frequency 0 – 2000 Hz
P o w e r o f d e v i c e [ k VA ]
S1
S6
60 s
2.5
3
4
5
6
7.5
11
14
19
Output current [ A ]
S6
60 s
4
5
6.5
8
10
18
19
24
30
25
31
41
50
Size
J
K
S1
P o w e r o f d e v i c e [ k VA ]
Output current [ A ]
S6
60 s
003
2.5
3
4
4
5
13
006
5
6
7.5
8
10
13
J
23
29
014
11
14
18
19
23
29
K
32
40
50
024
14
18
23
24
30
38
L
39
42
52
65
031
19
23
29
32
39
49
L
63
66
83
104
050
30
37
47
49
62
78
M
L
M
Minimum clearance for cooling above and below is 100 mm (4”)
J (20 kg/44 lb)
K (33 kg/73 lb)
L (55 kg/121 lb)
M (80 kg/176 lb)
S1
S6
Size
S1
60 s
6.5
J
The frequency converters 3 to 50 kVA
have an integrated line choke to reduce harmonic feedback and a mains
filter to maintain class A1 according to
EN 55111.
The sinusoidal filter that is integrated
into the ouput circuit produces sinusoidal wave forms from the current and
voltage in the spindle motor.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Frequency Converters 3 to 50 kVA S6
General Technical Data
Power supply
3-phase AC 380 V to 480 V (± 10%) 50/60 Hz
Power range
3 to 50 kVA S6 60% ED T = 120 sec
2.5 to 41 KVA S1 (continuous power)
Overload ability
125% for 60 sec
Braking chopper
integrated braking chopper and braking resistor,
a high-load resistor can be alternatively connected
Sinusoidal filter
integrated sinusoidal filter
Output voltage
3 AC 0 V to 0.87 x power supply
Output frequency
0 to 3000 Hz
Efficiency at nominal point
0.93 to 0.95 (depending on output range)
Mains power factor
λN >0.9 inductive; cos ϕ>0.96
Protection type
IP 20 according to EN 60529
Cooling type
forced air cooling
Installation height
1000 m (3300 ft) above seal level up to max.
2000 m (6600 ft); starting at 1000 m (3300 ft) power
reduction 1.7% per 100 m (330 ft)
Ambient temperature
0 to +40°C (32 to 104°F) operation,
up to 50°C (122°F) with power reduction of 2.5% per
degree; -25 to +70°C (-13 to 158°F) storage
Environmental class
3K3 according to DIN IEC 721-3-3
(ambient temperature 0 to +40°C (32 to 104°F))
Perm. air humidity
<85% at 28°C; non-condensing
Radio interference degree/
noise immunity
A1 according to EN 55011/EN 61800-3
Electromagnetic Compatibility
(EMC)
per EMC product standards for electric drives
EN 61800-3, IEC 1800-3
Contamination level
level 2 per DIN VDE 0110
CE label
EC low voltage guideline 73/23 (EWG)
per EN 50178
27
28
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Firmware FWA and Software Tool RDwin
F W A R D 5 0 0 *
0 2 0
0 2 V R S M S R D 5 1
020 fu to 200 Hz RD51, RD52
023 fu to 200 Hz RD51 NAMUR
100 fu to 1000 Hz RD51, RD52
140 fu to 1400 Hz RD52
150 fu to 1500 Hz RD51
300 fu to 3000 Hz RS51
301 fu to 3000 Hz and RS51 gap eliminator
In addition to the functions
that are specific for the type
of control, there are also
function modules that can
be linked as desired:
•
•
•
•
PID controller
PI controller
Logical function elements
Mathematical function
elements
• Comparators
• Set integral memory
S W A R D 5 W I N D P D
Software-Tool RDwin
RDwin enables parameter
sets to be saved and printed,
simplifies error searches and
thereby aids in starting up
02 Firmware version
V Complete version
RS Last release
RD51 VFC
RD52 FVC
RS51 VFSC
• Free characteristic curve
with 10 interpolation
points
• Timers
• Counters
• Sample & Hold
• Limiters
• Process data switches
• Friction characteristics
with automatic recording
routine
• Step controller
• Trip profile calculation
1 0 V R S M S C D 6 5 0
the system. RDwin includes
a 4-channel oscilloscope
function with a sampling
time from 0.2 msec to 500
msec.
Per channel, 512 measuring
values are recorded in real
time. Furthermore, RDwin
supports programming the
function modules, which are
R D 5 0 0
available in the firmware,
and enables easy archiving.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Operator Panel
2 Operator panel installed on device
3 Operator panel as an accessory
01 Top unit
R Z B 0 1.2
U Unlighted
U N
Operator panel installed on device
Operator Panel
The frequency converter
can be quickly and easily
brought into operation using the operator panel.
It has a 4-lined graphics
display with a multiplelanguage plain text display.
The frequency converter’s
set of parameters can be
saved in the operator panel.
The parameters can also be
B Lighted
03 Keypad
R Z B 0 3.2
1
2
3
6
With 1 m cable
With 2 m cable
With 3 m cable
With 6 m cable
B 1
Operator panel for cabinet installation, protection type IP 54
quickly transferred to another frequency converter
without a PC.
29
30
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Options Modules
Configuration of Module Slots 1 and 2
The RD500 can be integrated into the automation
network quickly and easily
using the following options.
The field buses can also be
achieved redundantly using
the 2 module slots. The
RD500 can be parameterized completely via the bus
(“download”). Interfaces
RS232 and RS 485 remain
available when using a communication module.
SERCOS interface
Compatability class A
Compatability class B
Speed control
Spindle positioning
IEC 61491, EN 61491
Code
PROFIBUS DP slave
S 1
Protocol: PROFIBUS DPconform according to
EN 50170 Volume 2 or
DIN 19245 Parts 1 and 3
Baud rate:
9.6 kbit/sec to 12 Mbit/sec
Plug: INS0704/K01
O
Co
pt
de
ion
sm
od
ule
R Z P 0 1.1
S E R C O S interface
S1
C ANopen
C1
I NTE R B U S S
B1
P R O F I B U S DP
P2
Incremental encoder emulation with resolver evaluation
G1
Input for gear encoder 1 Vss, TTL, sin/cos, Hiperface
absolute value encoder, incremental encoder emulation
G2
Increment al encoder emulation
G3
SynchroLink
L1
Peer-to-peer coupling
L2
C ontrol terminal strip ex tension
T1
CANopen
Protocol: Basic profile
(DS301) I/O-profile (DS401)
Baud rate:
125 kbit/sec, 250 kbit/sec,
500 kbit/sec, 1 Mbit/sec
Electrical isolation
G1, G2, G3 and L1: only for RD52
Configuration Type
Code
C F G R D 5 0 0
Product group
N N N N
Product group
CFG Configuration RD500
Module slots 1 and 2
RD51/RS51
INTERBUS S slave,
remote bus
Protocol: INTERBUS Sconform (DIN 19258 or
EN 50 254)
Baud rate: 500 kbit/sec
RD52
B1-L2 B1-NN B1-T1
B1-B1 B1-G2 G2-B1 B1-G3 B1-L1
B1-L2 B1-NN B1-T1
C1-C1 C1-L2 C1-NN C1-T1
C1-C1 C1-G1 G2-C1 C1-G3 C1-L1
C1-L2 C1-NN C1-T1
B1-B1
L2-T1
G1-L1 G1-L2 G1-NN G1-T1
NN-NN NN-T1
G2-L1 G2-L2 G2-NN G2-T1
L2-NN
P2-P2
P2-L2 P2-NN
G3-L1 G3-L2 G3-NN G3-T1
P2-T1
S1-L2 S1-NN S1-T1
If the options are fixed upon ordering of devices, they are ordered via
the configuration type code.
L1-NN
L1-T1
L2-NN
L2-T1
NN-NN NN-T1
P2-P2 P2-G1 G2-P2 P2-G3
P2-L1
P2-L2 P2-NN
S1-G1 S1-G2 S1-G3
S1-L1
S1-L2 S1-NN S1-T1
P2-T1
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
31
Frequency Converter
Communication
Two options modules are
available for coupling multiple RD500 units to each
other for quickly transferring controlled variables
such as set and actual values. Transfer by both methods takes place quickly via
fiber-optic cables and is immune to interference.
SynchroLink
Baud rate: 10 Mbit/sec
• Synchronization pulse
• Complete duplex operation
• Bus monitoring, even on
stand-by
Application areas:
• Angle synchronization
• Electric shaft
• Angle synchronized electric gears
• Frequency converter
synchronization
Peer-to-Peer Coupling
Baud rate: 230 kbit/sec
Application areas:
• Speed synchronization
• Load distribution control
• Speed synchronized electric gears
• Set value cascading
24 V Stand-by Power
Supply
The control electronics can
be supplied with external
power in order to be able to
Digit al inputs/outputs
Digit al inputs
Relay outputs
Analog input
0 to +-10 V / 0 / 4 to 20 mA
Analog output
0 to 10 V
0 / 4 to 20 mA
Terminal strip expansion
3
-
2
4 ( isolated )
1 changeover contact
( AC 230 V / 7 A /
D C 30 V / 7 A )
2 changeover contacts ,
2 normally open cont acts
( D C 30 V / 2 A )
1
1
1
access the RD500’s informational electronics even if the
power is turned off. This option should be used when
communication modules are
used. Since this option is
wired to power electronics
components in the interior
of the device we recommend
ordering it together with the
basic unit. Input:
24 V DC -15/+20%;
max. ripple 5%;
VDE0411/500 EN 61131-2
Power
consumption
St andard in frequency converter
ON current
Size A to E 40 W
Size G
80 W
Size H
160 W
5A
15 A
30 A
Terminal Strip Extension
This option makes additional digital and analog inputs and outputs available.
Second Encoder Connection and Incremental Encoder Emulation
The G1/G3 option helps to
evaluate a second encoder
(or a pilot frequency) with
TTL level and can also be
used for position or speed
synchronization.
The G3 option either reflects
this signal or the signal from
the incremental motor encoder, which is connected to
the base card, at the motor
output with RS422 level.
If the motor is equipped
with a resolver, the G1 option provides an incremental
encoder emulation with
2 ( isolated )
1024 pulses per 360°.
The G2 option is also used
to evaluate an incremental
encoder with sine-cosine
1VSS or TTL signal level or
the Hiperface absolute value
encoder. The encoder can be
used as a motor encoder, or
as a second encoder for position or speed synchronization.
When a sine-cosine encoder
is connected, an automatic
offset and amplitude comparison takes place.
The encoder input is thus
ideal for direct connection
of a gear encoder (field plate
encoder).
32
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Motor Filters up to 200 Hz
6 3-phase AC 400 V ± 15%
5 3-phase AC 500 V ± 10%
0 1 0
[W
ss
r lo
we
Co
de
Fr
eq
ou ue n
tp cy
ut
co con
d e ve
rt
]
[W
ss
r lo
we
Po
de
No
( a min
t 4 al
N o k H cur
z r
( a m i n a ) e nt
[A
t8 l
]
k cu
S i H z) r r e n
ze
t[
A]
er
Co
Fr
eq
ou ue n
tp cy
ut
co con
d e ve
rt
]
Motor filter for mains supply
voltage 500 V
er
Motor filter for mains supply
voltage 400 V
Po
6
No
( a min
t 4 al
N o k H cur
z r
( a m i n ) e nt
[A
t 8 al
]
k cu
S i H z) r r e n
ze
t[
A]
R Z M 0 1.1
Code
001 / 003 / 004
010
10
7.5
A
120
001 / 003 / 004
008
8
6
A
140
005 / 007 / 011 /
015
030
30
25
A
160
005 / 007 / 011 /
015 / 018
028
28
24
A
190
018 / 022 / 030
056
56
43
A
220
022 / 030 / 037
054
54
45
B
250
037 / 045 / 055
099
99
82
B
280
045 / 055 / 075*
108 108
80
C
440
075 / 090
165 165 135
D
400
110 / 132
230 230 195
D
600
130 130 108
E
65 0
160 / 200
350 350 280
F
800
Pulse frequency
Max . output frequency
Max . motor cable lengths
unshielded
Max . motor cable lengths
shielded
4 kHz
8 kHz
100 Hz
200 Hz
300 m
150 m
150 m
75 m
090*
* Order a frequency converter/inverter with the L1
additional function
Pulse frequency
Max . output frequency
Max . motor cable lengths
unshielded
Max . motor cable lengths
shielded
4 kHz
8 kHz
100 Hz
200 Hz
200 m
120 m
100 m
60 m
Dimensions
Size
mm
Height
(inch)
mm
Width
(inch)
mm
300
A
140
(5.5)
275
(10.8)
Depth
(inch)
(11.8)
B
260
(10.2)
275
(10.8)
300
(11.8)
C
260
(10.2)
275
(10.8)
340
(13.4)
D
360
(14.2)
285
(11.2)
260
(10.2)
E
480
(18.9)
275
(10.8)
315
(12.4)
F
400
(15.7)
360
(14.2)
260
(10.2)
Description
The motor filter protects
motors from transient voltage excesses and large voltage rising rates. The RD500
can be used without restric-
tions on a wide range of
three-phase motors with the
advantages of today’s IGBT
technology using the motor
filters especially developed
by Rexroth and adjusted to
the RD500 frequency converter series.
The maximum voltage
peaks occuring on the
motor terminal box are
restricted, for example,
to <1,000 V at a motor cable
length of 100 m and a mains
supply voltage of 400 V.
The filter must be used in
motors without interphase
insulation/separation in the
winding overhangs. Otherwise the filter is only recommended for older motors.
Three-phase motors with today’s insulation technology
are also without filters and
are suitable for operation on
a frequency converter without reducing the service life.
When using long motor cables, the frequency converters are additionally loaded
due to the conversion currents in the cable capacities.
By using a motor filter, the
converter load can be considerably reduced.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
33
Sinusoidal Filters up to 200 Hz
6 3-phase AC 400 V ± 15 %
5 3-phase AC 500 V ± 10 %
6
0 1 0
20
B
120
015 / 018 / 022
035
35
C
150
030 / 037 / 045
068
68
C
200
055 / 075
099
99
D
300
090
135
135
E
400
110 / 132
195
195
E
600
]
[A
[W
ss
A
50
005 / 007 / 011
015
15
B
80
015 / 018
024
24
C
140
022 / 030
034
34
C
180
037
045
45
C
280
045 / 055
066
66
E
360
075
080
80
E
420
090 / 110
130
130
E
640
Max . output frequency
8 kHz
100 Hz
Max . motor cable lengths
unshielded
Max . motor cable lengths
shielded
200 m
r lo
7
Pulse frequency
400 m
we
007
8 kHz
200 Hz
]
nt
re
ur
Po
020
lc
Si
007 / 011
ze
No
60
Max . motor cable lengths
unshielded
Max . motor cable lengths
shielded
Co
A
na
ss
r lo
we
10
Max . output frequency
001 / 003 / 004
Po
ze
010
Pulse frequency
Fr
eq
ou ue n
tp cy
ut
co con
d e ve
rt
[W
]
nt
re
ur
lc
na
Si
No
mi
de
Co
001 / 003 / 004 /
005
mi
]
er
Sinusoidal filter for mains
supply voltage 500 V
[A
Fr
eq
ou ue n
tp cy
ut
co con
d e ve
rt
er
Sinusoidal filter for mains
supply voltage 400 V
de
R Z S 0 1.1
Code
400 m
200 m
Dimensions
Size
mm
Height
(inch)
mm
Width
(inch)
mm
Depth
(inch)
A
180
(7.1)
75
(3.0)
290
(11.4)
B
180
(7.1)
116
(4.6)
340
(13.4)
C
260
(10.2)
275
(10.8)
300
(11.8)
D
260
(10.2)
275
(10.8)
350
(13.8)
E
480
(18.9)
275
(10.8)
315
(12.4)
Description
The use of a sinusoidal filter
is recommended to achieve
sinusoidal current and voltage values at the frequency
converter output.
The sinusoidal filter developed especially for the
RD500 offers the following
advantages:
• Limiting the rate-of-rise
time (du/dt) and the peak
• Motors can be fed through
long feeder cables (400 m)
• Operation of many parallel motors or group drives
• Reduction of supplementary losses in the motor
• Noise reduction of the
motor
• Reduction of noise voltage
on the motor feeder cable
for increased EMC requirements.
voltage value to 600 V at
a motor cable length of
100 m and a mains supply
voltage of 400 V.
• Reduction of winding insulation stressing
The technically and commercially optimized combination of frequency converter and sinusoidal filter
can be achieved with a pulse
frequency of ≥ 8 kHz. Our
sinusoidal filters are therefore only designed for operating at a pulse frequency
of 8 kHz. See the separate
table on page 10 for frequency converter “derating”.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
34
Radio Interference Suppression Filter B
Power code
4 3-phase AC 380 to 480 V ± 10%
0 0 7
]
4
30
A
015 / 018
018
42
B
022 / 030 / 037 /
045
045
100
C
055 / 075
075
130
C
090 / 110
110
180
D
od
rc
we
Po
In compliance with the radio interference degree B according to EN 55011, the use
of an RZF02 radio interference suppression filter in
conjunction with shielded
motor cables is obligatory.
ze
007
Size
A
Connectable power cable
lengths:
• fp = 12 kHz up to 35 m
• fp = 10 kHz up to 50 m
• fp = 4 kHz up to 80 m
[A
Si
003 / 005 / 007
e
R
fp ated
=4 c
k H ur re
z nt
Fr
eq
ou uen
tp cy
ut
co con
d e ve
rt
er
R Z F 0 2.1
The filters are suitable for
pulse frequencies between 4
and 12 kHz and are assigned
to the frequency converters
via the power code. The
same derating factors apply
as for the frequency converter.
B
C
The filters can be arranged
next to or above the frequency converter. Installation in a cabinet must be
done according to the valid
general recommendations
for EMC conforming installation.
See also:
Electromagnetic Compatibility (EMC) for Drive and
Control Systems
DOKU-GENERLEMV*******-PRJ1-DE-P
D
A (1.7 kg/3.8 lb)
B (2.1 kg/4.7 lb)
C (5.6 kg/12.4 lb)
D (8.9 kg/20 lb)
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
35
Standard Braking Resistors for RD51/RD52
Description
Assembly
There is an external braking
resistor for every frequency
converter in the RD500 series. The frequency converter monitors the external
braking resistor by calculating a thermal model with
the current braking power
using the firmware. If the
limit values for the thermal
model are exceeded, the frequency converter turns off
with a “braking resistor” error in order to protect the
braking resistor from overloading.
A class C frequency converter with the corresponding braking resistor is shown
in the drawing below.
Note on Resistor Cooling
The braking resistors are designed, both in their construction and their nominal
capacity, so that they should
be cooled in the frequency
converter’s exhaust air flow
to prevent their surface temperature from exceeding
100°C (212°F).
Braking resistor
Frequency converter
Minimum clearance for cooling above and below is 100 mm (4”)
The resistors may not be
operated at nominal capacity without air flow
cooling!
Technical Characteristics
of High-load Resistors
The braking unit resistors
are composed of a highly
durable metal plating. The
resistor element is in an aluminum housing embedded
in an insulating ceramic material with excellent thermal
conductivity. Complete encapsulation offers protection
from damaging ambient in-
fluences and accidental contact of live parts. High-load
resistors have the following
characteristics:
• Compact construction
and light weight
• High capacity and pulse
load
• Robust design
• High level of reliability
• High breakdown strength
• The resistor element is
non-flammable
36
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Standard Braking Resistors for RD51/RD52
Technical Data
Power code
0 0 7
N N N
Ma
W
ire
[ m c ro s
m2
ss
](
AW ecti
G ) on
ut
tp
ou
A
003
60
0.06
10
1.5 (15)
005/007
A
007
35
0.1
18
1.5 (15)
015/018
B
015
17.5
0.2
37
2.5 (13)
022
C
022
11.7
0.3
56
10
(7)
030
C
030
8.8
0.4
74
10
(7)
037
C
037
7
0.5
93
10
(7)
045
C
045
5.8
0.6
111
10
(7)
055
D
055
5
0.7
130
10
(7)
075
D
075
4.4
0.8
148
10
(7)
E
110
2.5
1.4
260
35
(2)
Si
090/110
Technical Data
must be observed since the
appropriate brake resistor
performance data for cal-
The frequency converter to
brake resistor assignment
Size
A
B
Re
003
Po
Ra
te d
tan
sis
xim
[ kW u m
] , 1 outp
se ut
c
]
[ kW
]
[W
ce
e
od
rc
we
ze
Fr
e
ou que
tp nc
ut y
co co
d e nv
e
r te
r
R Z W 0 1.1
C
D
Minimum clearance for cooling above and below is 100 mm (4”)
culating the thermal image
is saved in the frequency
converters.
E
A (1.5 kg/3 lb)
B (2.3 kg/5 lb)
C (5.6 kg/12 lb)
D (7.9 kg/17 lb)
E (15 kg/33 lb)
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
37
Reinforced Braking Resistors for RD51/RD52
Description
Description
Frequency converters with
an integrated braking chopper (types B and F) should
be fitted with “reinforced
braking resistors” for regenerative braking at higher
performance levels as they
occur in drives with larger
flywheel loads (i.e. centrifuges) and long braking procedures (i.e. crane hoisting
gear). The “reinforced braking resistors” are protected
from overloading thanks to
the monitoring function in
the RD500 firmware.
Assembly
The types A and B resistor
units are suited for vertical
and/or horizontal assembly.
The other types are to be assembled in a standing position.
Technical Characteristics
The model and dimension
drawing of the corresponding resistor type can be
found in the following list.
For Protection Type IP 20
Type A: potted, wire-wound
tubular fixed resistor units
bolted with side pieces and
perforated cover, mounted
parallel to the mounting
surface with 2 connections
wired to porcelain terminals
in the terminal box with a
PU fitting.
Type B and C: fixed resistor
in a steel-grid version. Including 2 screw terminals,
2 M6 or M8 stud terminals,
depending on the capacity,
housing as described above.
Type D: fixed resistor in a
steel-grid version in a galvanized sheet steel housing
with external ventilation via
built-in axial-flow fans
3-phase AC / 400 V / 50 Hz /
3.5 kVA, air flow monitoring
via air-vane relays on terminals.
For Protection Type IP 23
Type E: wire-wound, multiple-disk resistor unit for
wall mounting with 2 terminals and multiple drill
holes which are closed by
rubber grommets and are
used as cable guides.
Type F: fixed resistor in
steel-grid model. Including
2 screw terminals, 2 M6,
M8, M10 or M12 stud terminals, depending on the
capacity.
Type G: fixed resistor units
in a steel-grid model with
external ventilation via
built-in axial-flow fans
3-phase AC / 400 V / 50 Hz /
3.5 kVA, via air-vane relays
on terminals.
The resistors are delivered
with a galvanized sheet steel
housing.
Design
The resistor units are adjusted for the maximum
motor output that can be
connected to the frequency
converter. The braking
power given applies to the
relative ON time (ED)
named of 25%, 40%, and
60%.
The relative ON time refers
to a duration of 120 sec.
Example: at 40% ED, the resistor may only be switched
on for a maximum of 48 sec
(tONmax) without interruption
and then must be switched
off for 72 sec Shorter ON
periods are also permitted.
The OFF time required is
reduced at the same ratio.
At an ON period of 10 sec,
for example, the resulting
OFF time is
10 s
48 s x 72 sec = 15 sec.
The full-load power of the
relevant resistor type can be
calculated with the help of
the reduction factors given
in the following tables. To
do this, just divide the braking power for the corresponding ON time (ED) by
the reduction factor.
Example:
Resistor type A3;
Ppeak = 2.7 kW at 25% ED,
Reduction factor = 3.2
peak
Pduration= P3.2
= 0.844 kW
ON Cycles
ED
Ppeak
Pduration
tONmax
6%
8
15%
25%
40%
4
3.2
2.2
1.5
48 sec
72 sec
7.2 sec 18 sec 30 sec
Duration T=120 sec
60%
38
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Reinforced Braking Resistors IP20
Technical Data
Power code
1
2
3
Si
ze
R e fo r
sis ED
tan 60
ce %
[W
]
Si
ze
R e fo r
sis ED
tan 40
ce %
[W
]
Si
ze
R e fo r E
sis D
t a n 25
ce %
[W
]
0 2 5
Si
ze
R e fo r
sis ED
tan 15
ce %
[W
]
0 0 7
Fr
eq
ou ue n
tp cy
ut
c o c o nv
de er
Mi
te r
ni
c a mu m
n b re
e c sis
on tor
Ma
ne va
cte lue
xim
d [ th
at
u
gi v m o
W ] at
e n ut
ED put
[ kW
]
Si
ze
f
o
Re r
sis ED
tan 6 %
ce
[W
]
R Z W 0 2.1
ON time
003
60
2.7
A12
68
A2
68
A3
68
A4
68
A6
68
005
35
5
A2
47
A3
47
A7
47
A8
47
B2
42
007
35
6.5
A21
33
A5
33
B1
33
B1
33
B2
33
011
20
10
A3
22
A6
22
B1
23
B2
22
B3
23
015/018
17.5
13.5
A5
18
B1
19
B2
18
B2
18
B3
18
022
11.6
20
A6
15
B2
15
B3
14
B3
13
B4
13
030
8.75
27
B1
10
B2
9.5
B3
10
B4
10
B5
11
037
7
33
B1
7.4
B3
8.0
B3
7.3
B4
8.1
C3
7.2
045
6
40
B2
7.5
B3
6.6
B4
7.3
B5
6.7
C3
7
055
5
50
B2
6.1
B4
5.5
B5
5.1
C2
5.5
C4
5.4
075
3.75
67
B3
4.9
B4
5.1
C2
5.4
C3
5
C6
5.3
090
2.5
81
B3
3.1
B5
3.3
C3
3.7
C4
3.7
C7
110
2.5
100
C11
3.1
C3
2.8
C5
2.6
C6
2.7
2 x C5
132
2.2
119
C11
2.5
C3
2.7
C4
2.4
C7
2.3
2 x C6
4.4
160
2.2
144
C12
2.6
C4
2.7
C6
2.4
2 x C3
5.4
2 x C7
4.8
200
1.6
180
C2
1.8
C6
1.8
C7
1.8
2 x C4
3.7
D1 2
1.8
315
2 x 2.2
280
C4
2 x 2.6 2 x C5
2.6
2 x C6
2.4
D1
2 x 2.4
D2
2 x 2.7
400
2 x 1.6
360
C6
2 x 1.8 2 x C6
1.8
2 x C7
1.8
D1
2 x 2.1
D2
3.9
3
1
5.4
2 x 2.0
Pduration = 55 kW
Pduration = 100 kW
Pduration = 200 kW
ON Cycles
ED
Ppeak
Pduration
tONmax
6%
8
15%
25%
40%
4
3.2
2.2
1.5
48 sec
72 sec
7.2 sec 18 sec 30 sec
Duration T=120 sec
60%
Note: If two resistors are listed in one
position(2 x ...), they are to be wired in
parallel up to power code 200.
For devices with power codes 315 and
400, the two resistors with separate
line directions are connected to the
two corresponding braking choppers
in the frequency converter.
For frequency converters that have
power codes 132 to 400 and the W1
additional function, order a reinforced
braking resistor connection.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
39
Reinforced Braking Resistors IP20
Dimensions
Type A
Height
mm ( inch )
Width
mm
( inch )
Depth
mm ( inch )
1
120
(4.7)
386
(15.2)
92
(3.6)
1.8
(4.0)
2
120
(4.7)
486
(19.1)
92
(3.6)
2.3
(5.1)
Type A
B
T
H
Type B
B
T
H
3
120
(4.7)
686
(27.0)
92
(3.6)
3.4
(7.5)
4
120
(4.7)
486
(19.1)
185
(7.3)
4.3
(9.5)
5
120
(4.7)
586
(23.1)
185
(7.3)
5.2
(11)
6
120
(4.7)
686
(27.0)
185
(7.3)
6.2
(14)
7
120
(4.7)
486
(19.1)
275
(10.8)
6.5
(14)
8
120
(4.7)
586
(23.1)
275
(10.8)
7.5
(17)
9
120
(4.7)
686
(27.0)
275
(10.8)
8.8
(19)
11
77
(3.1)
282
(11.1)
66
(2.6)
0.8
(18)
12
87
(3.5)
386
(15.2)
75
(3.0)
1.2
(2.7)
21
120
(4.7)
586
(23.1)
92
(3.6)
2.8
(6.1)
Type B
Type C
T
B
H
Type D
T
H
B
Weight
kg
( lb )
Height
mm ( inch )
Width
mm ( inch )
Depth
mm ( inch )
Weight
kg
( lb )
1
270
(10.6)
490
(19.3)
330
(13.0)
9
(20)
2
270
(10.6)
490
(19.3)
430
(16.9)
12
(26)
3
270
(10.6)
490
(19.3)
630 (24.8)
21
(46)
4
270
(10.6)
490
(19.3)
830 (32.7)
32
(71)
5
270
(10.6)
490
(19.3)
1030 (40.6)
43
(95)
Type C
Height
mm ( inch )
Width
mm ( inch )
Depth
mm ( inch )
Weight
kg
( lb )
1
750 (29.5)
395
490 (19.3)
36
2
750 (29.5)
595 (23.4)
490
(19.3)
55
(121)
3
750 (29.5)
795
490 (19.3)
79
(174)
(15.6)
(31.3)
(79)
4
750 (29.5)
995
(39.2)
490 (19.3)
92
(203)
5
1000 (39.4)
595
(23.4)
490 (19.3)
74
(163)
6
1000 (39.4)
795
(31.3)
490 (19.3)
100
(220)
7
1000 (39.4)
995
(39.2)
490 (19.3)
123
(271)
11
500 (19.7)
795
(31.3)
490 (19.3)
44
(97)
12
500 (19.7)
995
(39.2)
490 (19.3)
53
(117)
Type D
Height
mm ( inch )
Width
mm ( inch )
Depth
mm ( inch )
Weight
kg
( lb )
1
1450
(57.1)
995
(39.2)
955
(37.6)
250
(551)
2
1750 (68.9)
995
(39.2)
955
(37.6)
350
(772)
40
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Reinforced Braking Resistors IP23
Technical Data
Power code
1
2
3
0 2 5
003
60
2.7
E11
68
E1
68
E2
68
E2
68
E3
68
005
35
5
E1
47
E2
47
E3
47
E3
47
F1
42
007
35
6.5
E2
33
E3
33
F1
33
F1
33
F1
33
011
20
10
E2
22
E3
22
F1
23
F1
22
F2
23
015/018
17.5
13.5
E3
18
F1
19
F1
18
F1
18
F2
18
022
11.6
20
E3
12
F1
15
F2
14
F2
13
F3
13
030
8.75
27
F1
10
F1
9.5
F2
10
F3
10
F4
11
037
7
33
F1
7.4
F2
8.0
F2
7.3
F3
8.1
F7
7.2
045
6
40
F1
7.5
F2
6.6
F3
7.3
F4
6.7
F7
7
055
5
50
F1
6.1
F3
5.5
F4
5.1
F6
5.5
F8
5.4
075
3.75
67
F2
4.9
F3
5.1
F6
5.4
F7
5
F10
5.3
090
2.5
81
F2
3.1
F4
3.3
F7
3.7
F8
3.7
F11
110
2.5
100
F3
3.1
F7
2.8
F9
2.6
F10
132
2.2
119
F3
2.5
F7
2.7
F8
2.4
160
2.2
144
F4
2.6
F8
2.7
F10
200
1.6
180
F6
1.8
F10
1.8
315
2 x 2.2
280
F8
2 x 2.6 2 x F9
400
2 x 1.6
360
F10
2 x 1.8 2 x F10
2.7
2 x F9
5.4
F11
2.3
2 x F10
4.4
2.4
2 x F7
4.8
2 x F11
4.8
F11
1.8
2 x F8
3.5
G1 2
1.8
2.6
2 x F10
2.4
G1
2 x 2.4
G2
2 x 2.7
1.8
2 x F11
1.8
G1
2 x 2.1
G2
ON Cycles
6%
8
15%
25%
40%
4
3.2
2.2
1.5
48 sec
72 sec
7.2 sec 18 sec 30 sec
Duration T=120 sec
60%
]
[W
3.9
1
Pduration = 55 kW
Pduration = 100 kW
Pduration = 200 kW
ED
Ppeak
Pduration
tONmax
ce
60
fo r
sis
ze
Re
Si
tan
ED
[W
40
ce
ED
tan
fo r
sis
ze
Re
Si
]
%
%
0 0 7
fo r
E
sis D 2
5%
tan
ce
[W
]
ze
Re
Si
Fr
e
ou que
tp
ut ncy
co co
d e nv
Mi
er
nu
te r
m
ca
u
nb mr
e c e si
on sto
Ma
ne r v
xim
cte alu
at
u
d [ e th
gi v m o
W ] at
en ut
ED put
[ kW
]
Si
ze
fo r
Re
E
sis D 6
%
tan
ce
[W
]
Si
ze
fo
Re r E
D
sis
tan 15%
ce
[W
]
R Z W 0 3.1
ON time
3
2 x 2.0
Note: If two resistors are listed in one
position(2 x ...), they are to be wired in
parallel up to power code 200.
For devices with power codes 315 and
400, the two resistors with separate
line directions are connected to the
two corresponding braking choppers
in the frequency converter.
For frequency converters that have
power codes 132 to 400 and the W1
additional function, order a reinforced
braking resistor connection.
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
41
Reinforced Braking Resistors IP23
Dimensions
Type E
T
Type E
B
Height
mm ( inch )
Width
mm ( inch )
Depth
mm ( inch )
Weight
kg
( lb )
1
270
(10.6)
190
(7.5)
180
(7.1)
5
(11)
2
335
(13.2)
230
(9.1)
182
(7.2)
7
(15)
3
480
(18.9)
290
(11.4)
200
(7.9)
15
(33)
11
270
(10.6)
190
(7.5)
130
(5.2)
3
(7)
H
Type F
T
B
H
Type F
Height
mm ( inch )
Width
mm ( inch )
Depth
mm ( inch )
Weight
kg
( lb )
1
560
(22.0)
395
(15.6)
490
(19.3)
25
(55)
2
560
(22.0)
595
(23.4)
490
(19.3)
35
(77)
3
560
(22.0)
795
(31.3)
490
(19.3)
50
(110)
4
560
(22.0)
995
(39.2)
490
(19.3)
60
(132)
5
810
(31.9)
395
(15.6)
490
(19.3)
40
(88)
6
810
(31.9)
595
(23.4)
490
(19.3)
60
(132)
7
810
(31.9)
795
(31.3)
490
(19.3)
85
(187)
8
810
(31.9)
995
(39.2)
490
(19.3)
100
(220)
9
1140
(44.9)
595
(23.4)
490
(19.3)
80
(176)
10
1140
(44.9)
795
(31.3)
490
(19.3)
110
(243)
11
1140
(44.9)
995
(39.2)
490
(19.3)
135
(298)
Type G
T
H
B
Type G
Height
mm ( inch )
Width
mm ( inch )
Depth
mm ( inch )
Weight
kg
( lb )
1
1450
(57.1)
995
(39.2)
955
(37.6)
260
(573)
2
1750 (68.9)
995
(39.2)
955
(37.6)
360
(794)
42
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Chemical Module
Drive Technology According to NAMUR Recommendations
N Without NAMUR terminal strip
T With NAMUR terminal strip
Power code
005
1.1 to 4 kW motor output
007
5.5
011
7.5
018
15
022
18.5
037
30
F 24 V external stand-by power supply
045*
37
with feedback of filter current
23 IP23
54 Prepared for IP54 cabinet installation
5 3-phase AC 500V ± 10%
6 3-phase AC 400V ± 15%
R Z C 0 1.1
5 N
With the chemical module,
the RD500 series of frequency converters fulfills
the specific requirements of
chemical and process engineering according to
NAMUR recommendations.
0 0 5
F
2 3
The space-optimized installation of a frequency converter and a chemical module in the same housing offers the following special advantages for process engineering:
* Only with 3-phase AC 400 V
• The devices can be easily
arranged in a row or submounted.
• Frequency converters and
chemical modules can be
ordered separately and be
easily retrofitted.
For reasons of space and
weight, the chemical modules for power supplies from
37 kW at 500 V and 45 kW
at 400 V are delivered as a
kit.
The following functions are
included in the chemical
module:
• Mains contactor
• PTC thermistor triggering
device (PTB-approved)
• Conversion relay for safe
mains isolation
• Sinusoidal filters are installed for up to 37 kW at
500 V and 45 kW at 400 V,
for higher outputs, motor
filters are used
• Input isolation amplifier
for external isolated setpoint entry
• Cabinet terminal strip
(in accordance with the
NAMUR recommendations)
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Converter side
43
Field side
As according to the
NAMUR recommendations,
the terminal strip in the
chemical module is divided
into three parts:
• X1 for the power supplies
• X2 for signal lines, which
must meet the requirements of “Functional extra-low voltage with safe
separation (PELV)”
• X3 for connecting the
motor’s PTC thermistor
connector.
optional
optional
The RD500 frequency converters correspond, in conjunction with the chemical
module, to the “Functional
extra-low voltage with safe
separation (PELV)” requirements according to
DIN/VDE 0100 part 410 and
DIN/VDE 0160 part 101.
They are manufactured as a
complete package as an installed or cabinet model.
All devices are preassembled
and completely wired and
are delivered with readymade cable and assembly
kits. This reduces the time
and expense for wiring as
well as the possibility of errors, and therefore ensures a
short assembly and system
start-up time.
• The “ON” input
(terminal 10) can be controlled statically or dyna-
NAMUR standard terminal strip
mically; setting the active
type of operation takes
place by parameterization
on the frequency converter.
• Binary inputs and outputs
are designed isolated. The
outputs can be loaded
with up to DC 24 V
500 mA.
• Analog inputs and outputs
are electrically isolated.
• The converter relay fulfills
the specifications under
“Functional extra-low
voltage with safe separation (PELV)”.
• The PLC thermistor triggering device displays the
PTB inspection symbol
(PTB/3.53-PTC) and is approved for flameproof motors.
44
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
Heat Exchangers for External Assembly
01 For assembly on top of cabinet
02 For assembly on the wall
BW With braking resistor
NN Not occupied
Power code
1 3 2
B W
He
c a at e
p a xc
cit ha
y [ ng
kW e
Si
]
ze
M
ax
[kWimu
m
] 0 ou
.1 tp
se ut
c
t[
pu
ut
do
Ra
te
sis
Re
we
Po
P]
[H
[ kW
]
rc
tan
od
ce
e
[W
]
kW
]
R Z K 0 1.1
Fan units for assembly on the top of the c abinet
132
165
132
2.2
2
270
4
A
160
200
160
2.2
2
270
4
A
200
250
200
1.6
2.5
370
5
B
315
400
315
2 x 2.2
2x2
2 x 270
2x4
2xA
400
500
400
2 x 1.6
2 x 2.5
2 x 370
2x5
2xB
Fan units for assembly on the wall
132
165
132
2.2
2
270
4
C
160
200
160
2.2
2
270
4
C
200
250
200
1.6
2.5
370
5
D
315
400
315
2 x 2.2
2x2
2 x 270
2x4
2xC
400
500
400
2 x 1.6
2 x 2.5
2 x 370
2x5
2xD
Heat exchanger assembled on top of cabinet
Sizes A and B
A (16 kg/35 lb)
B (23 kg/51 lb)
The RD500 series cooling
system is designed for an
ambient temperature of
40°C (104°F).
The nominal values in liquid-cooled systems refer to a
coolant-entry temperature
of 55°C (131°F). The coolant
warms up between 3°C (5°F)
and 5°C (9°F), depending on
the performance. As many
frequency converters can be
connected to the heat exchanger until the sum of all
individual frequency converter losses reaches the
cooling capacity of the heat
exchanger.
The power code is to be used
to assign the heat exchanger
to the frequency converter/
inverter.
The maximum distance for
assembly is 5 m.
Heat exchanger assembled on wall
Sizes C and D
C (16 kg/35 lb)
D (23 kg/51 lb)
Device selection | RD51/RD52 | RD41/RD42 | RS51 | Accessories
45
Accessories for Water-Cooled Devices
Code
0 0 2 0 4 4 7
n
ti o
Co
de
na
sig
De
Fr
e
i nv q u e
er nc
te r y c
siz on
e ve r
te r
/
R Z D 0 3.1
C–E
Worm drive hose clip
10-16 mm (3/8-5/8")
0023460
PVC hose with fabric insert
Di=10 mm (3/8")
0023457
Plug with hose nozzle
Di=9.6 mm (3/8")
0023504
Quick-release lock connection
0023503
Di=9.6 mm (3/8")
G+H
Plug with hose nozzle
Di=19 mm (3/4")
0015559
Coupling with hose nozzle
Di=19 mm (3/4")
0015558
Coupling with bulkhead gland
0016765
Di=19 mm (3/4")
Cooler hose
0017446
Hose coupling GS 19 mm
(3/4")
0017510
Elbow hose coupling WS
19 mm (3/4")
0020453
Worm drive hose clip
16-27 mm (5/8-1")
0013475
Sizes C – E
Sizes G + H
An external circulation
pump is necessary to circulate the coolant.
The drive converter/ inverter sizes C to E with cooling type W (liquid cooling)
can be connected to the customer’s cooling water circuit
with a PVC hose or, alternatively, with a soft polyamide tube (PA tube). Appropriate plug-in connections
are present on the frequency
converters/inverters.
Hose nozzles should be installed on the converter/
inverter side for connecting
the PVC hose. The hose
should be fixed to the nozzle
using the worm drive hose
clip. The PA tube can be inserted directly into the
plug-in connections on the
frequency converter/inverter
cooler. The minimum bend
is 100 mm (3.9 inches).
A circulation pump is necessary in the frequency
converter/inverter to circulate the coolant. The cooler
hose mentioned can be used
for connecting a frequency
converter/inverter of class G
or H with cooling type R to
the external heat exchanger.
The quick-release lock connections given, product no.
0015559 or 0015558, should
be used for connecting the
inverter or heat exchanger
side. The cooler hose should
also be attached to the heat
exchanger with a worm
drive hose clip. The couplers/plugs are self-locking
which means that the coolant is prevented from running out when the connection is broken.
Appropriate connection
pieces must be used for extensions and 90° curves. The
hose should be attached to
the connection pieces using
a worm drive hose clip.
46
47
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr
Germany
Phone +49 93 52/40-0
Fax
+49 93 52/40-48 85
www.boschrexroth.com
Presented by:
The data shown are for general information only.
Please contact your local sales office for up-to-date information.
A01 - SM - Copyright reserved!
Subject to revisions!
Printed in Germany
71 020 EN/03-01