Bosch Rexroth Rexroth IndraControl VDP 40.1 User manual

Project Planning Manual

Electric Drives

and Controls Pneumatics

Service

Linear Motion and

Assembly Technologies

Hydraulics

Rexroth IndraControl

VDP 16.1/40.1/60.1

Operator Display

R911307654

Edition 03

Rexroth IndraControl

VDP 16.1/40.1/60.1

Operator Display

Project Planning Manual

DOK-SUPPL*-VDP16/40/60-PR03-EN-P

RS-3819577ef0bf23a20a6846a0007da7dd-1-en-US-5

This documentation describes the displays IndraControl VDP 16.1, VDP 40.1

and VDP 60.1 as well as the Y-repeaters available as accessories.

Edition Release Date Notes

120-2100-B368-01/EN 06.2004 First edition

120-2100-B368-02/EN 01.2005 Second edition

120-2100-B368-03/EN 05.2010 Third edition

Copyright

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).

Validity

The specified data is for product description purposes only and may not be

deemed to be guaranteed unless expressly confirmed in the contract. All rights

are reserved with respect to the content of this documentation and the availa‐

bility of the product.

Published by

Bosch Rexroth AG

Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr am Main, Germany

Phone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85

http://www.boschrexroth.com/

Development Control Platform HB (CS)

Note

This document has been printed on chlorine-free bleached paper.

Title

Type of Documentation

Document Typecode

Internal File Reference

Purpose of Documentation

Record of Revision

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Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display

Table of Contents

Page

1 System Presentation...................................................................................................... 5

1.1 Brief Description of the VDP 16.1, VDP 40.1 and VDP 60.1 Operator Displays ................................... 5

1.2 Variants................................................................................................................................................... 5

1.2.1 Characteristic Features....................................................................................................................... 5

1.2.2 Displays with Foil Keyboard................................................................................................................ 6

1.2.3 Displays with Touch Screen................................................................................................................ 6

1.2.4 VDP 16.1 Variants............................................................................................................................... 6

VDP 16.1 - Variants.......................................................................................................................... 6

1.2.5 VDP 40.1 - Variants............................................................................................................................. 7

1.2.6 VDP 60.1............................................................................................................................................. 8

1.3 Accessories............................................................................................................................................ 9

1.4 Commissioning....................................................................................................................................... 9

2 Important Instructions on Use ..................................................................................... 11

2.1 Appropriate Use ................................................................................................................................... 11

2.1.1 Introduction........................................................................................................................................ 11

2.1.2 Areas of Use and Application............................................................................................................ 11

2.2 Inappropriate Use................................................................................................................................. 12

3 Safety Instructions for Electric Drives and Controls .................................................... 13

3.1 Definitions of Terms.............................................................................................................................. 13

3.2 General Information.............................................................................................................................. 14

3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 14

3.2.2 Requirements for Safe Use............................................................................................................... 14

3.2.3 Hazards by Improper Use.................................................................................................................. 15

3.3 Instructions with Regard to Specific Dangers....................................................................................... 16

3.3.1 Protection Against Contact with Electrical Parts and Housings......................................................... 16

3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 17

3.3.3 Protection Against Dangerous Movements....................................................................................... 17

3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 19

3.3.5 Protection Against Contact With Hot Parts........................................................................................ 19

3.3.6 Protection During Handling and Mounting......................................................................................... 19

3.3.7 Battery Safety.................................................................................................................................... 20

3.3.8 Protection Against Pressurized Systems........................................................................................... 20

3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 21

4 Technical Data............................................................................................................. 23

4.1 Front Panel .......................................................................................................................................... 23

4.2 Voltage Supply...................................................................................................................................... 23

4.3 Ambient Conditions............................................................................................................................... 24

4.4 Standards............................................................................................................................................. 24

4.4.1 Used Standards................................................................................................................................. 24

4.4.2 CE Marking........................................................................................................................................ 25

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Table of Contents

Page

Declaration of Conformity .............................................................................................................. 25

Note for the Machine Manufacturer................................................................................................ 25

4.4.3 UL/CSA Certified............................................................................................................................... 25

4.5 Wear Parts............................................................................................................................................ 26

4.6 Compatibility Test................................................................................................................................. 26

5 Dimensions and Installation......................................................................................... 27

5.1 Housing Dimensions............................................................................................................................. 27

5.1.1 Housing Dimensions VDP 16.1......................................................................................................... 27

5.1.2 Housing Dimensions VDP 40.1......................................................................................................... 29

5.1.3 Housing Dimensions VDP 60.1......................................................................................................... 31

5.2 Housing Dimensions of the Y-Repeater............................................................................................... 31

5.3 Installation ............................................................................................................................................ 32

5.3.1 Installation Notes............................................................................................................................... 32

5.3.2 Mounting Cut-out............................................................................................................................... 32

5.3.3 Mounting Dimensions VDP 16.1........................................................................................................ 34

5.3.4 Mounting Dimensions VDP 40.1........................................................................................................ 35

5.3.5 Mounting Dimensions VDP 60.1........................................................................................................ 35

6 Display and Operating Components............................................................................ 37

6.1 Backlight Switch-off.............................................................................................................................. 37

6.1.1 General Information........................................................................................................................... 37

6.2 Operating and Error Displays............................................................................................................... 37

6.3 Foil Keyboard........................................................................................................................................ 38

6.3.1 System Requirements....................................................................................................................... 38

6.3.2 Position of the Buttons....................................................................................................................... 39

6.3.3 VDP 16.1 Keys and VDP 40.1 Keys.................................................................................................. 39

Function and Operating Keys (F... + OP...).................................................................................... 39

Use of an External Keypad............................................................................................................. 39

M-Keys........................................................................................................................................... 40

6.3.4 Keys VDP 60.1.................................................................................................................................. 41

Function and Special Keys (F... + S...)........................................................................................... 41

M-Keys .......................................................................................................................................... 42

Alphanumeric Block........................................................................................................................ 43

6.4 Touch Screen....................................................................................................................................... 43

6.5 LEDs at the Y-Repeater........................................................................................................................ 43

7 Interfaces..................................................................................................................... 45

7.1 Interfaces at the VDP............................................................................................................................ 45

7.1.1 View on the Connector Panel............................................................................................................ 45

7.1.2 General Information........................................................................................................................... 45

7.1.3 Overview............................................................................................................................................ 45

7.1.4 S3/S4 Rotary Switch.......................................................................................................................... 46

Overview......................................................................................................................................... 46

7.1.5 DC 24 V Voltage Supply.................................................................................................................... 46

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Table of Contents

Page

7.1.6 XUSB Interfaces................................................................................................................................ 47

7.1.7 G4 Display Interface.......................................................................................................................... 48

7.1.8 Combined Keyboard/Mouse Interface............................................................................................... 48

7.1.9 Mouse Interface................................................................................................................................. 48

7.1.10 PROFIBUS DP Interface................................................................................................................... 49

7.2 Intefaces at the Y-Repeater.................................................................................................................. 50

7.2.1 View on the Connector Panels.......................................................................................................... 50

7.2.2 Description of the Interfaces - Overview............................................................................................ 51

7.2.3 Connection of the Y-Repeater (Block Diagram)................................................................................ 51

7.2.4 G4 Display Interfaces........................................................................................................................ 51

7.2.5 Digital 24 V Input (Changeover Input)............................................................................................... 52

8 Maintenance................................................................................................................ 55

8.1 General Information.............................................................................................................................. 55

8.2 LCD Display.......................................................................................................................................... 55

8.3 Connecting two VDPs via the Y-Repeater............................................................................................ 56

9 Software....................................................................................................................... 57

9.1 Touch Screen Software........................................................................................................................ 57

10 Environmental Protection and Disposal ...................................................................... 59

10.1 Environmental Protection...................................................................................................................... 59

10.2 Disposal................................................................................................................................................ 59

11 Ordering Information.................................................................................................... 61

11.1 Type Designation Code........................................................................................................................ 61

11.1.1 General Information........................................................................................................................... 61

11.2 VDP 16.1.............................................................................................................................................. 61

11.3 VDP 40.1.............................................................................................................................................. 62

11.4 VDP 60.1.............................................................................................................................................. 63

11.5 Accessories.......................................................................................................................................... 64

11.5.1 Y-Repeater........................................................................................................................................ 64

11.5.2 Connecting Cable to Control Cabinet PC IPC 40.2........................................................................... 64

12 Service and Support.................................................................................................... 65

Index............................................................................................................................ 67

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Table of Contents

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1 System Presentation

1.1 Brief Description of the VDP 16.1, VDP 40.1 and VDP 60.1

Operator Displays

The VDP 16.1/40.1/60.1 operator displays are passive operator and visualiza‐

tion terminals. They form a PC-based operator terminal when used with a

control cabinet PC (IPC) equipped with a G4 display interface. At present, the

IPC 40.2, VSB 40.1 or VPB 40.1 devices are available as control cabinet PCs.

While the VDP 16.1, VDP 40.1 and VDP 60.1 displays are mounted in the door

of the control cabinet or on a bracket with little mounting depth, the control

cabinet PC (IPC) can for example be mounted in the control cabinet. Data is

transmitted between control cabinet PC and VDP 16.1/40.1/60.1 operator dis‐

play via G4 display interface.

Y-repeater

A Y-repeater is an accessory to connect VDP devices to a control cabinet PC

(see chapter 11.5 "Accessories" on page 64). The Y-repeater can be used

to connect two VDP devices to a control cabinet PC (IPC).

1.2 Variants

1.2.1 Characteristic Features

The displays are available as differnet variants, see type designation code in

chapter 11.1 "Type Designation Code" on page 61. They differ in display size

and touch screen capability.

VDP 16.1 BB - BK

Customized design for Bosch - AC -

Display 304.8 mm TFT (12")

Touch screen Yes Yes No

Keys (foil keyboard) No No 16 machine

function keys

Fig.1-1: Characteristic features of the VDP 16.1 devices

VDP 40.1 BE - BI

Customized design for Bosch AG

Display 381 mm TFT (15")

Touch screen Yes Yes No

Keys (foil keyboard) No No 16 machine

function keys

Fig.1-2: Characteristic features of the VDP 40.1 devices

VDP 60.1 BL

Display 304.8 mm (12")

Touch screen No

Keys (foil keyboard) Machine function keys and alphanumeric keys

Fig.1-3: Characteristic features of the VDP 60.1 devices

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System Presentation

1.2.2 Displays with Foil Keyboard

The front panel with foil keyboard consists of a 4 mm thick aluminum panel with

beveled edges covered by a chemical resistant polyester foil with embossed

keys. Machine functions keys are integrated in the application-oriented function

keypad.

1.2.3 Displays with Touch Screen

The front panel with touch screen allows to operate the application software via

the touch-sensitive surface of the display without keyboard and mouse.

Danger of destruction of the touch screen if

operated with inappropriate objects (e.g.

screwdriver).

NOTICE

Operate the touch screen only with your finger or with a touch pen.

1.2.4 VDP 16.1 Variants

VDP 16.1 - Variants

VDP 16.1BB with touch screen

Fig.1-4: VDP 16.1 with touch screen

VDP 16.1AC with touch screen, without front USB, customized Bosch design

Principally, they differ from the standard variant in its rounded edges, the miss‐

ing USB connection and the different mounting dimensions.

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System Presentation

VDP 16.1BK with keypad and 16 M-keys, standard variant

Fig.1-5: VDP 16.1 with foil keyboard

1.2.5 VDP 40.1 - Variants

VDP 40.1BE with touch screen

Fig.1-6: VDP 40.1 with touch screen

VDP 40.1AG with touch screen, without front USB, customized Bosch design

Principally, they differ from the standard variant in its rounded edges, the miss‐

ing USB connection and the different mounting dimensions.

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System Presentation

VDP 40.1BI with foil keyboard and 16 machine function keys, standard variant

Fig.1-7: VDP 40.1 with foil keyboard

1.2.6 VDP 60.1

VDP 60.1BL with foil keyboard, 16 machine function keys, alphanumeric keys

and 12" display

Fig.1-8: VDP 60.1 with foil keyboard

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System Presentation

1.3 Accessories

Using the Y-repeater (VAC01.1S-YG4-EXTN) provided as accessory part, two

VDP displays can be connected to a control cabinet PC (IPC). The Y-repeater

can be cascaded. Therefore, three or more VDPs can be connected to a control

cabinet PC.

1.4 Commissioning

Mount the device properly, see also chapter 5.3 "Installation " on page 32.

Connect the device to the de-energized control cabinet PC (IPC); then connect

the 24 V supply voltage.

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System Presentation

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2 Important Instructions on Use

2.1 Appropriate Use

2.1.1 Introduction

Rexroth products represent state-of-the-art developments and manufacturing.

They are tested prior to delivery to ensure operational safety and reliability.

Physical injury and material damage might re‐

sult from an inappropriate use of the products!

WARNING

The products are designed for the use in an industrial environment and may

therefore only be used for the intended purpose. If they are not used as inten‐

ded, situations causing personal injury as well as material damage can occur.

Rexroth disclaims as manufacturer any warranty, liability or dam‐

ages occurring due to inappropriate use of the products. Further‐

more, Rexroth is not paying any compensation. The user is

responsible for any risks resulting from inappropriate use of the

products.

Before using Rexroth products, the following requirements must be met to en‐

sure appropriate use of the products:

● Anyone handling one of the Rexroth products in any way has to read and

understand the respective safety-related guidelines as well as the instruc‐

tions on appropriate use.

● Hardware products have to remain in their original state, i. e. no modifi‐

cation regarding the design is allowed. Software products must not be

decompiled and their source codes must not be modified.

● Damaged or faulty products must not be implemented or put into opera‐

tion.

● It must be ensured that the products are installed as specified in the doc‐

umentation.

2.1.2 Areas of Use and Application

The Rexroth VDP 16.1/40.1/60.1 displays are passive operating and visuali‐

zation terminals forming a PC-based machine operating terminal when used

with an industrial PC.

Danger of destruction of the device if not ex‐

pressly stated accessories, add-on compo‐

nents and other components, cables, conduits,

software and firmware is used.

NOTICE

The VDP 16.1/40.1/60.1 displays may exclusively be used with the accessories

and add-on components specified in this documentation. Components not

named expressly mentioned must neither be mounted nor connected. The

same applies to cables and conduits.

The products may only be operated with the expressly stated configurations

and component combinations as well as with the software and firmware which

is given and specified in the respective functional description.

Typical areas of application of the VDP 16.1/40.1/60.1 are:

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Important Instructions on Use

● Handling systems and assembly systems

● Packaging and food processing machines

● Printing machines and paper converting machines

● Machine tools

● Wood processing machines

The VDP 16.1/40.1/60.1 operator displays may only be operated under the as‐

sembly conditions and installation conditions, in the specified position of appli‐

cation and under the specified ambient conditions (temperature, degree of

protection, humidity, EMC etc.) given in this documentation.

2.2 Inappropriate Use

The application of VDP 16.1/40.1/60.1 that are not within the specified areas

of application or under operating conditions deviating from the operating con‐

ditions and technical data specified in the documentation is considered as

"inappropriate".

VDP 16.1/40.1/60.1 must not be used if ...

● it is exposed to operating conditions that do not fulfill the ambient condi‐

tions specified. For instance, operation under water, in case of extreme

variations of temperature or in extreme maximum temperatures is not al‐

lowed.

● the intended applications have not expressly been allowed by Rexroth. It

is imperative that you also note the information given in the general notes

on safety!

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Important Instructions on Use

3 Safety Instructions for Electric Drives and Controls

3.1 Definitions of Terms

Application Documentation

Application documentation comprises the entire documentation used to inform

the user of the product about the use and safety-relevant features for config‐

uring, integrating, installing, mounting, commissioning, operating, maintaining,

repairing and decommissioning the product. The following terms are also used

for this kind of documentation: User Guide, Operation Manual, Commissioning

Manual, Instruction Manual, Project Planning Manual, Application Manual, etc.

Component

A component is a combination of elements with a specified function, which are

part of a piece of equipment, device or system. Components of the electric drive

and control system are, for example, supply units, drive controllers, mains

choke, mains filter, motors, cables, etc.

Control System

A control system comprises several interconnected control components placed

on the market as a single functional unit.

Device

A device is a finished product with a defined function, intended for users and

placed on the market as an individual piece of merchandise.

Electrical Equipment

Electrical equipment encompasses all devices used to generate, convert, trans‐

mit, distribute or apply electrical energy, such as electric motors, transformers,

switching devices, cables, lines, power-consuming devices, circuit board as‐

semblies, plug-in units, control cabinets, etc.

Electric Drive System

An electric drive system comprises all components from mains supply to motor

shaft; this includes, for example, electric motor(s), motor encoder(s), supply

units and drive controllers, as well as auxiliary and additional components, such

as mains filter, mains choke and the corresponding lines and cables.

Installation

An installation consists of several devices or systems interconnected for a de‐

fined purpose and on a defined site which, however, are not intended to be

placed on the market as a single functional unit.

Machine

A machine is the entirety of interconnected parts or units at least one of which

is movable. Thus, a machine consists of the appropriate machine drive ele‐

ments, as well as control and power circuits, which have been assembled for

a specific application. A machine is, for example, intended for processing,

treatment, movement or packaging of a material. The term "machine" also cov‐

ers a combination of machines which are arranged and controlled in such a way

that they function as a unified whole.

Manufacturer

The manufacturer is an individual or legal entity bearing responsibility for the

design and manufacture of a product which is placed on the market in the in‐

dividual's or legal entity's name. The manufacturer can use finished products,

finished parts or finished elements, or contract out work to subcontractors.

However, the manufacturer must always have overall control and possess the

required authority to take responsibility for the product.

Product

Examples of a product: Device, component, part, system, software, firmware,

among other things.

Project Planning Manual

A project planning manual is part of the application documentation used to

support the sizing and planning of systems, machines or installations.

Qualified Persons

In terms of this application documentation, qualified persons are those persons

who are familiar with the installation, mounting, commissioning and operation

of the components of the electric drive and control system, as well as with the

hazards this implies, and who possess the qualifications their work requires. To

comply with these qualifications, it is necessary, among other things,

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Safety Instructions for Electric Drives and Controls

1) to be trained, instructed or authorized to switch electric circuits and devices

safely on and off, to ground them and to mark them

2) to be trained or instructed to maintain and use adequate safety equipment

3) to attend a course of instruction in first aid

User

A user is a person installing, commissioning or using a product which has been

placed on the market.

3.2 General Information

3.2.1 Using the Safety Instructions and Passing Them on to Others

Do not attempt to install and operate the components of the electric drive and

control system without first reading all documentation provided with the product.

Read and understand these safety instructions and all user documentation prior

to working with these components. If you do not have the user documentation

for the components, contact your responsible Bosch Rexroth sales partner. Ask

for these documents to be sent immediately to the person or persons respon‐

sible for the safe operation of the components.

If the component is resold, rented and/or passed on to others in any other form,

these safety instructions must be delivered with the component in the official

language of the user's country.

Improper use of these components, failure to follow the safety instructions in

this document or tampering with the product, including disabling of safety de‐

vices, could result in property damage, injury, electric shock or even death.

3.2.2 Requirements for Safe Use

Read the following instructions before initial commissioning of the components

of the electric drive and control system in order to eliminate the risk of injury

and/or property damage. You must follow these safety instructions.

● Bosch Rexroth is not liable for damages resulting from failure to observe

the safety instructions.

● Read the operating, maintenance and safety instructions in your language

before commissioning. If you find that you cannot completely understand

the application documentation in the available language, please ask your

supplier to clarify.

● Proper and correct transport, storage, mounting and installation, as well

as care in operation and maintenance, are prerequisites for optimal and

safe operation of the component.

● Only qualified persons may work with components of the electric drive and

control system or within its proximity.

● Only use accessories and spare parts approved by Bosch Rexroth.

● Follow the safety regulations and requirements of the country in which the

components of the electric drive and control system are operated.

● Only use the components of the electric drive and control system in the

manner that is defined as appropriate. See chapter "Appropriate Use".

● The ambient and operating conditions given in the available application

documentation must be observed.

● Applications for functional safety are only allowed if clearly and explicitly

specified in the application documentation "Integrated Safety Technolo‐

gy". If this is not the case, they are excluded. Functional safety is a safety

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Safety Instructions for Electric Drives and Controls

concept in which measures of risk reduction for personal safety depend

on electrical, electronic or programmable control systems.

● The information given in the application documentation with regard to the

use of the delivered components contains only examples of applications

and suggestions.

The machine and installation manufacturers must

– make sure that the delivered components are suited for their individ‐

ual application and check the information given in this application

documentation with regard to the use of the components,

– make sure that their individual application complies with the appli‐

cable safety regulations and standards and carry out the required

measures, modifications and complements.

● Commissioning of the delivered components is only allowed once it is sure

that the machine or installation in which the components are installed

complies with the national regulations, safety specifications and standards

of the application.

● Operation is only allowed if the national EMC regulations for the applica‐

tion are met.

● The instructions for installation in accordance with EMC requirements can

be found in the section on EMC in the respective application documenta‐

tion.

The machine or installation manufacturer is responsible for compliance

with the limit values as prescribed in the national regulations.

● The technical data, connection and installation conditions of the compo‐

nents are specified in the respective application documentations and must

be followed at all times.

National regulations which the user must take into account

● European countries: In accordance with European EN standards

● United States of America (USA):

– National Electrical Code (NEC)

– National Electrical Manufacturers Association (NEMA), as well as

local engineering regulations

– Regulations of the National Fire Protection Association (NFPA)

● Canada: Canadian Standards Association (CSA)

● Other countries:

– International Organization for Standardization (ISO)

– International Electrotechnical Commission (IEC)

3.2.3 Hazards by Improper Use

● High electrical voltage and high working current! Danger to life or serious

injury by electric shock!

● High electrical voltage by incorrect connection! Danger to life or injury by

electric shock!

● Dangerous movements! Danger to life, serious injury or property damage

by unintended motor movements!

● Health hazard for persons with heart pacemakers, metal implants and

hearing aids in proximity to electric drive systems!

● Risk of burns by hot housing surfaces!

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Safety Instructions for Electric Drives and Controls

● Risk of injury by improper handling! Injury by crushing, shearing, cutting,

hitting!

● Risk of injury by improper handling of batteries!

● Risk of injury by improper handling of pressurized lines!

3.3 Instructions with Regard to Specific Dangers

3.3.1 Protection Against Contact with Electrical Parts and Housings

This section concerns components of the electric drive and control

system with voltages of more than 50 volts.

Contact with parts conducting voltages above 50 volts can cause personal

danger and electric shock. When operating components of the electric drive

and control system, it is unavoidable that some parts of these components

conduct dangerous voltage.

High electrical voltage! Danger to life, risk of injury by electric shock or serious

injury!

● Only qualified persons are allowed to operate, maintain and/or repair the

components of the electric drive and control system.

● Follow the general installation and safety regulations when working on

power installations.

● Before switching on, the equipment grounding conductor must have been

permanently connected to all electric components in accordance with the

connection diagram.

● Even for brief measurements or tests, operation is only allowed if the

equipment grounding conductor has been permanently connected to the

points of the components provided for this purpose.

● Before accessing electrical parts with voltage potentials higher than 50 V,

you must disconnect electric components from the mains or from the pow‐

er supply unit. Secure the electric component from reconnection.

● With electric components, observe the following aspects:

Always wait 30 minutes after switching off power to allow live capacitors

to discharge before accessing an electric component. Measure the elec‐

trical voltage of live parts before beginning to work to make sure that the

equipment is safe to touch.

● Install the covers and guards provided for this purpose before switching

on.

● Never touch electrical connection points of the components while power

is turned on.

● Do not remove or plug in connectors when the component has been pow‐

ered.

● Under specific conditions, electric drive systems can be operated at mains

protected by residual-current-operated circuit-breakers sensitive to uni‐

versal current (RCDs/RCMs).

● Secure built-in devices from penetrating foreign objects and water, as well

as from direct contact, by providing an external housing, for example a

control cabinet.

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Safety Instructions for Electric Drives and Controls

High housing voltage and high leakage current! Danger to life, risk of injury by

electric shock!

● Before switching on and before commissioning, ground or connect the

components of the electric drive and control system to the equipment

grounding conductor at the grounding points.

● Connect the equipment grounding conductor of the components of the

electric drive and control system permanently to the main power supply at

all times. The leakage current is greater than 3.5 mA.

● Establish an equipment grounding connection with a copper wire of a

cross section of at least 10 mm

2

(8 AWG) or additionally run a second

equipment grounding conductor of the same cross section as the original

equipment grounding conductor.

3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock

Protective extra-low voltage is used to allow connecting devices with basic in‐

sulation to extra-low voltage circuits.

On components of an electric drive and control system provided by Bosch

Rexroth, all connections and terminals with voltages between 5 and 50 volts

are PELV ("Protective Extra-Low Voltage") systems. It is allowed to connect

devices equipped with basic insulation (such as programming devices, PCs,

notebooks, display units) to these connections.

Danger to life, risk of injury by electric shock! High electrical voltage by incorrect

connection!

If extra-low voltage circuits of devices containing voltages and circuits of more

than 50 volts (e.g., the mains connection) are connected to Bosch Rexroth

products, the connected extra-low voltage circuits must comply with the re‐

quirements for PELV ("Protective Extra-Low Voltage").

3.3.3 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of connected motors.

Some common examples are:

● Improper or wrong wiring or cable connection

● Operator errors

● Wrong input of parameters before commissioning

● Malfunction of sensors and encoders

● Defective components

● Software or firmware errors

These errors can occur immediately after equipment is switched on or even

after an unspecified time of trouble-free operation.

The monitoring functions in the components of the electric drive and control

system will normally be sufficient to avoid malfunction in the connected drives.

Regarding personal safety, especially the danger of injury and/or property dam‐

age, this alone cannot be relied upon to ensure complete safety. Until the

integrated monitoring functions become effective, it must be assumed in any

case that faulty drive movements will occur. The extent of faulty drive move‐

ments depends upon the type of control and the state of operation.

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Safety Instructions for Electric Drives and Controls

Dangerous movements! Danger to life, risk of injury, serious injury or property

damage!

A risk assessment must be prepared for the installation or machine, with its

specific conditions, in which the components of the electric drive and control

system are installed.

As a result of the risk assessment, the user must provide for monitoring func‐

tions and higher-level measures on the installation side for personal safety. The

safety regulations applicable to the installation or machine must be taken into

consideration. Unintended machine movements or other malfunctions are pos‐

sible if safety devices are disabled, bypassed or not activated.

To avoid accidents, injury and/or property damage:

● Keep free and clear of the machine’s range of motion and moving machine

parts. Prevent personnel from accidentally entering the machine’s range

of motion by using, for example:

– Safety fences

– Safety guards

– Protective coverings

– Light barriers

● Make sure the safety fences and protective coverings are strong enough

to resist maximum possible kinetic energy.

● Mount emergency stopping switches in the immediate reach of the oper‐

ator. Before commissioning, verify that the emergency stopping equip‐

ment works. Do not operate the machine if the emergency stopping switch

is not working.

● Prevent unintended start-up. Isolate the drive power connection by means

of OFF switches/OFF buttons or use a safe starting lockout.

● Make sure that the drives are brought to safe standstill before accessing

or entering the danger zone.

● Additionally secure vertical axes against falling or dropping after switching

off the motor power by, for example,

– mechanically securing the vertical axes,

– adding an external braking/arrester/clamping mechanism or

– ensuring sufficient counterbalancing of the vertical axes.

● The standard equipment motor holding brake or an external holding brake

controlled by the drive controller is not sufficient to guarantee personal

safety!

● Disconnect electrical power to the components of the electric drive and

control system using the master switch and secure them from reconnec‐

tion ("lock out") for:

– Maintenance and repair work

– Cleaning of equipment

– Long periods of discontinued equipment use

● Prevent the operation of high-frequency, remote control and radio equip‐

ment near components of the electric drive and control system and their

supply leads. If the use of these devices cannot be avoided, check the

machine or installation, at initial commissioning of the electric drive and

control system, for possible malfunctions when operating such high-fre‐

quency, remote control and radio equipment in its possible positions of

normal use. It might possibly be necessary to perform a special electro‐

magnetic compatibility (EMC) test.

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Safety Instructions for Electric Drives and Controls

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