Bosch Rexroth RE29090-B-01 User manual

The Drive & Control Company

IAC R valve

Operating manual

(with CANopen)

Operating manual

RE 29090-B-01/06.05

II Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

IAC-R valve

Operating manual

(with CANopen)

Operating manual

RE 29090-B-01/06.05

This manual provides information on

Dthe commissioning and operation of the IAC-R valve.

Description Release

Date

Notes

RE 29090-B-01 06.2005 Firmware: SV02xx

EBosch Rexroth AG, 1998 − 2005

Copying this document, giving it to others and the use or

communication of the contents thereof without express authority, are

forbidden. Offenders are liable for the payment of damages. All rights

are reserved in the event of the grant of a patent or the registration

of a utility model or design (DIN 34-1).

The data specified above only serve to describe the product. No

statements concerning a certain condition or suitability for a certain

application can be derived from our information. The given

information does not release the user from the obligation of own

judgement and verification. It must be remembered that our products

are subject to a natural process of wear and aging.

Bosch Rexroth AG

Industrial Hydraulics

Zum Eisengießer 1

97816 Lohr, Germany

Tel.: +49 (0) 9352/18−0

Fax: +49 (0) 9352/18−1638

support.nc−[email protected]

www.boschrexroth.com/iac

Title

Type of Documentation

Document Order No.

Purpose of Documentation

Record of Revisions

Copyright

Validity

Published by

Contents

Industrial Hydraulics IIIBosch Rexroth AGIAC-R valveRE 29090-B-01/06.05

Contents

Page

1 Safety Instructions 1−1 . . . . . . . . . . . . . . . . . . . . . . .

1.1 Proper use 1−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Qualified personnel 1−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Safety markings on products 1−4 . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Safety instructions in this manual 1−4 . . . . . . . . . . . . . . . . . . . . . .

1.5 General safety instructions 1−5 . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Documentation, software release and trademarks 1−7 . . . . . . .

2 Installation 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Conditions of use 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Installation, mounting orientation and clearances 2−1 . . . . . . . .

2.3 Maintenance instructions 2−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Installation of CANopen bus system 2−2 . . . . . . . . . . . . . . . . . . .

2.4.1 Introduction 2−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2 Set-up of the CANopen bus transmission cables 2−4 . . . . . . .

3 Overview 3−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 IAC-R valve 3−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Application 3−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 IAC-R valve variants 3−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Housing variants 3−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Hydraulic valve body variants 3−4 . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Interface combinations for system variants 3−4 . . . . . . . . . . . .

3.4 Applicable standards and guidelines 3−5 . . . . . . . . . . . . . . . . . . .

4 Electrical connection and interfaces 4−1 . . . . . . .

4.1 Overview 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Protective ground conductor (PE) and shielding 4−1 . . . . . . . . .

4.3 24 VDC supply 4−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Safety functions 4−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Interface overview 4−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Device interface X1 4−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Power supply 4−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.2 Analog inputs and PLC switching signals (inputs) 4−8 . . . . . .

4.6.3 Analog outputs and PLC switching signals (outputs) 4−11 . . . .

4.6.4 Enable input 4−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.5 Fault output / Power switching output 4−15 . . . . . . . . . . . . . . . . .

4.7 LVDT interface X2 4−16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 Field bus / programming interface X3 4−17 . . . . . . . . . . . . . . . . . .

4.9 Sensor interfaces X4 and X7 4−18 . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.1 Analog sensor interface X4 4−19 . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.2 Analog sensor interface X7 4−21 . . . . . . . . . . . . . . . . . . . . . . . . .

4.9.3 Position feedback interface X7 4−23 . . . . . . . . . . . . . . . . . . . . . .

Contents

IV Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

4.10 Mating connectors for IAC-R valve interfaces 4−25 . . . . . . . . . . .

4.10.1 Mating connector for X1 4−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.2 Mating connector for X2 4−26 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.3 Mating connector for X3 4−26 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.4 Mating connector for X4 4−27 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.5 Mating connector for X7 4−27 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10.6 T-adapter for analog sensor interfaces X4 and X7 4−28 . . . . . .

5 First Commissioning 5−1 . . . . . . . . . . . . . . . . . . . . .

5.1 Introduction 5−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 System principles of the IAC-R valve 5−2 . . . . . . . . . . . . . . . . . . .

5.2.1 Configuration tool and auxiliary aids 5−3 . . . . . . . . . . . . . . . . . .

5.2.2 Hardware requirements for commissioning 5−3 . . . . . . . . . . . .

5.2.3 Parameter definition 5−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.4 Bus, node, baud rate 5−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.5 Analog/digital mode with device state, device function,

device control and device status 5−15 . . . . . . . . . . . . . . . . . . . . .

5.3 Short overview: First Commissioning 5−33 . . . . . . . . . . . . . . . . . . .

5.4 Selecting digital mode 5−37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Selecting analog mode 5−37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Connect IAC-R valve with system (Step 1) 5−38 . . . . . . . . . . . . . .

5.7 Powering up the IAC-R valve (Step 2) 5−38 . . . . . . . . . . . . . . . . . .

5.8 Establishing communication with the valve (Step 3) 5−39 . . . . . .

5.9 Selection of the control function (Step 4) 5−41 . . . . . . . . . . . . . . .

5.10 Mode configuration (Step 5) 5−42 . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11 Interface configuration to master controller (Step 6) 5−44 . . . . . .

5.11.1 Digital control via PDOs (CANopen) 5−44 . . . . . . . . . . . . . . . . . .

5.11.2 Analog control via I/O signals of the IAC-R valve 5−57 . . . . . . .

5.12 Q control demand value programming (Step 7) 5−60 . . . . . . . . . .

5.13 Configuration for local control (Step 8) 5−63 . . . . . . . . . . . . . . . . .

5.14 Saving and loading parameters (Step 9) 5−64 . . . . . . . . . . . . . . . .

5.15 Starting the IAC-R valve in analog mode (Step 10) 5−67 . . . . . . .

5.15.1 Starting the system (Step 11) 5−68 . . . . . . . . . . . . . . . . . . . . . . .

5.15.2 Set enable (Step 12) 5−68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.15.3 Modifying and testing parameters (Step 13) 5−68 . . . . . . . . . . .

5.16 Start the IAC-R valve in digital mode (Step 10) 5−69 . . . . . . . . . .

5.16.1 Starting the system (Step 11) 5−71 . . . . . . . . . . . . . . . . . . . . . . . .

5.16.2 Set enable (Step 12) 5−72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16.3 Modify parameters and test them (Step 13) 5−73 . . . . . . . . . . .

6 Controller function and optimization 6−1 . . . . . .

6.1 Introduction 6−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Introduction of the controller structure 6−2 . . . . . . . . . . . . . . . . . .

6.2.1 Set-up of the controller structure 6−2 . . . . . . . . . . . . . . . . . . . . .

6.2.2 Criteria for an optimum closed loop control 6−7 . . . . . . . . . . . .

6.3 Short overview: Commissioning the controller function 6−11 . . .

6.4 Connect sensors to system (Step 1) 6−16 . . . . . . . . . . . . . . . . . . .

6.5 Power up of the IAC-R valve (Step 2) 6−16 . . . . . . . . . . . . . . . . . .

6.6 Establishing communication with the valve (Step 3) 6−16 . . . . . .

6.7 Selection of the control function (Step 4) 6−17 . . . . . . . . . . . . . . .

6.8 Mode selection/configuration (Step 5) 6−18 . . . . . . . . . . . . . . . . . .

6.9 Configuration of the interface to controller (Step 6) 6−18 . . . . . . .

Contents

Industrial Hydraulics VBosch Rexroth AGIAC-R valveRE 29090-B-01/06.05

6.10 p/Q control configuration (Step 7a) 6−19 . . . . . . . . . . . . . . . . . . . .

6.10.1 Demand value generator 6−21 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10.2 Sensor calibration (analog pressure sensor) 6−31 . . . . . . . . . . .

6.10.3 p/Q controller 6−40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10.4 Controller output adaptation 6−47 . . . . . . . . . . . . . . . . . . . . . . . . .

6.10.5 Optimization 6−55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 Position control configuration (Step 7b) 6−63 . . . . . . . . . . . . . . . . .

6.11.1 Demand value generator 6−65 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11.2 Sensor variations for position control 6−75 . . . . . . . . . . . . . . . . .

6.11.3 Sensor calibration (analog position sensor) 6−75 . . . . . . . . . . . .

6.11.4 Sensor calibration

(digital absolute position feedback system SSI) 6−85 . . . . . . . .

6.11.5 Sensor calibration

(digital incremental position feedback system 1Vpp) 6−90 . . . .

6.11.6 Test mode (referencing, Jog mode) 6−94 . . . . . . . . . . . . . . . . . .

6.11.7 Position controller 6−106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11.8 Controller output adaptation 6−109 . . . . . . . . . . . . . . . . . . . . . . . . .

6.11.9 Optimization 6−113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12 Alternating control configuration (Step 7c) 6−136 . . . . . . . . . . . . . .

6.12.1 Demand value generator 6−137 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12.2 Sensor calibration 6−137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12.3 Alternating controller 6−137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12.4 Calibration output adaptation functions 6−137 . . . . . . . . . . . . . . .

6.12.5 Optimization 6−137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13 Concluding commissioning measures (Step 8−13) 6−137 . . . . . . .

6.14 Controller structure functions 6−138 . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.1 Setpoint input 6−139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.2 Setpoint calibration 6−142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.3 Setpoint limiting 6−143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.4 Ramp/Interpolator 6−144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.5 Actual value conditioning 6−146 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.6 p/Q controller function 6−151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.7 Position controller function 6−152 . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.8 Alternating control function 6−153 . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.9 Filter 6−154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.10 Characteristic compensation 6−160 . . . . . . . . . . . . . . . . . . . . . . . .

6.14.11 Dead band compensation 6−162 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.12 Zero offset 6−165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.13 Controller output limitation 6−165 . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.14 Inversion 6−166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.15 Friction compensation 6−167 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.16 Directional gain 6−170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Special functions 7−1 . . . . . . . . . . . . . . . . . . . . . . . .

7.1 Device response/device states: 7−1 . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Configuration of the enable response 7−1 . . . . . . . . . . . . . . . . .

7.2 Extended functionality of the I/O interfaces 7−2 . . . . . . . . . . . . .

7.2.1 Analog control of the inputs pins 4 and 7 of X1 7−3 . . . . . . . . .

7.2.2 Analog control of the outputs, pin 6 and pin 8 of X1 7−7 . . . . .

Contents

VI Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

7.3 Special cases of application 7−15 . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1 Live counter 7−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.2 Power switching signal function 7−15 . . . . . . . . . . . . . . . . . . . . . .

7.3.3 Monitoring of target window (InPos message) 7−17 . . . . . . . . .

7.3.4 Range monitoring (software cam) 7−21 . . . . . . . . . . . . . . . . . . . .

7.3.5 Control error monitoring (following error) 7−22 . . . . . . . . . . . . . .

7.4 Firmware update 7−26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 Customer-specific information 7−26 . . . . . . . . . . . . . . . . . . . . . . . . .

8 Creating and processing NC programs 8−1 . . . .

8.1 Introduction 8−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.1 Program syntax 8−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1.2 Program structure 8−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Commands supported by the IAC-R valve 8−8 . . . . . . . . . . . . . .

8.2.1 G00 Rapid Traverse 8−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.2 G01 Linear interpolation 8−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.3 G04 Dwell time 8−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.4 G22-G24 Subroutine calls and program jumps 8−11 . . . . . . . .

8.2.5 G53, G54-G59 Zero offsets (shifts) 8−14 . . . . . . . . . . . . . . . . . .

8.2.6 G61, G62 In-position logic On/Off (accurate halt) 8−18 . . . . . .

8.2.7 G64, G65 Inhibit/enable following error monitoring 8−19 . . . . .

8.2.8 G70, G71 Setpoint input in inches or mm 8−20 . . . . . . . . . . . . .

8.2.9 G90, G91 Absolute or relative dimensioning 8−21 . . . . . . . . . . .

8.2.10 M00, M01 Unconditional/Conditional Program Halt 8−22 . . . .

8.2.11 M02, M30 End-of-program tag for main program

and subroutine 8−24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.12 M90, M91 Setting/Resetting PLC outputs 8−26 . . . . . . . . . . . . .

8.3 Callback functions (mapped M functions) 8−27 . . . . . . . . . . . . . . .

8.3.1 M functions with compulsory acknowledgement 8−27 . . . . . . . .

8.4 Spindle speed 8−30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 Axis names 8−31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6 Programmable variables (R parameters) 8−32 . . . . . . . . . . . . . . .

8.7 Operation with NC program selection 8−36 . . . . . . . . . . . . . . . . . .

8.7.1 Automatic mode 8−36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7.2 Single step/Automatic mode 8−37 . . . . . . . . . . . . . . . . . . . . . . . . .

8.8 Debugging NC files 8−38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8.1 Checking an NC file when loading 8−38 . . . . . . . . . . . . . . . . . . .

8.8.2 Syntax verification 8−40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8.3 Logic analysis 8−41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8.4 Interpreter errors (runtime errors) 8−42 . . . . . . . . . . . . . . . . . . . .

9 Error messages and how to deal with them 9−1

9.1 Introduction 9−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Determining the error state 9−1 . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2.1 Read out error state via bus system 9−1 . . . . . . . . . . . . . . . . . .

9.2.2 Read out error state via analog fault signal 9−2 . . . . . . . . . . . .

9.3 Error codes 9−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3.1 Error code table 9−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3.2 Read error code 9−13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 Reaction to errors 9−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4.1 Types of errors and priority 9−15 . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

Industrial Hydraulics VIIBosch Rexroth AGIAC-R valveRE 29090-B-01/06.05

9.5 Error reaction configuration 9−16 . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5.1 Changing types of errors 9−16 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6 Masking the monitoring of the output stages 9−16 . . . . . . . . . . . .

9.7 Fault reaction in the NOT READY and INIT states 9−17 . . . . . . .

9.8 Acknowledge error 9−17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Annex A−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 Index A−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Abbreviations A−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.3 Glossary A−8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.4 Parameter tables A−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parameter table: sorted by numbers A−11 . . . . . . . . . . . . . . . . . .

Parameter table: sorted by names A−34 . . . . . . . . . . . . . . . . . . .

A.5 Parameters with PDO mapping A−57 . . . . . . . . . . . . . . . . . . . . . . .

A.6 Change log A−58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents

VIII Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

Notes:

Safety Instructions

Industrial Hydraulics 1−1Bosch Rexroth AGIAC-R valveRE 29090-B-01/06.05

1 Safety Instructions

.This user manual exclusively refers to the electrical connection

and the commissioning of the IAC-R valve electronics.

There are catalogs available on the hydraulic aspects of the IAC-R

valve (see page 1−7).

.Furthermore, please note the ”General Operating Instructions for

Hydraulic Systems” (see page 1−7) relevant for hydraulic

products. It includes applicable regulations and instructions con-

cerning hydraulic systems and components.

LCarefully read this manual before installing and commissioning valves

of the model IAC-R.

LStore this manual in a place to which all users have access at all times.

1.1 Proper use

This manual contains information required for the intended use of this

product. For reasons of clarity, however, it cannot contain each and ev-

ery detail about each and all combinations of functions. Likewise, as the

control unit is usually part of a larger installation or system, it is impossi-

ble to consider each and any aspect of integration or operation.

The IAC-R valve serves to control

Dposition, pressure/velocity and synchronization* of hydraulic axes

(* currently not yet available)

Dby analog setpoints (+/−10 V oder 4..20 mA) or by setpoint via field

bus (CANopen).

For applications as a control valve via analog setpoint commands, a

higher-level control logic with corresponding I/O components is re-

quired to control the motion process on the machine and through inter-

connection with the IAC-R valve provide safety interlocking and to act

as a safety monitor.

Any other application methodology is deemed improper use!

Safety Instructions

1−2Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

The product described herein:

Dhas been developed, manufactured, tested and documented in

compliance with the safety standards. These products pose no dan-

ger to persons or property if they are used in accordance with the

handling stipulations and safety notes prescribed for their configura-

tion, mounting, and proper operation.

Dcomplies with the requirements of the:

DEMC Directives (89/336/EEC, 93/68/EEC and 93/44/EEC)

Dharmonized standards EN 50081-2 and EN 50082-2

Dis designed for operation in industrial environments (emission

class A). I.e.

Dno direct connection to a non-isolated low voltage power supply

Dconnection to the medium or high voltage system via a trans-

former is required.

In residential areas, in trade and commerce as well as small busi-

nesses, Class A equipment may only be used if it does not unallow-

ably interfere with other equipment.

The fault-free, safe functioning of the product requires proper transport,

storage, mounting and installation as well as careful operation.

Safety Instructions

Industrial Hydraulics 1−3Bosch Rexroth AGIAC-R valveRE 29090-B-01/06.05

1.2 Qualified personnel

The requirements as to qualified personnel depend on the qualification

profiles described by ZVEI (Zentralverband Elektrotechnik und Elektro-

nikindustrie − German Electrical and Electronic Manufacturers’ Associ-

ation) and the VDMA (Verband deutscher Maschinen- und Anlagenbau

− German Engineering Federation) in:

Weiterbildung in der Automatisierungstechnik

edited by: ZVEI and VDMA

Mechanical engineering publishing house

Postfach 71 08 64

60498 Frankfurt

This manual was written for specialists in the fields of hydraulics,

drives and controls . They require special knowledge of commission-

ing and optimization.

Installation, connection, configuration, programming and operation

may be conducted only by appropriately trained, skilled personnel!

The personnel must be able to judge potential hazards arising from the

above-mentioned tasks and also those arising, in general from the me-

chanical, electrical or electronic equipment.

Usage of the hardware and/or software of our products, outside that are

described in this manual, may only be performed by BoschRexroth spe-

cialized personnel.

Tampering with the hardware or software, ignoring warning signs at-

tached to the components, or non-compliance with the warning notes

given in this manual may result in serious bodily injury or material dam-

age.

Only specialized personnel who are familiar with the relevant documen-

tation are permitted to install and service the products described.

Such personnel are

Dthose who, being well trained and experienced in their field and famil-

iar with the relevant norms, are able to analyze the jobs being carried

out and recognize any hazards which may arise.

Dthose who have acquired an equal amount of expert knowledge

through years of experience that would normally be acquired

through formal technical training.

Safety Instructions

1−4Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

1.3 Safety markings on products

Electrostatically sensitive components!

PE conductor

Ground in general

1.4 Safety instructions in this manual

DANGEROUS ELECTRICAL VOLTAGE

This symbol warns of a dangerous electrical voltage . The failure to

observe the instructions in this manual in whole or in part may result

in personal injury .

DANGER

This symbol is used wherever insufficient compliance or non-com-

pliance with instructions may result in personal injury .

CAUTION

This symbol is used wherever insufficient or non-compliance with in-

structions may result in damage to equipment or data files.

.This symbol is used to draw the user’s attention to special circum-

stances.

LThis symbol is used if user activities are required.

Safety Instructions

Industrial Hydraulics 1−5Bosch Rexroth AGIAC-R valveRE 29090-B-01/06.05

1.5 General safety instructions

DANGER

Danger to life through inadequate EMERGENCY-STOP devices!

EMERGENCY-STOP devices must be effective and attainable in

all modes of the system. Releasing an EMERGENCY-STOP device

must not result in an uncontrolled restart of the system!

First verify the EMERGENCY-STOP sequence, then switch on!

DANGER

Incorrect or unintentional reaction of the control valve!

We accept no liability for damage resulting from the execution of

an NC program, an individual NC line or the manual movement of

axes!

Furthermore, we accept no liability for consequential damages

which could have been avoided by programming the PLC appro-

priately!

DANGEROUS ELECTRICAL VOLTAGE

Unless described otherwise, maintenance work must always be

performed on inactive systems that are not under any hydraulic

pressure! The system must be protected against unauthorized or

accidental restarting.

Should electrical measuring or test activities need to be

conducted on the live system, then they must be executed by

qualified electrical personnel!

DANGER

Hydraulic axes can still be under pressure after switching off the

system!

This can result in unintentional axis movements.

Please ensure that hydraulic axes are depressurized before car-

rying out any critical tasks.

DANGER

Tool and axis movement!

Electrically and hydraulically powered axes generate very power-

ful mechanical forces and can accelerate very quickly due to their

high dynamics.

DAlways stay outside the danger area of the machine when it is

running!

DDo not ever deactivate safety-relevant functions!

DReport any malfunction of the unit to your service or repair de-

partment immediately!

Safety Instructions

1−6Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

CAUTION

Only spare parts approved by BoschRexroth may be used!

CAUTION

Observe all precautions for ESD protection when handling mod-

ules and components! Avoid electrostatic discharge!

The following protective measures must be observed for modules and

components sensitive to electrostatic discharge (ESD)!

DPersonnel responsible for storage, transport, and handling must

have training in ESD protection.

DESD-sensitive components must be stored and transported in the

prescribed protective packaging.

DESD-sensitive components may only be handled at special ESD-

workplaces.

DPersonnel, working surfaces, as well as all equipment and tools

which may come into contact with ESD-sensitive components must

have the same potential (e.g. by grounding).

DWear an approved grounding bracelet. The grounding bracelet must

be connected with the working surface through a cable with an inte-

grated 1 MΩ resistor.

DESD-sensitive components may by no means come into contact with

chargeable objects, this includes most plastic materials.

DWhen ESD-sensitive components are installed in or removed from

equipment, the equipment must be de-energized and potential-free.

Safety Instructions

Industrial Hydraulics 1−7Bosch Rexroth AGIAC-R valveRE 29090-B-01/06.05

1.6 Documentation, software release and trademarks

Documentation

Overview Order no.

IAC-R valve operation manual (CANopen) RE 29090-B-01

IAC-R valve data sheet (4WRPNH) RE 29191

IAC-R valve explanation on environmental

compatibility (4WRPNH)

Information on the environmental simulation

test for the EMC sector (electromagnetic com-

patibility, climatic and mechanical rating)

RE 29191-U

General operating instructions for hydraulic

systems (AB 01-01.02) 2003-02-24

RE 07008

Version

.This manual is valid for IAC-R valves with firmware version

SV02xx.

For information concerning a firmware update, see Chap. 7.4.

.Customer-specific information (e.g. commissioning date, etc.) can

be stored by the user himself in the IAC-R valve (see Chap. 7.5).

Trademark

All trademarks of software installed on our products upon delivery are

the property of the respective manufacturers.

Upon delivery, all installed software is copyright-protected. The soft-

ware may only be reproduced with our written consent or in accordance

with the license agreement of the respective manufacturer.

Windowstis a registered trademark of the Microsoft Corporation.

Safety Instructions

1−8Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

Notes:

Installation

Industrial Hydraulics 2−1Bosch Rexroth AGIAC-R valveRE 29090-B-01/06.05

2 Installation

2.1 Conditions of use

DANGER

The device may not be used in potentially explosive atmo-

spheres!

For more information on the conditions of use, please refer to Data Sheet

RE 29191 and Data Sheet environment RE 29191-U.

2.2 Installation, mounting orientation and clearances

For installation, please observe the references to applicable standards

and conditions of use in sections 3.4 and 2.1.

CAUTION

Hazard to the product!

The surrounding air must be free of electrically conductive con-

taminant (acids, alkalis, corrosive materials, salts, metal vapors,

etc.).

.Please note the following:

DDo not use any sealing, adhesive or insulation materials con-

taining silicon.

DPlease pay attention to service-friendly installation, i.e. easy ac-

cess to the cable connections.

DWrite down the information on the nameplates before installa-

tion. In this manner you still will be able to quickly access this

data even if nameplates should not be visible or readable after

installation.

DTry to maintain as much clearance as possible to sources of

electrical interference.

DAll electrical connecting lines should always be routed with a

strain relief.

DFree access to the cable connections must be maintained.

For more information on installation, mounting orientation and clear-

ances, please refer to Data Sheet RE 29191.

Installation

2−2Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

2.3 Maintenance instructions

LIn the interest of a long service life and functionality, please enter the fol-

lowing tasks in your maintenance schedule for the IAC-R valve:

DAll plugs and terminal connections of the IAC-R valve components

should be checked at least once a year for proper fit and damages.

Lines should be examined for breakage or deformation.

DImmediately exchange any defective or damaged parts.

.The IAC-R valve must always be exchanged as a complete unit.

2.4 Installation of CANopen bus system

2.4.1 Introduction

The IAC-R valve is equipped with a CANopen bus port for central control

via other bus stations (host computer, PC, PLC, etc.).

When setting up the CANopen bus system (according to specifications

ISO11898 and CiA-102-V2) some special features must be observed

concerning the configuration, the transmission rate selected, the length

of the cables, the presence of stub lines and shield and ground wiring:

DBus structure:

The bus is to be set up in a line configuration. Star or tree structures

are generally not suited. In practice, long stub lines are often required

to connect stations to the bus. These must be kept short in order to

avoid reflections, particularly for higher transmission rates

(> 250 kBit/s).

DTransmission rate and cable length:

High transmission rates (up to 1 Mbit/s) or long cable lengths (up to

5,000m) are possible. Applications with high transmission rates are

therefore restricted to short cable lines, whereas low transmission

rates allow greater bus cable lengths. The cable length for slow ap-

plications is mainly restricted by the d.c. resistance of the cable. For

faster applications, the power-frequency characteristics of the cable

influence the quality of the signals and thus require the use of shorter

lines.

DStub lines:

Stub lines mainly act as a capacitive load on the bus and prevent cor-

rect bus termination. This causes signal reflections that no longer per-

mit operation − particularly in the case of higher transmission rates.

Stub lines are therefore to be kept as short as possible. (Length of

stub lines is max. 0.3 m according to ISO11898). Ideally, a direct con-

nection of the bus T-pieces to the stations without the use of an addi-

tional stub line is recommended.

Installation

Industrial Hydraulics 2−3Bosch Rexroth AGIAC-R valveRE 29090-B-01/06.05

DGround wiring

The correct functioning of bus driver requires closed electrical circuits

for signal currents. This can be achieved through a common signal

ground between the ground conductors of the individual bus stations.

Either use an extra ground core for this purpose, or all bus stations

must be connected to each other by a common equipotential bonding

system. All types of connections result in ground loops , in which

equalizing currents can occur, particularly in widespread networks

with a high common-mode interference potential. In order to interrupt

the paths for the equalizing currents, the IAC-R valve offers electrical

isolation between the electronics and the bus driver, including its sup-

ply power.

For systems with high installed electrical capacities and large, area

connections, proper equipotential bonding is compulsory in order to

prevent equalizing currents from superimposing electrical noise on

signal lines and thus interfering with communication.

The installation of an equipotential bonding line is of great signifi-

cance for data transmission in general. When possible, it should be

installed parallel to the data line at minimal distance between. The

data line shield may never serve as an equalizing line. The equipoten-

tial bonding conductor must be finely stranded in order to remain ef-

fective even with high-frequency interference currents.

The connection for CAN Gnd is to be linked to the reference ground

system, especially when stations are operated at the bus that have no

electrical isolation (also see Cia-DR303-1).

DShielding:

The cable shield is to be connected principally at both ends and to be

linked to the protective ground conductor. If there is a danger of equal-

izing currents, then an equipotential grounding conductor with a suffi-

ciently sized area must be laid in parallel, as described above. Shield

connections need as much physical connection area as possible,

otherwise the shielding effect in the high frequency zone will drop off.

Installation

2−4Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05

2.4.2 Set-up of the CANopen bus transmission cables

Number of bus stations: max. of 32 (master, slave or repeater)

Spatial set-up: linear bus without branches with passive terminator

at both ends, stub line length is max. 0.3 m for sta-

tions.

The complete bus line length includes the total of all

stub line lengths!

Transmission rates: 10 kBit/s to 1 MBit/s

Cable length: maximum possible longitudinal elongations is de-

pendent on the transmission rate (see the following

table):

Transmission rate

[kBit/s]

max. cable length: [m] nominal bit time

[ms]

10 5000 100

20 2500 50

50 1000 20

125 500 8

250 200 4

500 100 2

1000 30 1

Medium: shielded twisted pair cable according to ISO11898

(corresponding to the following table):

Parameter Unit Value Comment

Surge impedance [O] 108 ... 132 measured be-

tween the

signal wires

Loop resistance [O/km]  70 Common supply

and return

Signal propaga-

tion delay

[ns/m]  5

Page is loading ...

Bosch Rexroth RE29090-B-01 User manual

Bosch Rexroth RE29090-B-01 User manual

Related papers

Other documents