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Electrical Connections

5–1

1070 073 825-103 (02.04) GB

5

Electrical Connections

Please note that, with respect to all electrical connections, the terminal con-
nection plans and work instructions provided by the machine manufacturer
shall always be binding!

The system planner is also charged with providing and planning for the inte-
gration and implementation of required components, such as Emergency-
STOP circuits, mains switches, etc. in accordance with current technical
standards and at the highest levels of safety attainable.

CAUTION
Risk of damage to system components caused by insertion or remo-
val of plug connectors on energized circuits!
Connections must be made only while the system is switched off.

Observe the following to prevent malfunction:

D

Provide for isolated 24 VDC and 0 V terminal strips inside the control ca-
binet. With regard to cable routing, maintain a minimum distance of 10
cm from all power cables.

D

Connect the CPS21and other industrial components (e.g. CNC, PLC) in
such a way that they are always switched on simultaneously.

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Summary of Contents for CPS21_3

Page 1: ...Antriebs und Steuerungstechnik CPS21_3 CPS21_4 Interface Conditions Industrial PC Edition 103 ...

Page 2: ...ions 1070 073 825 103 02 04 GB E 1999 2002 by Bosch Rexroth AG Erbach Germany All rights reserved including applications for protective rights Reproduction or distribution by any means subject to our prior written permission Discretionary charge 6 ...

Page 3: ...2 5 Rechargeable Battery Pack 2 9 2 6 Operating Conditions 2 11 2 7 Applicable Standards 2 12 3 Safety Functions 3 1 3 1 Temperature Monitoring 3 1 3 2 Function of Uninterruptible Power Supply UPS 3 2 3 3 UPS Program 3 4 3 3 1 Function 3 4 3 3 2 Operation 3 5 3 3 3 Parameter settings 3 7 4 Installation 4 1 4 1 Installation Positions and Clearances 4 2 4 2 Dimensioned Drawing 4 4 4 3 Installation w...

Page 4: ...7 Display and Control Elements 7 1 7 1 Display 7 3 7 1 1 Backlight Function 7 3 7 2 Keyboard 7 5 7 2 1 Blocks of Function Keys 7 5 7 2 2 Key Blocks Control 7 6 7 2 3 Key Block Machine 7 6 7 2 4 Number Cursor Control and Special Keys Blocks 7 7 7 2 5 Key Mouse 7 8 7 3 LED Indicators 7 9 7 3 1 Hardware Indicators 7 9 7 3 2 Customer Specific Indicators 7 10 7 4 Front Panel Labeling 7 11 7 5 Keyboard ...

Page 5: ... and or software The products described hereunder D were developed manufactured tested and documented in accordance with the relevant safety standards In standard operation and provided that the specifications and safety instructions relating to the project phase installation and correct operation of the product are followed there should arise no risk of danger to personnel or property D are certi...

Page 6: ...Instructions 1 2 1070 073 825 103 02 04 GB Proper transport handling and storage placement and installation of the product are indispensable prerequisites for its subsequent flawless service and safe operation ...

Page 7: ...d in this instruction manual or indicated on the product may result in serious personal injury or damage to property Installation and maintenance of the products described hereunder is the ex clusive domain of trained electricians as per IEV 826 09 01 modified who are familiar with the contents of this manual Trained electricians are persons of whom the following is true D They are capable due to ...

Page 8: ...3 02 04 GB 1 3 Safety markings on components DANGER High voltage DANGER Corrosive battery acid CAUTION Electrostatically sensitive components Disconnect mains power before opening Lug for connecting PE conductor only Screened conductor only ...

Page 9: ...sonal injury DANGER This symbol is used wherever insufficient or lacking observance of this in struction can result in personal injury CAUTION This symbol is used wherever insufficient or lacking observance of instruc tions can result in damage to equipment or data files This symbol is used to alert the user to an item of special interest L This asterisk symbol indicates that the manual is describ...

Page 10: ...nces may be severe personal injury or damage to equipment or the environment Therefore any system retrofitting or modification utilizing equipment components from other manufac turers will require express approval by Bosch DANGEROUS ELECTRICAL VOLTAGE Unless described otherwise maintenance procedures must always be carried out only while the system is isolated from the power sup ply During this pr...

Page 11: ...uipped for this particular purpose D Employees work surfaces and all devices and tools that could come into contact with EEMs must be on the same potential e g earthed D An approved earthing wrist strap must be worn It must be connected to the work surface via a cable with integrated 1 MW resistor D EEMs may under no circumstances come into contact with objects sus ceptible to accumulating an elec...

Page 12: ...ter PgUp Del D Key combinations pressed simultaneously e g Ctrl PgUp Release The software version of Windows NT may be displayed as follows 1 Click with right mouse key on the My Computer icon on your desktop 2 Select menu item Properties Trademarks All trademarks referring to software that is installed on Bosch products when shipped from the factory represent the property of their respective owne...

Page 13: ...D a membrane keyboard with additional operating and display devices and D a built in high performance industrial PC The CPS21_3 CPS21_4 is distinguished by the following D being largely fail safe e g shock and vibration resistant hard disk sus pension UPS uninterruptible power supply and D simple maintenance The standard operating system Windows NT 4 0 and the Bosch application software are preins...

Page 14: ...ttons is fa stened on each side left and right of the frame in order to provide a user friendly operation On its rear side the PC is fastened to the plastic frame Front panel Display membrane keyboard and the PC which at its rear side is fixed to the plastic frame are fastened to the front panel If the frame and the front panel are swung to the side the display and the hard disk can easily be repl...

Page 15: ...iew CPS21_3 CPS21_4 2 3 1070 073 825 103 02 04 GB CPS21_3 Aluminum housing Handle Handle 13 8 Color TFT Display Keyboard Front panel LEDs Plastic frame PC internal Battery internal Navigation keys Tilt tip adapter ...

Page 16: ...view CPS21_3 CPS21_4 2 4 1070 073 825 103 02 04 GB CPS21_4 Aluminum housing 15 Color TFT Display LEDs Plastic frame PC internal Battery internal Navigation keys Tilt tip adapter Handle Handle Keyboard Front panel ...

Page 17: ...les 128 MB SDRAM Hard Disk 3 2 GB IDE Display 13 8 Color TFT CPS21_3 or 15 Color TFT CPS21_4 with non reflecting and scratch resistant front screen 3 expansion slots PCI ISA 3 0 or 2 1 ex works including 2 PCI cards Power supply 24 VDC UPS uninterruptible power supply via integrated rechargeable battery pack 2 series connected 6 V battery packs Interfaces for detailed information refer to Section ...

Page 18: ...uration Operating system The CPS21_3 CPS21_4 has been equipped and tested with the following operating systems from Microsoft Corp D Windows NT version 4 0 including possibly necessary NT service re leases from Microsoft Corp Utility programs Additionally the following utility program is installed D UPSNT Uninterruptible Power Supply Program for Windows NT is not part of the Windows NT operating s...

Page 19: ...bus slot ISA bus slot Combi nation slot A3 PCI bus slot Slot A1 CAUTION Destruction of an expansion card or the motherboard PCI and ISA cards must never be inserted simultaneously in the PCI ISA BUS combination slot The following expansion cards are used in the CPS21_3 CPS21_4 D PCI CAN card CAN bus interface D PCI_BM CAN card CAN bus interface busmaster interface PCI CAN card on A1 ISA PCI combin...

Page 20: ...d Auto IRQ 3 4 5 7 9 10 11 12 14 15 Default AUTO ISA slot IRQ In the BIOS submenu The Advanced Menu PCI Configuration sub menu PCI PNP ISA IRQ Resource Exclusion IRQx the IRQ Address for Legacy ISA cards ISA cards without plug and play capability can be assigned per manently BIOS selection IRQ 3 4 5 7 9 10 11 15 Option Available Reserved Default Available ISA slot UMB In the BIOS menu The Advanced...

Page 21: ...echarged by means of a charging circuit If the rechargeable battery pack 2 5 Ah is abso lutely empty the charging process lasts 5 hours The number of charging cycles that the rechargeable battery pack can with stand and therefore its useful life depend on the ambient temperature in which the battery pack is used Ambient temperature here is defined as the one in which the operating terminal is situ...

Page 22: ...ry operation can be read off refer to section 3 3 D Charging cycles Number of previously performed charging cycles shutdown count D Checking the battery charge level Presence of a rechargeable battery pack is checked with each system startup e g re chargeable battery pack not defective no cable break positive plug contact D UPS interface COM4 In case of an insufficient level of charge it might be ...

Page 23: ...unlight or other sources of heat radiation Humidity Climate class 3K3 to EN 60721 condensation not permitted Clearances and creeping distances In accordance with prEN50178 11 96 at pollution level 2 Atmospheric pressure Operation at up to 2000 m above sea level to DIN 60204 Degrees of Protection Front panel IP 65 otherwise IP 54 Resistance ll surfaces are resistant to abrasion and media such as D ...

Page 24: ...pply safety isolation D EN 61 131 24 V output requirements D EN 61 131 2 Requirements for 24 VDC power supply D EN 418 Machine safety EMERGENCY OFF devices D EN 60 529 Protection categories incl housings and installa tion compartments D EN 60 721 Classification of environmental conditions D EN 60 068 2 6 Vibration test D EN 60068 2 27 Impact test D IS 114 X ray radiation directive as per Official ...

Page 25: ...re war ning is issued D via the red flashing LED TEMP on the front panel of the operating termi nal D via a window displayed by the operating system This message must be interpreted by all application programs as well especially by I O processes Bosch application programs comply fully with this requirement The temperature warning function can be disabled via the program D UPSNT for Windows NT 4 0 ...

Page 26: ...e UPS is not designed ho wever to maintain the operation over a longer period of time DANGER In the event that rechargeable batteries are found to be missing de fective or in a discharged condition a voltage dip exceeding 20 ms will trigger a RESET of the CPS21 without prior warning Possible consequences might be uncontrolled machine movements and loss of data Users are advised to check the rechar...

Page 27: ...stem startup Operating voltage interrupted for 8 seconds t t V not loaded loaded standard operation Operating system Mains voltage failure Mains voltage available Shutdown of the operating system Delay Time adjustable Power failure interval exceeding 60 sec When approx 60 seconds have elapsed the UPS will internally de energize the power supply t0 t1 800 ms t4 t1 60 sec UPS de energizes power supp...

Page 28: ...itoring function has responded the system shut down can no longer be avoided Closing down all active applications prevents loss of data in case of sudden power failure After a maximum of 60 seconds the UPS shuts down the CPS21_3 CPS21_4 power supply unit if the mains voltage has not yet returned refer to section 3 2 Function of uninterruptible power supply CAUTION Restarting the system manually le...

Page 29: ... or restarting the service e g for new installa tion or update select Services from the Control Panel window see the following illustration left of UPSNT Control In the Services window of Windows NT the status of the UPSNT Service is displayed D UPSNT stopped Status column is empty D UPSNT started Status column displays Started Start and stop the selected entry UPSNT Service with the Start and Sto...

Page 30: ... UPS NT Control from the Control Pa nel window see below The dialog UPS NT Configuration determines the start and runtime beha vior of UPS control The individual values of the configuration are stored in the Registry The pa rameters can be changed at any time After modifying the parameters the UPS program must be stopped and restarted in order to become operative This can be achieved by restarting...

Page 31: ...g enough to shut down the operating system close all Windows system files and make backups If the period of time chosen is too short the shut down process is interrupted because the UPS interrupts the power supply of the CPS21_3 CPS21_4 This might lead to data loss CAUTION On expiry of the Delay Time the operating system is shut down wi thout further notice Data from open application programs that...

Page 32: ...at the checkbox is deac tivated during normal operation CAUTION Loss of data If this checkbox is activated a regular shutdown of the operating sy stem is not possible after a voltage breakdown The CPS21_3 CPS21_4 shuts down immediately Info Shutdown count The displayed value shows how often the system was shut down by UPS i e how many charging cycles the battery has been subjected to More details ...

Page 33: ...rrosives salts metallic vapors etc Note D The use of silicon based sealing compounds adhesives and insulating agents is prohibited D Ensure that the installation is easy to maintain i e that it provides unrestricted access to connecting cables and fuses D Prior to installation please write down the information on equipment rating plates In the event that rating plates are hidden from view as a res...

Page 34: ...tom mounting device Top mounting device 100 100 100 D Install the CPS21 control panel ensuring that it can be operated ergono mically In addition the operator must be provided with a permanent and unobstructed line of sight to moving machine parts D To prevent reduced screen readability and additional thermal load avoid installation locations that are exposed to direct sunlight D The LEDs on the f...

Page 35: ...cooling of CPS21 100 mm min to all sides D for maintenance procedures on the PC 400 mm min in front of front pa nel opening angle max 1205 Opening angle max 1205 min 400 mm CAUTION Excessive operating temperature Please do not expose the housing of the CPS21 to direct sunlight or other sources of heat radiation ...

Page 36: ... 103 02 04 GB 4 2 Dimensioned Drawing 432 509 151 5 383 Housing lock 5 double bit key 177 Housing bottom Front view CPS21_3 Aluminium housing with cooling fins Handle bar plastic Plastic frame Housing top 432 509 Front view CPS21_4 ...

Page 37: ... opening 70 mm in diameter with 4 bores 5 mm in diameter for fastening the tip tilt adapter and through which all cables are led into the housing The opening that is not used is covered with a rectangular cover plate Ex works the bottom opening is covered A A 64 64 362 383 151 5 6 Bm5 4X Bm5 6x A A 23 70 Bezel 4 x 45_ Housing Installation opening The flange for the suspended or floor installation ...

Page 38: ...upper opening L Open the housing with a 5 mm double bit key and swing out the PC L Insert the cables that lead to the PC and the distribution card through the opening L Fasten the tip tilt adapter of the swivel arm or the stand to the opening with 4 screws Make sure the connection is impermeable IP54 L Connect all cables with the corresponding plugs on the PC and the distribu tion card L Close the...

Page 39: ...S21 housing and fasten the CPS21 Coolkit with the new cover from the accessory kit to the base plate from below see diagram New cover from the accessory kit with 4 threaded holes Screw holes not used View of CPS21 from below with Coolkit in place Plastic frame CPS21 side view with Coolkit in place Coolkit New cover CPS21 base plate with outlet PC box L Screw the Coolkit on using the 4 long screws ...

Page 40: ...y into new cover CPS21 base plate Á Á Á Coolkit ÁÁ ÁÁ ÁÁ New cover with 4 threaded holes CPS21 housing opened L The 6 screw holes not used on the bottom of the Coolkit can be covered from below with stoppers from the accessory kit L Instructions for making the electrical connections to the Coolkit are in section 6 4 ...

Page 41: ...ches etc in accordance with current technical standards and at the highest levels of safety attainable CAUTION Risk of damage to system components caused by insertion or remo val of plug connectors on energized circuits Connections must be made only while the system is switched off Observe the following to prevent malfunction D Provide for isolated 24 VDC and 0 V terminal strips inside the control...

Page 42: ...cted to the mounting plate with max 20 cm long adequately di mensioned copper straps Arrange the PE lines so that the length of the outgoing protective earth con ductor connections to the individual modules in the control cabinet does not exceed 1 m L When specifying the PE wiring ensure sufficiently dimensioned cross sec tion In this regard also observe EN 60204 Part 1 max electrical resistance a...

Page 43: ...ence suppression all of these components should be taken into consideration because they are most effective when working in conjunction with each other In principle interference suppres sion should be implemented as follows D Apply suppression measures as close to the source of interference as possible D Use only components that are identified as interference suppressors D Limit leakage currents i...

Page 44: ...contacts residual current when contact open to c Voltage dependent resistance residual current when contact open Suppression of an inductive load Motors solenoid relay and contactor coils R C R a b c d VDR D D ZD e U VDR C to c For relay drop off delay to d For relay defined drop off delay to e Must be optimized for inductance Suppression example mains input M L1 N SL M L1 Cy SL Cx Cx L2 L3 Cx Cx ...

Page 45: ...se position refer to page 6 3 Reverse voltage protection via decoupling diode Polarity reversal will blow input fuse DANGEROUS ELECTRICAL VOLTAGE The 24 VDC input voltage must fulfill the requirements of Safety Iso lation Offset AC components of the type produced by an unregulated 3 phase cur rent bridge circuit without smoothing with a ripple factor of 5 refer to DIN 40110 10 75 Section 1 2 are p...

Page 46: ...opper straps of a length not exceeding 200 mm The cross section of the copper straps must equal at least that of the supply cable 3 0 5 mm2 up to 4 meters 0 75 mm2 up to 6 meters 1 5 mm2 up to 10 meters Distances in excess of 10 m require separate power supply close to load Terminals in insulated design PE A 102 green yellow 2 A B A Terminal row 42 B Terminal row 102 Max length 4 m 62 1 blue PE L1...

Page 47: ...le DB 9 bus connector IP 20 Comnet DP bus system P X59 optional serial port RS422 485 unused alternative to RS232 cf COM1 no plug available because op tional male DB 9 Female DB 9 connector P COM1 Serial port RS232 UART 16550 free alternative optional RS485 422 cf X59 Male DB 9 connector Female DB 9 connector P COM2 Serial port RS232 UART 16550 free Male DB 9 connector Female DB 9 connector P COM3...

Page 48: ...k data connector PE conductor lug Floppy disk power supply accessible through opening in housing Floppy disk data connector accessible through opening in housing Battery connection X75 X76 X19 Batter y Side view side of hinges Supply and distribution circuit board DP ADR DIP SEL COM3 DIP Rear covering plate Carrier board Supply and distribution circuit board Rear view X28 X24 X27 X29 X25 X26 ...

Page 49: ...ns 6 3 1070 073 825 103 02 04 GB PC and PCI Expansion Cards Interfaces Fuse Side view from right 24 VDC connector PE conductor lug PCI CAN Card PCI_BM CAN Card CAN X71 Busmaster X72 CAN for PCL X71 24 V fuse M6 3A unscrewable ...

Page 50: ...as follows D 24 VDC supply voltage of CPS21 D all buttons on the front panel START STOP EMERGENCY OFF D key codes of the front panel X24 X27 X25 X26 1 1 1 1 2 4 4 8 8 7 6 5 4 3 2 1 4 3 2 1 4 3 2 1 2 1 24 V Lamp in START button Connector START key 24V 0V 0V 24V 24V 0V 0V 24V 24V 0V Assignment Connection EMERGENCY OFF and OFF button for connection in series 1st path Connection EMERGENCY OFF OFF reco...

Page 51: ...and substantial material dama ges Please integrate the EMERGENCY OFF button of the CPS21 into the EMERGENCY OFF circuit as well X28 X28 X29 1 1 8 8 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 24VOut Bit1 24VOut Bit2 24VOut Bit3 24VOut Bit4 24VOut Bit1 24VOut Bit2 24VOut Bit3 24VOut Bit4 Pin Assignment Distributor Keys Codes Supply and distribution circuit board Internal connection of 24 Vout X29 ...

Page 52: ...2 04 GB Overview of connections ex works X26 to X10_1 24 VDC connector X28 to connector 24 V out Connector 24Vout with cable Connector X10_1 24 VDC with cable Cable 10 mm2 to PE lug front panel and housing X27 fan power supply X26 X27 X28 X25 X24 X29 ...

Page 53: ...tion card X25 1 4 X24 3 1 X29 1 8 X31 1 4 X32 1 4 3 2 1 24 V Lamp in START button Connector START key Assignment Pin X24 4 3 2 1 X27 4 3 2 1 X26 24V 0V 0V 24V X28 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 24VOut Bit1 24VOut Bit2 24VOut Bit3 24VOut Bit4 24VOut Bit1 24VOut Bit2 24VOut Bit3 24VOut Bit4 Distributor Keys Codes Internal connection of 24 Vout X29 24VOut Bit5 24VOut Bit6 24VOut Bit7 24VOut Bit8 24V...

Page 54: ...xisting 4 conductor cable between the X26 plug and the X10_1 connecting plug by a 2 conductor cable 2 x 0 752 The cable is connected on the one side to the X26 Pin 2 24 V and X26 Pin3 0 V and on the PC side to the X10_1 Pin 2 24 V and X10_1 Pin 3 0 V Alternatively it is also possible to clamp off the two wires that are not needed on the existing 4 conductor cable L Connect the Coolkit s red connec...

Page 55: ...ngth Max 0 5 m Cable type 34 conductor ribbon cable screened Interrupt IRQ empty I O address 300H BIOS preset Floppy disk controller Enabled in the I O Device Configuration submenu X75 Pin Assignment 1 3 GND 1 34 5 GND 7 9 11 13 15 17 19 21 23 25 27 29 31 33 GND GND GND GND GND GND GND GND GND GND GND GND GND GND GND 2 4 Density Select 6 N C 8 10 12 14 16 18 20 22 24 26 28 30 32 34 N C Index Motor...

Page 56: ...provide for connections with proper conductor alignment L The power supply for the floppy disk drive must also be connected This is accomplished by connecting the connecting cable on the floppy disk drive 4 pin plug connector to the X76 power supply connector L If the system does not recognize the floppy disk drive the latter must be acti vated in the I O Device Configuration BIOS submenu by chang...

Page 57: ...X TX 4 COM1 Screen applied to metal shell of DB 9 plug connector 5 GND 6 7 8 9 RI DTR DSR RTS CTS 1 5 6 9 Assigned as RS 232 COM1 DCD Data Carrier Detect RCV channel used for example by a con nected modem to inform the PC that it is receiving a carrier signal active connection RX Receive Data Line on which data is received TX Transmit Data Line on which data is transmitted to peripheral DTR Data T...

Page 58: ...etallic shell of the D Sub connector COM2 Serial port freely assignable Male DB 9 connector Type RS232 Cable length Max 15 m Cable type Screened min cross section 0 14 mm2 Transmission rate Max 115200 bps Handshake Hardware and software handshake XON XOFF Interrupt IRQ 3 I O address 2F8H or AUTO recommended BIOS preset Serial Port B Enabled To peripheral devices 1 2 3 DCD RX TX 4 COM2 Screen appli...

Page 59: ...pply UPS and thus only available for external applications if an uninterruptible power supply is not required The interface plug is covered by a hood USB Serial interface Universal Serial Bus currently not supported The USB interface provides for the connection of up to 128 devices equipped with USB functions USB socket 4 pin 1 2 3 USB_P 4 USB USB device USB2 USB_M USB Screen applied to metal shel...

Page 60: ...r assignment If you desire direct parameter assignment you should adopt the following settings D COM1 3F8H D COM2 2F8H Ex works the settings for COM3 and COM4 are preset to not available Disabled The modification of BIOS settings is discussed in the manual entitled BT150 BT200 BT215 and CPS21_3 Software Configuration Modi fications are necessary only in the event that changing the default set ting...

Page 61: ...in 19 GND 20 21 GND 22 23 24 25 GND GND GND GND GND Write Data0 Intr Wait n u Datastb GND n u n u n u Addrstrb GND GND GND GND GND GND GND Data1 Data3 Data7 Data2 Data4 Data5 Data6 Data1 Data3 Data7 Data2 Data4 Data5 Data6 To peripheral device LPT1 The parallel port normally runs in the default SPP mode Provided that suita ble peripheral devices are present it can also be operated in EPP Enhan ced...

Page 62: ...erface connection please follow the instructions of the manufacturer New settings in the operating system and or BIOS may be necessary The following CD ROM drive with parallel interface connection may be used Type CD Jet SL Multiport CD ROM drive parallel port Manufacturer Multiport Computer Systeme GmbH Ruselstr 84 D 94469 Deggendorf ...

Page 63: ... Type Ethernet 10 100BaseTX Cable length Max 100 m Cable type Screened twisted pair Transmission rate 10 or100 Mbit s Interrupt IRQ 5 I O address 340H 1 2 3 TXD TXD 4 Ethernet 5 RXD 6 RXD 7 8 max 100 m To network Ethernet RJ45 1 8 The driver configuration of the network connection can be called up in the task bar or in Control Panel with the icon Network Interface card Here it is possible to set t...

Page 64: ...D Screen applied to metal shell of DB 9 plug connector 6 7 8 RED GND GREEN GND 9 10 BLUE GND Digital GND 11 12 13 ID0 ID1 14 15 Hsync Vsync ID3 VGA Video Adapter CRT Resolution and colours for the VGA port can be selected in the Control Panel of the operating system The following standard resolutions can be used with a minimum refresh rate of 72 Hz D VGA mode 640 x 480 pixels 72 Hz 256 colors D SV...

Page 65: ...ecifications applying to your CRT or LCD monitor and adapt the operating system parameters accordingly Recommended monitors for external use are low radiation models to TCO95 In addition you should achieve the desired display resolution at a refresh rate of no less than 72 Hz The insertion of a graphics card disables the integrated video adapter ...

Page 66: ... must be activa ted by changing the BIOS setting from Absent to Present Keyboard adapter In the event that the MF2 keyboard is equipped with a standard 5 pin DIN plug you will require a keyboard plug adapter to a female PS 2 Mini DIN con nector A suitable adapter is approx 20 cm in length with a DIN connector and a mini DIN coupling on the ends Connector assignment as per diagram below These prema...

Page 67: ...een applied to metal shell of DB 9 plug connector Screen 2 1 4 3 6 6 5 Mouse In the event that the system fails to recognize the PS 2 mouse it must be activated by changing the BIOS setting from Absent to Present A subsequent connection of the external mouse will not be recognized by the operating system because initialization is only possible during booting The connected mouse must be PS 2 compat...

Page 68: ...nsferred to out puts of the 24 Vout port From here the key codes are transferred over the already existing wiring to the X28 plug on the connection and distribution card refer to section 6 3 At this point they can be read for further proces sing via an external input node Female DB 15 Cable length Max 20 m Cable type Screened min cross section 0 14 mm2 1 2 Screen applied to metal shell of DB 9 plu...

Page 69: ...ing bus sy stems Name Bus system PCI_BM CAN CAN bus PCI_BM IBS InterBus S PCI_BM DP PROFIBUS DP X71 CAN Bus PCI_BM CAN Male DB 9 connector Type CANopen bus Cable length depending on baud rate max 25 m with 1 Mbit s Cable type Screened min cross section 0 14 mm2 Transmission rate up to 1 Mbit s CAN bus 1 2 3 reserved CAN_L GROUND_ISO 4 Screen applied to metal shell of DB 9 plug connector 5 CAN SHIE...

Page 70: ...0178 InterBus S 1 2 3 DO DI GND ISO 4 Screen applied to metal shell of DB 9 plug connector 5 5V ISO 6 7 8 9 GND DO DI 1 5 6 9 X71 5V X71 InterBus S Please comply with the installation instructions and recommenda tions of Phoenix Contact e g IBS SIG Part 1 UM or the IBS SYS INST UM installation manual X72 This interface is not used ...

Page 71: ...tion 0 14 mm2 1 2 Screen applied to metal shell of DB 9 plug connector 3 File 4 5 Repeater GND ISO 6 5V ISO 7 8 Data 9 Repeater RS 485 signal RS 485 signal TTL signal for repeater control GND for repeater P Voltage supply for repeater 5 V 100 mA ISO GND X71 PROFIBUS DP External PROFIBUS DP node Meaning Receiving Transmitting S data P Repeater control signal P Receiving TransmittingS data N Repeate...

Page 72: ...e PC X71 CAN bus Male DB 9 connector Type CAN Bus Cable length depending on baud rate max 25 m with 1 Mbit s Cable type Screened min cross section 0 14 mm2 Transmission rate up to 1 Mbit s CAN bus 1 2 3 reserved CAN_L GROUND_ISO 4 Screen applied to metal shell of plug connector 5 CAN SHIELD 6 7 8 9 CAN_24V reserved CAN_GND CAN_H reserved 1 5 6 9 X71 X71 CAN ...

Page 73: ...he following display and control components D Display D Membrane keyboard D Buttons for START STOP and EMERGENCY OFF D LED displays D Insertion labels for front panel D Keyboard controller CPS21_3 Front Rear 13 8 Color TFT Display LEDs Plastic frame PC internal Battery intern al Navigation keys Handle Handle Keyboard Front panel ...

Page 74: ...nd Control Elements 7 2 1070 073 825 103 02 04 GB CPS21_4 Aluminum housing 15 Color TFT Display LEDs Plastic frame PC internal Battery internal Navigation keys Tilt tip adapter Handle Handle Keyboard Front panel ...

Page 75: ...light provides the background illumination for the LCD display As its service life is limited only 50 of its original brightness will remain after approx 15 000 operating hours Refer to section 8 2 2 for information about replacing the backlight unit To extend the service life of both display and backlight tube the flat screen display features a timer sleep function for the backlight This function...

Page 76: ...following key blocks belong to those keys whose function can be pro grammed by means of the application program D 8 keys arranged horizontally below the display e g for the softkey functions customary in industry Description of this key row F1 F8 D 4 keys F9 F12 arranged horizontally below the F1 F8 function key block Description of this key row provided by the user description tags D 2 x 3 naviga...

Page 77: ...ontain 16 keys 14 of which are provided with an integrated LED Keypad Control 1 Keypad Control 2 Keypad Control 3 7 2 3 Key Block Machine The key block Machine contains the following keys D START button white illuminated D STOP button black D EMERGENCY OFF red complying with the requirements of EN 418 START STOP EMERGENCY OFF ...

Page 78: ...21_3 Special keys Key mouse For easy operation the keys are divided into blocks D Number block 15 keys D Numbers 0 to 9 Esc Escape Tabulator Return D Cursor block and key mouse 7 keys D Cursor keys right left up down D Key mouse activate deactivate mouse mouse key right and left D Special keys 7 keys D Page up to beginning of page Page dn to end of page Shift capital small letters Alt Alternate Ba...

Page 79: ...ovement RIGHT left mouse button right mouse button Mouse movement Diagonally to upper left Mouse movement Diagonally to upper right Mouse movement Diagonally to bottom right Mouse movement Diagonally to bottom left Mouse movement UP If the key mouse is active the cursor keys are not available If an external mouse is connected before start up or after RESET it is reco gnized automatically and the k...

Page 80: ...k the supply vol tage at the power sup ply unit VOut LED green Standard operation LED off Internal voltage 5V 12V not available Check the supply vol tage at the power sup ply unit HD LED yellow Access to hard disk Temp LED off Standard operation LED flashes red Internal housing temperature exceeds 50 C Shutdown will occur if temperature conti nues to rise Lower ambient tempe rature Check fan of PC...

Page 81: ...e as the interfaces Button Initiates rebooting process of PC LED red RESET button is pressed 7 3 2 Customer Specific Indicators 8 LEDs at the upper rim of the CPS21_3 and CPS21_4 are provided for cu stomer specific indications 7 LED indicators yellow CPS21_3 Space for LED description 1 LED indicator red 7 LED indicators yellow CPS21_4 Space for LED description 1 LED indicator red ...

Page 82: ...e of front panel D programmable key blocks Control 1 3 D integrated buttons The openings for inserting the label cross section 2 5 x 12 0 mm are loca ted below the handlebars and are therefore sealed from the outside Insertion label View A A A A Opening for insertion label in the membrane cross section 2 5 x 12 0 mm Handlebar dismounted Handlebar dismounted 6 vertical bores each for fastening hand...

Page 83: ...art the system Make sure that the labels can be read easily CAUTION Incorrect labeling may lead to false operation Make sure that the descriptions on the labels correspond to the func tions of the described keys and LEDs Dimensions of the labels The label is made of plastic or laminated paper It can also be written on in a normal printer The height of the readable section is max 8 mm 8 Space for d...

Page 84: ...tion program can be further processed over the X28 connection Transferring Key Codes to the PC via MF2 The MF2 codes are available in the standard design in the first input byte and are passed on from the controller to the PC refer to the assignment table on page 7 14 Transferring Key Codes to the 24 V out outputs Bit 1 corresponds to the low order bit Pressed navigation buttons and cursor mouse k...

Page 85: ... H10 H11 H12 H13 H01 H02 H03 H04 H05 S09 S10 S11 S12 S13 S14 S01 S02 S03 S04 S05 S07 S08 S06 S15 S16 S18 S19 S20 S21 S22 S23 S24 S15 S25 S26 S28 S29 S30 S31 S32 S33 S34 S27 S35 S36 S38 S39 S40 S41 S42 S43 S37 S44 S45 S46 S47 S48 S49 S50 S51 S52 S54 S55 S56 S57 S58 S53 S59 S60 S61 S62 S63 S64 S65 S66 ...

Page 86: ...T2 S13 CRTL R Yes Bit2 ST2 S14 CRTL D Yes Bit3 ST2 S15 Yes Bit1 RF15 S16 Yes Bit2 RF15 yellow S17 F9 Yes RF15 S18 F10 Yes RF15 S19 F11 Yes RF15 S20 F12 Yes RF15 S21 Bit3 RF15 yellow S22 Bit4 RF15 yellow S23 Bit5 RF15 yellow S24 Bit6 RF15 yellow S25 Bit7 RF15 yellow S26 Bit8 RF15 yellow S27 Bit9 RF15 yellow S28 Bit10 RF15 yellow S29 Bit11 RF15 yellow S30 Bit12 RF15 yellow S31 Bit13 RF15 yellow S32 ...

Page 87: ...6 Cursor up Mouse up Yes Bit4 RF15 S47 4 Yes RF15 S48 5 Yes RF15 S49 6 Yes RF15 S50 Tab Yes RF15 S51 Shift Yes RF15 S52 Del Yes RF15 S53 Cursor left Mouse left Yes RF15 S54 Cursor right Mouse right Yes RF15 S55 1 Yes RF15 S56 2 Yes RF15 S57 3 Yes RF15 S58 Enter Yes RF15 S59 CRTL I Yes RF15 S60 Cursor down Mouse down Yes Bit4 RF15 S61 Yes RF15 S62 0 Yes RF15 S63 RF15 S64 START Rafix 16 24 V glow S6...

Page 88: ...RF15 Spot yellow S27 B Bit15 RF15 Spot yellow S28 B Bit16 RF15 Spot yellow S29 B Bit17 RF15 Spot yellow S30 B Bit18 RF15 Spot yellow S31 B Bit19 RF15 Spot yellow S32 B Bit20 RF15 Spot yellow S33 B Bit21 RF15 Spot yellow S34 B Bit22 RF15 Spot yellow S38 B Mouse active inactive Bit23 RF15 Spot yellow Communication with the PC is done via COM3 with special telegrams The PC sends a lamp telegram to th...

Page 89: ... next lamp telegram 7 5 3 Customer defined Assignment of Key Codes The keycodes can be changed dynamically The following keyboard characteristics can be entered as codes D Meaning of key e g A 3 D Position of the key within the keyboard field D Output of position and meaning of keys to the 24 Vout outputs You can receive further information in this regard on request DANGER An incorrect assignment ...

Page 90: ...Display and Control Elements 7 18 1070 073 825 103 02 04 GB Notes ...

Page 91: ...t least once a year check that all plug and socket and terminal connec tions of the components are correctly seated and not damaged Check that cables are not broken or crushed Replace damaged parts immedia tely D Check the screwed connection for suspended installation connection between tip tilt adapter and housing cover of CPS21 once per year D Make sure that the CPS21 is equipped with a well fun...

Page 92: ... up all essential application data and system operating configura tions to an external data carrier or by using the network connection 2 Turn off the supply voltage If necessary unplug all cables 3 Wait until the power supply unit shuts down automatically after UPS ope ration the UPS LED on the front of the CPS21 is red until the UPS shuts down the power supply unit 4 Open the aluminum housing wit...

Page 93: ...emble the components in the reverse sequence to that described above Once the plug connector has been reinstalled the ribbon cable must again be secured with a dab of hot glue at both sides When remounting the hard disk make sure that cables especially those between display and PC housing are not flattened or squeezed Testing the new component 10 If the new hard disk is of the same type as the old...

Page 94: ... PC housing Holding fixture for hard disk Mounting screw for fastening the hard disk holding fixture Clamping joints for fastening the hard disk holding fixture First pull fixture down then turn it outwards Controller ribbon cable disconnected from hard disk View PC pulled down side facing display PC holding fixture ...

Page 95: ...nverter Display rear LCD mounting frame LCD ribbon cable Inverter cable to the LCD connector motherboard of the PC 4 fastening screws LCD mounting frame CPS21 Rear of display PC housing dismounted Fastening screws for PC housing Fastening screw for safety chain Plug connector Inverter cable 1 Switch off the supply voltage If necessary unplug all cables 2 Wait until the power supply unit shuts down...

Page 96: ...ting it out of the lower swing bearings of the plastic frame 8 Unfasten the 4 fastening screws of the LCD mounting frame Now you can pull out the display and its holding fixture 9 It is also possible to replace only the two backlights 10 Reassemble the components in the reverse sequence to that described above When remounting the hard disk make sure that cables especially those between display and...

Page 97: ...g the PC power supply unit on and off As long as the control terminal is connected to mains power a deep di scharge of the rechargeable battery pack is prevented The number of charging cycles that the rechargeable battery pack can with stand and therefore its useful life depends on the ambient temperature in which the battery pack is used Ambient temperature here is defined as the one in which the...

Page 98: ... If necessary unplug all cables 2 Wait until the power supply unit shuts down automatically after UPS ope ration the UPS LED on the front of the CPS21 is red until the UPS shuts down the power supply unit 3 Open the aluminum housing with a 5 mm double bit key and swing the front panel and its frame to the side 4 Open the rear cover of the PC housing 5 Remove the male connector with the twin conduc...

Page 99: ...e to that described above If the new battery pack has not yet been charged for 2 5 Ah approx 5 hours charging time the UPS protection against an uncontrolled shutdown of the PC is not sufficient during the charging time There fore use only fully charged batteries if possible Testing the new component 9 Restart the system 10 Observe the UPS indication on the front panel If the batteries are al read...

Page 100: ...Maintenance and Replacements 8 10 1070 073 825 103 02 04 GB Notes ...

Page 101: ...1 1070 078 905 1070 080 379 1070 083 813 Hard disk in mounting frame with out software 1070 081 537 LCD display TFT 13 8 2 back lights included 1070 919 799 LCD display TFT 15 2 backlights included 1070 920 377 Backlight 1070 920 285 Front panel with buttons and con nection card without display 1070 921 870 1070 919 675 Pushbuttons each consisting of base and button button for STOP button for EMER...

Page 102: ...Spare Parts 9 2 1070 073 825 103 02 04 GB Notes ...

Page 103: ...rds etc FD Floppy Disk GB Gigabyte HD Hard Disk ISA Industrial Standard Architecture PC bus system IDE Integrated Device Electronics interface for hard disk CD ROM etc KBD Keyboard LCD Liquid Crystal Display flat panel display LPT Line Printer Terminal printer port MB Megabyte PCI Peripheral Component Interconnect PC bus system PE Protective Earth PLC Programmable Logic Controller RAM Random Acces...

Page 104: ...1 Documentation 1 8 E earthing wrist strap 1 7 EEM 1 7 Electrical Connections 5 1 Electrostatically endangered modules 1 7 EMERGENCY OFF 6 4 Emergency OFF devices 1 6 Ersatzteile 9 1 ESD protection 1 7 ESD work stations 1 7 Ethernet connection 6 17 Expansion Cards PCI CAN 2 7 PCI_BM CAN 2 7 BIOS Setup 2 8 External monitor 6 18 F Floor mounting 4 5 Floppy disk Connection 6 9 floppy disk drive 1 8 F...

Page 105: ...assignment COM1 4 USB 6 11 LPT1 6 15 Power supply 5 5 PROFIBUS DP connector 6 22 Protection categories 2 11 PS 2 keyboard connection 6 20 PS 2 mini DIN to MF2 keyboard adapter 6 20 PS 2 mouse connection 6 21 Q Qualified personnel 1 3 R Receiving telegram 7 16 Rechargeable Battery Pack 8 7 Rechargeable battery pack 2 9 Charge level 2 10 Charging function 2 9 Release 1 8 Replacements Backlight Inver...

Page 106: ...Annex A 4 1070 073 825 103 02 04 GB ...

Page 107: ...utomationstechnik Antriebs und Steuerungstechnik Postfach 11 62 D 64701 Erbach Fax 49 0 60 62 78 4 28 1070 073 825 103 02 04 GB HB PC BRC EPY Printed in Germany USA Robert Bosch Corporation Automation Technology Division Fluid Power Products 7505 Durand Avenue USA Racine Wisconsin 53406 Fax 414 5 54 81 03 Robert Bosch Corporation Automation Technology Division Factory Automation Products 816 East ...

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