Bosch Rexroth RE29090-B-01 User manual

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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) 9352/180
Fax: +49 (0) 9352/181638
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 11 . . . . . . . . . . . . . . . . . . . . . . .
1.1 Proper use 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Qualified personnel 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Safety markings on products 14 . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Safety instructions in this manual 14 . . . . . . . . . . . . . . . . . . . . . .
1.5 General safety instructions 15 . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Documentation, software release and trademarks 17 . . . . . . .
2 Installation 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Conditions of use 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Installation, mounting orientation and clearances 21 . . . . . . . .
2.3 Maintenance instructions 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Installation of CANopen bus system 22 . . . . . . . . . . . . . . . . . . .
2.4.1 Introduction 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Set-up of the CANopen bus transmission cables 24 . . . . . . .
3 Overview 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 IAC-R valve 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Application 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 IAC-R valve variants 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Housing variants 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.2 Hydraulic valve body variants 34 . . . . . . . . . . . . . . . . . . . . . . .
3.3.3 Interface combinations for system variants 34 . . . . . . . . . . . .
3.4 Applicable standards and guidelines 35 . . . . . . . . . . . . . . . . . . .
4 Electrical connection and interfaces 41 . . . . . . .
4.1 Overview 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Protective ground conductor (PE) and shielding 41 . . . . . . . . .
4.3 24 VDC supply 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Safety functions 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Interface overview 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Device interface X1 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 Power supply 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.2 Analog inputs and PLC switching signals (inputs) 48 . . . . . .
4.6.3 Analog outputs and PLC switching signals (outputs) 411 . . . .
4.6.4 Enable input 414 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.5 Fault output / Power switching output 415 . . . . . . . . . . . . . . . . .
4.7 LVDT interface X2 416 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Field bus / programming interface X3 417 . . . . . . . . . . . . . . . . . .
4.9 Sensor interfaces X4 and X7 418 . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.1 Analog sensor interface X4 419 . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.2 Analog sensor interface X7 421 . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.3 Position feedback interface X7 423 . . . . . . . . . . . . . . . . . . . . . .
Contents
IV Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05
4.10 Mating connectors for IAC-R valve interfaces 425 . . . . . . . . . . .
4.10.1 Mating connector for X1 425 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.2 Mating connector for X2 426 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.3 Mating connector for X3 426 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.4 Mating connector for X4 427 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.5 Mating connector for X7 427 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10.6 T-adapter for analog sensor interfaces X4 and X7 428 . . . . . .
5 First Commissioning 51 . . . . . . . . . . . . . . . . . . . . .
5.1 Introduction 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 System principles of the IAC-R valve 52 . . . . . . . . . . . . . . . . . . .
5.2.1 Configuration tool and auxiliary aids 53 . . . . . . . . . . . . . . . . . .
5.2.2 Hardware requirements for commissioning 53 . . . . . . . . . . . .
5.2.3 Parameter definition 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4 Bus, node, baud rate 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.5 Analog/digital mode with device state, device function,
device control and device status 515 . . . . . . . . . . . . . . . . . . . . .
5.3 Short overview: First Commissioning 533 . . . . . . . . . . . . . . . . . . .
5.4 Selecting digital mode 537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Selecting analog mode 537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Connect IAC-R valve with system (Step 1) 538 . . . . . . . . . . . . . .
5.7 Powering up the IAC-R valve (Step 2) 538 . . . . . . . . . . . . . . . . . .
5.8 Establishing communication with the valve (Step 3) 539 . . . . . .
5.9 Selection of the control function (Step 4) 541 . . . . . . . . . . . . . . .
5.10 Mode configuration (Step 5) 542 . . . . . . . . . . . . . . . . . . . . . . . . . .
5.11 Interface configuration to master controller (Step 6) 544 . . . . . .
5.11.1 Digital control via PDOs (CANopen) 544 . . . . . . . . . . . . . . . . . .
5.11.2 Analog control via I/O signals of the IAC-R valve 557 . . . . . . .
5.12 Q control demand value programming (Step 7) 560 . . . . . . . . . .
5.13 Configuration for local control (Step 8) 563 . . . . . . . . . . . . . . . . .
5.14 Saving and loading parameters (Step 9) 564 . . . . . . . . . . . . . . . .
5.15 Starting the IAC-R valve in analog mode (Step 10) 567 . . . . . . .
5.15.1 Starting the system (Step 11) 568 . . . . . . . . . . . . . . . . . . . . . . .
5.15.2 Set enable (Step 12) 568 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.15.3 Modifying and testing parameters (Step 13) 568 . . . . . . . . . . .
5.16 Start the IAC-R valve in digital mode (Step 10) 569 . . . . . . . . . .
5.16.1 Starting the system (Step 11) 571 . . . . . . . . . . . . . . . . . . . . . . . .
5.16.2 Set enable (Step 12) 572 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.16.3 Modify parameters and test them (Step 13) 573 . . . . . . . . . . .
6 Controller function and optimization 61 . . . . . .
6.1 Introduction 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Introduction of the controller structure 62 . . . . . . . . . . . . . . . . . .
6.2.1 Set-up of the controller structure 62 . . . . . . . . . . . . . . . . . . . . .
6.2.2 Criteria for an optimum closed loop control 67 . . . . . . . . . . . .
6.3 Short overview: Commissioning the controller function 611 . . .
6.4 Connect sensors to system (Step 1) 616 . . . . . . . . . . . . . . . . . . .
6.5 Power up of the IAC-R valve (Step 2) 616 . . . . . . . . . . . . . . . . . .
6.6 Establishing communication with the valve (Step 3) 616 . . . . . .
6.7 Selection of the control function (Step 4) 617 . . . . . . . . . . . . . . .
6.8 Mode selection/configuration (Step 5) 618 . . . . . . . . . . . . . . . . . .
6.9 Configuration of the interface to controller (Step 6) 618 . . . . . . .
Contents
Industrial Hydraulics VBosch Rexroth AGIAC-R valveRE 29090-B-01/06.05
6.10 p/Q control configuration (Step 7a) 619 . . . . . . . . . . . . . . . . . . . .
6.10.1 Demand value generator 621 . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10.2 Sensor calibration (analog pressure sensor) 631 . . . . . . . . . . .
6.10.3 p/Q controller 640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10.4 Controller output adaptation 647 . . . . . . . . . . . . . . . . . . . . . . . . .
6.10.5 Optimization 655 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.11 Position control configuration (Step 7b) 663 . . . . . . . . . . . . . . . . .
6.11.1 Demand value generator 665 . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.11.2 Sensor variations for position control 675 . . . . . . . . . . . . . . . . .
6.11.3 Sensor calibration (analog position sensor) 675 . . . . . . . . . . . .
6.11.4 Sensor calibration
(digital absolute position feedback system SSI) 685 . . . . . . . .
6.11.5 Sensor calibration
(digital incremental position feedback system 1Vpp) 690 . . . .
6.11.6 Test mode (referencing, Jog mode) 694 . . . . . . . . . . . . . . . . . .
6.11.7 Position controller 6106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.11.8 Controller output adaptation 6109 . . . . . . . . . . . . . . . . . . . . . . . . .
6.11.9 Optimization 6113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12 Alternating control configuration (Step 7c) 6136 . . . . . . . . . . . . . .
6.12.1 Demand value generator 6137 . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12.2 Sensor calibration 6137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12.3 Alternating controller 6137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.12.4 Calibration output adaptation functions 6137 . . . . . . . . . . . . . . .
6.12.5 Optimization 6137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.13 Concluding commissioning measures (Step 813) 6137 . . . . . . .
6.14 Controller structure functions 6138 . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.1 Setpoint input 6139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.2 Setpoint calibration 6142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.3 Setpoint limiting 6143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.4 Ramp/Interpolator 6144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.5 Actual value conditioning 6146 . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.6 p/Q controller function 6151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.7 Position controller function 6152 . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.8 Alternating control function 6153 . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.9 Filter 6154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.10 Characteristic compensation 6160 . . . . . . . . . . . . . . . . . . . . . . . .
6.14.11 Dead band compensation 6162 . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.12 Zero offset 6165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.13 Controller output limitation 6165 . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.14 Inversion 6166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.15 Friction compensation 6167 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.14.16 Directional gain 6170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Special functions 71 . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Device response/device states: 71 . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Configuration of the enable response 71 . . . . . . . . . . . . . . . . .
7.2 Extended functionality of the I/O interfaces 72 . . . . . . . . . . . . .
7.2.1 Analog control of the inputs pins 4 and 7 of X1 73 . . . . . . . . .
7.2.2 Analog control of the outputs, pin 6 and pin 8 of X1 77 . . . . .
Contents
VI Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05
7.3 Special cases of application 715 . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.1 Live counter 715 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Power switching signal function 715 . . . . . . . . . . . . . . . . . . . . . .
7.3.3 Monitoring of target window (InPos message) 717 . . . . . . . . .
7.3.4 Range monitoring (software cam) 721 . . . . . . . . . . . . . . . . . . . .
7.3.5 Control error monitoring (following error) 722 . . . . . . . . . . . . . .
7.4 Firmware update 726 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Customer-specific information 726 . . . . . . . . . . . . . . . . . . . . . . . . .
8 Creating and processing NC programs 81 . . . .
8.1 Introduction 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1 Program syntax 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2 Program structure 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Commands supported by the IAC-R valve 88 . . . . . . . . . . . . . .
8.2.1 G00 Rapid Traverse 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2 G01 Linear interpolation 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.3 G04 Dwell time 810 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.4 G22-G24 Subroutine calls and program jumps 811 . . . . . . . .
8.2.5 G53, G54-G59 Zero offsets (shifts) 814 . . . . . . . . . . . . . . . . . .
8.2.6 G61, G62 In-position logic On/Off (accurate halt) 818 . . . . . .
8.2.7 G64, G65 Inhibit/enable following error monitoring 819 . . . . .
8.2.8 G70, G71 Setpoint input in inches or mm 820 . . . . . . . . . . . . .
8.2.9 G90, G91 Absolute or relative dimensioning 821 . . . . . . . . . . .
8.2.10 M00, M01 Unconditional/Conditional Program Halt 822 . . . .
8.2.11 M02, M30 End-of-program tag for main program
and subroutine 824 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.12 M90, M91 Setting/Resetting PLC outputs 826 . . . . . . . . . . . . .
8.3 Callback functions (mapped M functions) 827 . . . . . . . . . . . . . . .
8.3.1 M functions with compulsory acknowledgement 827 . . . . . . . .
8.4 Spindle speed 830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Axis names 831 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6 Programmable variables (R parameters) 832 . . . . . . . . . . . . . . .
8.7 Operation with NC program selection 836 . . . . . . . . . . . . . . . . . .
8.7.1 Automatic mode 836 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.2 Single step/Automatic mode 837 . . . . . . . . . . . . . . . . . . . . . . . . .
8.8 Debugging NC files 838 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.1 Checking an NC file when loading 838 . . . . . . . . . . . . . . . . . . .
8.8.2 Syntax verification 840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.3 Logic analysis 841 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.4 Interpreter errors (runtime errors) 842 . . . . . . . . . . . . . . . . . . . .
9 Error messages and how to deal with them 91
9.1 Introduction 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Determining the error state 91 . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1 Read out error state via bus system 91 . . . . . . . . . . . . . . . . . .
9.2.2 Read out error state via analog fault signal 92 . . . . . . . . . . . .
9.3 Error codes 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.1 Error code table 93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.2 Read error code 913 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Reaction to errors 915 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4.1 Types of errors and priority 915 . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
Industrial Hydraulics VIIBosch Rexroth AGIAC-R valveRE 29090-B-01/06.05
9.5 Error reaction configuration 916 . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.1 Changing types of errors 916 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 Masking the monitoring of the output stages 916 . . . . . . . . . . . .
9.7 Fault reaction in the NOT READY and INIT states 917 . . . . . . .
9.8 Acknowledge error 917 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Annex A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Index A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Abbreviations A7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3 Glossary A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.4 Parameter tables A9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter table: sorted by numbers A11 . . . . . . . . . . . . . . . . . .
Parameter table: sorted by names A34 . . . . . . . . . . . . . . . . . . .
A.5 Parameters with PDO mapping A57 . . . . . . . . . . . . . . . . . . . . . . .
A.6 Change log A58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
VIII Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05
Notes:
Safety Instructions
Industrial Hydraulics 11Bosch 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 17).
.Furthermore, please note the ”General Operating Instructions for
Hydraulic Systems” (see page 17) 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
12Industrial 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 13Bosch 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
14Industrial 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 15Bosch 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
16Industrial 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 Mresistor.
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 17Bosch 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
18Industrial HydraulicsBosch Rexroth AG IAC-R valve RE 29090-B-01/06.05
Notes:
Installation
Industrial Hydraulics 21Bosch 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
22Industrial 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 23Bosch 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
24Industrial 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
/