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Electrical Connections

5–1

1070 073 822-104 (02.06) 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 in-
tegration and implementation of required components, such as
Emergency-STOP circuits, mains switches, etc., in accordance with the cur-
rent state of the art and at the highest level of safety attainable.

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

Observe the following to prevent functional failures:

D

Provide for isolated 24 VDC and 0 V terminal bars inside the control cabi-
net. With regard to cable routing, maintain a minimum distance of 10 cm
(4 in.) from all power cables.

D

Design the overall system power circuits in a manner ensuring the simul-
taneous startup of operating terminals and other industrial components,
such as CNC and PLC.

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Summary of Contents for IPC

Page 1: ...Antriebs und Steuerungstechnik IPC IPC300 Connectivity Manual Industrial PC 104 Edition ...

Page 2: ...l 1070 073 822 104 02 06 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: ...onditions 2 4 2 6 Standards compatibility 2 5 3 Security Functions 3 1 3 1 Temperature monitoring function 3 1 3 2 Uninterruptible power supply UPS 3 2 3 3 UPS program 3 4 3 3 1 Functions 3 4 3 3 2 Operating and configuring UPSplus Windows95 3 5 3 3 3 Operating and configuring UPSNT WindowsNT 3 9 4 Installation 4 1 4 1 Installed positions and clearances 4 2 4 2 IPC IPC300 dimensioned drawings 4 3 ...

Page 4: ... and Replacement 8 1 8 1 Fuse protection 8 2 8 2 Replacing the hard disk 8 4 8 2 1 Replacing the CD ROM drive 8 6 8 2 2 Replacing the 3 5 floppy disk 8 7 8 2 3 Replacing the battery pack 8 9 8 3 Expansion cards 8 12 8 3 1 Installing an expansion card 8 12 8 3 2 BIOS settings for IPC 8 14 8 3 3 BIOS settings for IPC300 8 14 9 Software 9 1 9 1 BIOS software 9 1 9 2 Operating system and utilities 9 1...

Page 5: ...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 certified to be in full compliance with the requirements of the D COUNCIL DIRECTIVE 89 336 EEC o...

Page 6: ... in serious personal injury or damage to property Installation and maintenance of the products described hereunder are the exclusive 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 their professional training skills and expertise and based upon the...

Page 7: ...4 02 06 GB 1 3 Safety markings on components DANGER High voltage DANGER Corrosive battery acid CAUTION Electrostatically sensitive devices ESD Disconnect mains power before opening Lug for connecting PE conductor only Screened conductor only ...

Page 8: ...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 9: ...ces 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 shall require express approval by Bosch Rexroth 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...

Page 10: ... for this particular purpose D Personnel work surfaces and all devices and tools that could might come into contact with ESDs 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 ESDs may under no circumstances come into contact with objects sus ceptible to accumulating an elec...

Page 11: ...ys e g Enter PgUp Del D Key combinations pressed simultaneously e g Ctrl PgUp Release Information on the software version for Windows95 or WindowsNT can be obtained by 1 Clicking with the right mouse button on the My Computer icon Workplace on the desktop 2 Select Properties menu option Trademarks All trademarks referring to software that is installed on Bosch Rexroth prod ucts when shipped from t...

Page 12: ...Safety Instructions 1 8 1070 073 822 104 02 06 GB Notes ...

Page 13: ...failure resistance e g shock and vibration proof cushioned hard disk UPS uninterruptible power supply and D Simple maintenance In accordance with requirements the IPC IPC300 is supplied with installed Microsoft Windows 95B or Windows NT4 0 operating system and appropri ate Bosch Rexroth application software refer to Section 9 3 2 1 Versions The IPC and IPC300 are available in two equipment version...

Page 14: ...utdown 4 LEDs Display of essential operating statuses Display of essential operating statuses Standard interfaces 4x serial RS 232 of which 1x optional RS 485 422 1x parallel PS 2 keyboard PS 2 mouse VGA 4x serial RS 232 of which 1x optional RS 485 422 1x parallel PS 2 keyboard PS 2 mouse VGA Enhanced interfaces Ethernet LVDS video transmission touch screen signals via COM2 power supply for contro...

Page 15: ...d by authorized specialists For more information on installing expansion cards refer to Section 8 3 2 4 Rechargeable battery pack The IPC and IPC300 feature an integrated rechargeable battery pack 2 series connected 6V batteries In the presence of a power failure the battery pack facilitates a controlled and safe shutdown of the PC operating system as described in Section 3 2 UPS Functions Loss of...

Page 16: ...ve humidity Climate class 3K3 as per EN 60529 condensation not permitted Atmospheric pressure To DIN 60204 when operating at altitudes up to 2000 m above sea level Protection Category ratings IP00 Control cabinets and installation compartments for the control panels must conform to IP 54 rating dust filters upstream of air intake and exhaust CAUTION Conditions hazardous to the product The ambient ...

Page 17: ...otective se paration D EN 60 950 Overvoltage category II D EN 61 131 Requirements w respect to 24 V outputs D EN 61 131 2 Requirements w respect to 24 V power supply D EN 418 Machine safety Emergency STOP devices D EN 60 529 Protection categories incl housings and instal lation compartments D EN 60 068 2 6 Vibration test D EN 60 068 2 27 Impact test D IS 114 X ray Radiation Directive as per Offici...

Page 18: ...IPC System Overview 2 6 1070 073 822 104 02 06 GB Notes ...

Page 19: ...message window displayed by the operating system This message must also be interpreted by all PC applications and by I O processes in particular Bosch Rexroth application programs are in full compliance with this requirement The descibed temperature monitor can be disabled by means of the follow ing program D UPSplus for Windows 95 D UPSNT for Windows NT 4 0 See also Section 3 3 If temperatures in...

Page 20: ...d never cycle the power more often than 4 times in succession The battery pack must again be fully recharged thereafter D The UPS locgic function requires hard disk capacity for intermediate datza storage Ensure that the hard disk never fills up completely D Check and verify whether or not the preset Delay Time of 30 seconds selected in the UPS Dialog window will allow the safe shutdown of all ap ...

Page 21: ...0 sec t3 t2 8 sec Shutdown of the application program Operating system startup Operating vol tage interrupted for 8 seconds t t V not loaded loaded standard operation Operating system Mains voltage failure Mains voltage available Operating system shutdown Delay Time adjustable Voltage interruption in excess of 60 seconds After approx 60 sec the UPS internally switches off the power supply t0 t1 80...

Page 22: ...cial application routines D By following the expiration of the Delay Time by shutting down the operat ing system Once the UPS power monitoring function has been triggered aborting the system shutdown routine is no longer possible Closing all active applications prevents data loss in the event of a sudden voltage interruption If the mains voltage has not been restored the UPS switches off the IPC p...

Page 23: ...installation or after a Stop command the program is again started with this command Once the start has been successful the main window disappears after approx 2 seconds and a symbol is added to the task bar The USP program is exited by selecting the Stop menu command Hide Hides the main window of the program and adds a symbol to the task bar The command is not available while the program is stoppe...

Page 24: ...The UPS program is always connected to the UPS via the COM4 serial port UPS Shutdown Parameter Brute Shutdown Upon receipt of the shutdown signal from the UPS the shutdown command for the Windows operating system is issued without delay This causes the immediate termination of all active aplications followed by the shutdown of Windows Smart Shutdown Upon receipt of the shutdown signal from the UPS...

Page 25: ...s power This may cause loss of data in some circumstances CAUTION Upon expiry of the Delay Time the operating system is shut down without prior security query Unsecured data belonging to open ap plications will be lost Advanced Controls Enable Accu Test When this check box is checked the system performs a test of the battery pack during each restart In the case of a faulty battery pack e g defecti...

Page 26: ... many charging cycles it is necessaary to replace the re chargebale batteries is contained in section 8 2 3 UPSplus Mode There are two operating modes for the UPSplus program Run as Service The program is started as part of the Windows 95 startup and remains active until Windows 95 is again terminated Changing user logins have no influ ence on the program s characteristics The user in unable to st...

Page 27: ...opped ended or restarted e g during a reinstallation or update procedure select Services Manager in the system control see icon below to the left of UPSNT Control The status of the UPSNT service is displayed in the Services Manager of WindowsNT D UPSNT stopped No entry in Status column D UPSNT started Started entry in Status column The marked entry of the UPSNT service is started and stopped via t...

Page 28: ...have no influence on this characteristic A user without Ad ministrator privileges is neither able to terminate the program nor stop the monitoring function To allow new parameter values to take effect subsequent to their modification the UPS program must be stopped and restarted This may be accomplished by restarting the computer or with the aid of the Services Manager COM Port The UPS program is ...

Page 29: ...e UPS disrupts the mains power This may cause loss of data in some circumstances CAUTION Upon expiry of the Delay Time the operating system is shut down without prior security query Unsecured data belonging to open ap plications will be lost Enable Accu Test When this check box is checked the system performs a test of the battery pack during each restart In the case of a faulty battery pack e g de...

Page 30: ...rd operation CAUTION Loss of data Activation of this checkbox no longer makes a safe shutdown poss ible in the event of a power failure The device switches off instantly 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 regarding after how many charging cycles it is necessaary to repla...

Page 31: ... user logins have no influence on this characteristic A user without Ad ministrator privileges is neither able to terminate the program nor stop the monitoring function To allow new parameter values to take effect subsequent to their modification the UPS is automatically stopped and restarted No monitoring function is enabled during this interval 5 to 10 sec COM Port The UPS program is always conn...

Page 32: ...ion of an error the red LED UPS flashes and an error message is generated Accu Test failed The Accu is not installed or empty and distributed throughout the system The UPS program continues to operate The battery test is automatically repeated after 12 hours D If no error is found automatic test repetition in 12 hour intervals ensues D Upon detection of an error the red LED UPS flashes and an erro...

Page 33: ...ware installations it must always be disabled during standard operation No Powerdown on Shortbreak When this checkbox has been activated interruptions in the power supply of up to 5 seconds are permitted without affecting ongoing operations Only in the case of power interruptions lasting in excess of 5 seconds will the UPS logic be started and the safe shutdown of the system initiated Command This...

Page 34: ...ge measured under load is low D The LED illuminated green when the battery pack is fully functional Excessive repetitions of the battery test will discharge the battery pack Never perform more than 5 battery tests within a 24 hour period The following applies to Fan Speed monitoring D Red LED Fan at standstill or fan speed is too low or too high D Green LED Fan is working properly Pressing the Sto...

Page 35: ...ned to be installed in housings or control cabinets will be severely impeded if they are used or operated without having first been installed Therefore do not use or operate the IPC until it has been installed Note D The use of silicon based sealing compounds adhesives and insu lating agents is prohibited D Ensure that the installation is maintenance friendly i e that it provides unrestricted acce...

Page 36: ... the integrated CD ROM drive may be operated in a horizontal position only For this reason the IPC must be installed in a horizontal position D When installing the IPC IPC300 ensure that the connection side of the respective unit remains easily accessible D Because it must be possible to verify the operating status of the unit at any time the LED displays must not be concealed in any way D Provide...

Page 37: ...Installation 4 3 1070 073 822 104 02 06 GB 4 2 IPC IPC300 dimensioned drawings IPC 8 4 482 6 19 445 465 9 37 7 57 2 132 5 Mounting hole 256 2 ...

Page 38: ...65 5 18 8 5 6 6 8 4 3 Installing IPC IPC300 in mounting frame L Construct a 19 in mounting frame with fasteners for the 4 holes in the front panel of the IPC or IPC300 L Insert the IPC or IPC300 into the mounting frame from the front L Using 4 suitable mounting screws attach the unit to the mounting frame ...

Page 39: ... the cur rent state of the art and at the highest level of safety attainable CAUTION Risk of damage to system components through by insertion or re moval of plug connectors on energized circuits Connections must be made only while the system is switched off Observe the following to prevent functional failures D Provide for isolated 24 VDC and 0 V terminal bars inside the control cabi net With rega...

Page 40: ...ounting plate with max 20 cm long adequately dimensioned copper bands Position 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 and testing PE ...

Page 41: ...ctors D Screening To ensure optimum suppress interference all of these components should be taken into consideration because they are most effective when working in combination In principle interference suppression 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 ...

Page 42: ...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 43: ...ross sect 1 5 mm2 see next page X10_1 2 1 3 4 Pin Signal 1 24V 2 3 24V 0V 0V 4 Rated voltage UN 24 VDC 20 15 Residual ripple at UN See diagram below Interference surge immunity Umax 35 V at t 100 ms Current draw at UN max 5 A Input fuse 6 3 A 5x20 medium time lag Reverse polarity protection Via decoupling diode Polarity reversal will blow input fuse DANGEROUS ELECTRICAL VOLTAGE The 24 VDC input vo...

Page 44: ...th a ripple factor of 5 refer to DIN 40110 10 75 Section 1 2 are permissible As an upper voltage limit this produces a maximum absolute value of 30 2 V and as a minimum voltage limit the minimum absolute value of 18 5 V t 0 cos 30 0 866 0 30 el 0 1 05 28 8 V 30 2 V Upper limit 28 8 V 0 866 30 2 V 26 1 V 1 05 20 4 V 21 4 V Lower limit 20 4 V 0 866 21 4 V 18 5 V U ...

Page 45: ...um the cross section of the copper straps must be equal to that of the supply cable 3 0 5 mm2 up to 4 m 0 75 mm2 up to 6 m 1 5 mm2 up to 10 m Distances in excess of 10 m necessitate a separate power supply at the machine Terminals in isolated arrangement A 102 green yellow 2 A B A Terminal block 42 B Terminal block 102 Max length 4 m 62 1 blue 0 V Load 24 V Load Earth bar Cross sections dependent ...

Page 46: ...equirements of Overvoltage Category II Otherwise the integrated power supply may be de stroyed Use a separation transformer to generate the 230 115 VAC refer to next page Coupler for non heating apparatus 3 pin Max conductor cross0section 1 5 mm2 X20 Assignment PE N1 U2 PE Rated voltage 85VAC to 264VAC Extended range input Current draw at UN 230 VAC 0 6 A Current draw at UN 115 VAC 1 2 A Inrush cu...

Page 47: ...ellow all housing components PE lug To utilize neutral conductor N operator permission is required PE 102 green yellow PE terminal bar for V wiring see Fig 2 Terminals in isolated arrangement PE PE PE PE PE Fuses motor protection switch preferred L1 1 L2 1 L3 1 N 230 V supply IPC see Fig 3 possibly 230 V fan Service sockets U2 e g drives Incoming mains PE star point connection Transform er as per ...

Page 48: ...page Cross sections dependent on current draw but MIN of 0 5 mm2 Cross sections dependent on current draw but MIN of 0 75 mm2 BF2xxT Control Panel X33 LVDS X34 PE PE IPC 230 115 VAC version Power supply protective separation to EN 60950 X11 LVDS COM2 BF3xxT Control Panel X33 LCD X10_1 PE PE IPC300 230 115 VAC version Power supply protective separation to EN 60950 X11 LCD X10_2 Fan power Fan U2 N1 ...

Page 49: ...able Ethernet Ethernet 10 Base T Network connection Female RJ45 8 pin Male RJ45 connector 8 conductor twisted prs USB USB interface Female USB connector 4 pin Male USB 4 conductor LVDS for BF2xxT Video transmission Female RJ45 8 pin Male RJ45 connector 8 conductor twisted prs LCD Gigabit for BF3xxT Video transmission and RS 422 for touch screen controller COM2 Female RJ45 8 pin Male RJ45 connector...

Page 50: ...ccessed connectors are located on the front panel All con nectors are clearly labelled In addition in the IPC300 DIP switches S1 and S3 provide external access 24 VDC IPC IPC300 X57 COM2 RS 485 422 COM2 RS 232 PE lug S1 S3 230 115 VAC on 230 115 V version DIP switch for display resolution see page 6 14 COM1 X57 switch over and connecting COM3 with X11 see page 6 18 24 VDC PE lug M6 230 115 VAC on ...

Page 51: ...ess 3F8H or AUTO recommended BIOS preset IPC Onboard Serial Port1 Auto IPC300 Serial Port A Enabled To peripheral devices 1 2 3 DCD RX TX 4 COM1 Screen applied to metal shell of connector 5 GND 6 7 8 9 RI DTR DSR RTS CTS 1 5 6 9 RS 232 Assignment as an RS 232 DCD Data Carrier Detect RCV channel used for example by a connected modem to inform the PC that it is receiving a carrier signal active conn...

Page 52: ...abit bus making a special data line unnecessary In exceptional cases the IPC also permits the use of the COM1 or COM3 port for the touch screen provided that the BIOS settings are changed to suit On the IPC the COM2 is also applied to X57 to provide RS 422 485 service Parallel operation is not possible however Male DB 9 connector Type RS 232 Cable length Max 15 m Cable type Screened min cross sect...

Page 53: ...l Port 2 AUTO IPC300 Serial Port A Enabled To peripheral devices 1 2 3 4 Screen applied to metal shell of connector 5 6 7 8 9 1 5 6 9 RS 485 422 DCD RXD TXD GND RI DTR DSR RXD TXD X57 Assignment as an RS 485 422 For more information on pin assignment see Page 6 3 DCD as for RS 232 RXD RXD Receive Data Line on which data is received TXD TXD Transmit Data Line on which data is transmitted to periphe...

Page 54: ...assignments COM4 Serial port assigned to UPS logic refer to Section 3 2 COM4 is internally assigned to the uninteruptible power supply UPS On the IPC COM4 can be used for external applications if the UPS ios not required On the IPC300 the COM4 is not externally accessible Male DB 9 connector Type RS 232 Cable length Max 15 m Cable type Screened min cross section 0 14 mm2 Transmission rate Max 1152...

Page 55: ...ently 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 shell of connector Screen 2 1 4 3 USB1 PIN Signal 1 USB power supply max 500 mA 2 Data 3 Data 4 USB Ground ...

Page 56: ...al supplied with the installed operating system Windows 95 NT Go to Start Settings Control Panel etc BIOS The factory shipped BIOS settings for COM1 through COM4 have been set to Present CAUTION Interrupt IRQ and I O address must correspond to BIOS settings In the case of address conflicts regarding COM3 4 e g if IRQ 10 or 11 are already in use by other PC expansion cards free IRQs must be used in...

Page 57: ...8 GND SEL out ERROR INIT SEL 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 The parallel port normally runs in the default SPP mode Provided that suit able peripheral devices are present it can also be o...

Page 58: ...Base T IPC300 Ethernet 10 100BaseTX Cable length Max 100 m Cable type Screened twisted pair Transmission rate 10 Mbit s and or 100 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 functions for the network connection can be ac cessed in the task bar or in the Control Panel under the Network Card sym bol...

Page 59: ...o information on premanufactured connecting cables in Section 10 2 1 2 3 4 LVDS 5 6 7 8 max 10 m To BF200T or BF212T LVDS LVDS 1 8 TXCLKOUTP TXCLKOUTN TXOUT1P TXOUT2P TXOUT2N TXOUT1N TXOUT0P TXOUT0N Selecting the display resolution The display resolutions must be selected in the connected IPC or rho4 via the S3 DIP switch see diagram below D BF200T 10 4 in colour display 640 x 480 pixels 256000 co...

Page 60: ... 822 104 02 06 GB Floppy disk CD ROM drive S3 S3 DIP switch Main board Hard disk Battery Battery D 640 x 480 pixels Switches 7 8 ON 1 2 3 4 5 6 7 8 ON OFF S3 D 800 x 600 pixels Switch 7 OFF Switch 8 ON 1 2 3 4 5 6 7 8 ON OFF S3 Factory setting ...

Page 61: ... Cable type Twisted pair 8 pin screened Refer to information on premanufactured connecting cables in Section 10 2 To BF312T or BF315T Gigabit 1 2 3 4 Gigabit 5 6 7 8 max 15 m LCD 1 8 Gigabit data video data COM Touch Control signal COM Touch TX Gigabit data video data COM Touch TX Control signal Gigabit receiver COM Touch RX COM Touch RX GBIT repeater The use of the Gigabit repeater extends the re...

Page 62: ...x 600 pixels D BF315T 15 in colour display 1024 x 768 pixels factory presets S1 S3 Changes are made on the externally accessible switch segments 1 though 8 of the S1 DIP switch D 800 x 600 pixels 1 2 3 4 5 6 7 8 OFF ON S1 D 1024 x 768 pixels IPC300 with Pentium I 266 MHz 1 2 3 4 5 6 7 8 OFF ON S1 factory setting D 1024 x 768 pixels IPC300 with Pentium III 400 MHz 1 2 3 4 5 6 7 8 OFF ON S1 factory ...

Page 63: ... 02 06 GB If aGigabit Repeater is used the DIP switch has to be configured as follows depending on the connected control panels D 800 x 600 Pixel BF312T 1 2 3 4 5 6 7 8 OFF ON S1 Einstellung ab Werk D 1024 x 768 Pixel BF315T 1 2 3 4 5 6 7 8 OFF ON S1 ...

Page 64: ...ed by the BIOS Inserting a graphics card will disable the integrated video adapter Also on the IPC300 the BIOS setting must be changed Female VGA HD 15 pin Cable length Max 1 5 m Cable type Screened min cross section 0 14 mm2 Max resolution 1280 x 1024 pixels max 16 million colours 1 15 VGA 1 2 3 RED GREEN 4 5 BLUE max 1 5 m Display ID2 GND Screen applied to metal shell of connector 6 7 8 RED GND ...

Page 65: ... the selections possible on the LVDS or LCD interface the connec tion between LVDS and or LCD and VGA must be interrupted D IPC with S3 DIP switch VGA resolution as per BIOS Segment 7 OFF Segment 8 OFF 1 2 3 4 5 6 7 8 ON OFF S3 D IPC300 with S1 DIP switch VGA resolution as per BIOS Segment 5 OFF Segment 6 OFF Segment 7 OFF Segment 8 OFF S1 1 2 3 4 5 6 7 8 OFF ON With these settings connecting a co...

Page 66: ...el as required The connec tion is configured with the use of the S3 DIP switch and is identical for IPC and IPC300 COM3 interconnected with X11 S3 switch segments 1 and 2 ON IPC300 with Pentium III 400 MHz only Always make sure that segment 4 of the DIP switch S3 is closed ON in order to activate the backlight sleep function of the BF3xx 1 2 3 4 5 6 7 8 ON OFF S3 Female DB 15 connector Cable lengt...

Page 67: ...BD 5 max 1 5 m Keyboard GND 5 V KBD Screen applied to metal shell of DIN plug connector Screen 2 1 4 3 6 6 5 If the system fails to recognize the keyboard the interface in the BIOS may have been set to Absent i e Not Connected Change the BIOS setting to Present IPC only Keyboard adapter In the event that the MF2 keyboard is equipped with a standard 5 pin DIN plug you will require a keyboard plug a...

Page 68: ...MF2 keyboard port 1 3 2 4 5 Screen applied to metal shell of DIN plug connector 2 1 4 3 6 5 1 2 3 Keyboard Clock Keyboard Data 4 PS 2 mini DIN connector male 5 max 0 2 m GND 5V 6 Mini DIN keyboard connection Screen applied to metal shell of DIN plug connector Screen Screen Adapter für PS 2 connector ...

Page 69: ...o metal shell of DB09 plug connector Screen 2 1 4 3 6 6 5 Mouse If the system fails to recognize the PS 2 mouse the interface in the BIOS may have set to Disabled i e Not Available Change the BIOS setting to Enabled IPC only The operating system will not recognize the insertion of an external mouse after completed startup because the mouse initialization occurs during the boot phase The connected ...

Page 70: ...Interfaces Ports Connectors 6 22 1070 073 822 104 02 06 GB Notes ...

Page 71: ...present Check IPC power supply for power Temp LED off Standard operation LED flashes red Internal housing temp above 50 C shutdown will occur if temperature continues to rise Reduce internal IPC housing temperature Check verify fan func tions UPS LED off Standard operation LED red IPC currently in battery mode i e no mains power present Restore mains power to IPC Initiate controlled IPC restart LE...

Page 72: ...LED Display 7 2 1070 073 822 104 02 06 GB Notes ...

Page 73: ...ms into the fan impeller D Ensure that the rechargeable batteries battery pack are fully functional To enesure that the battery pack is tested during each system startup and afterwards in 12 hour intervals enable the Battery Test option of the UPS control program CAUTION Loss of data Back up the data from the hard disk at regular intervals D Depending on temperature vibration and daily operating h...

Page 74: ...cedures in Section 8 2 1 D IPC300 accessible externally at the front panel Refer to fuse ordering information in Section 10 3 In the event that the power supply remains faulty after replacing the power supply fuse please contact Bosch Rexroth Service Telephone 49 0 60 62 78 888 CAUTION Loss of data Service repairs of devices returned by customers do not entail back ups of user data Repaired units ...

Page 75: ...Maintenance and Replacement 8 3 1070 073 822 104 02 06 GB IPC300 Fuse ...

Page 76: ...z drive supplied with the package if a hard disk replace ment is required this image must simply be copied back to the newly installed hard disk Please refer to Section 10 3 for ordering information Data voltage connection Hard disk with holder Mounting screw for hard disk holder Hard disk data voltage connection Motherboard 1 Switch off the power supply to the unit If required unplug all connecto...

Page 77: ... disk parameters To do this press the Y button Yes IPC300 To enable recognition of the new hard disk parameters by the system go to the main menu select the Primary Master menu option followed by the Type AUTO option Select Exit Saving Changes sav ing new parameter settings to exit the BIOS menu Restart the operating system and again access the BIOS menu In the Primary Master option set the Type o...

Page 78: ...D ROM drive Only a defective cable must be disconnected from the motherboard 5 Loosen the mounting screw on the front panel 6 Remove the CD ROM drive including the carrier plate 7 Loosen the mounting screws and replace the drive 8 Installation is in reverse sequence to that described above 9 When the IPC has started the CD ROM drive should be recognized again by the operating system if the drive i...

Page 79: ... supply 3 Open the housing 4 If applicable remove all expansion cards and all cables connected to these cards 5 Unplug the female connector together with the controller ribbon cable and the female connector for the power supply from the floppy disk Only a defective cable must be disconnected from the motherboard 6 Loosen the two mounting screws on the front panel Loosen the 4 mounting screws on th...

Page 80: ...u option and select the new floppy disk type Exit the BIOS via the Save Settings and Exit option save hard disk parameters To do this press the Y button Yes IPC300 Go to the main menu and select Diskette 1 Select the new floppy disk type Select Exit Saving Changes saving new parameter settings to exit the BIOS menu 10 If the floppy disk drive cannot be accessed check for D Proper connection betwee...

Page 81: ... pack is prevented as long as the IPC or IPC300 is not connected to mains power 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 operating terminal is situated e g the temperature in the control cabinet or in t...

Page 82: ...n be replaced when the 4 mounting screws have been removed cf figure below Insert the two new battery packs as shown in the figure below Please also observe the installation instructions delivered together with the packs Battery pack connector X19 Battery Battery CD ROM drive Battery retaining screws 1 2 5 Plug the connector with the bipolar cable back onto terminal X19 Ensure correct polarity of ...

Page 83: ... charged UPS LED Off D Battery pack discharged UPS LED flashes red Wait approx 5 hours until the battery pack is fully charged and the UPS LED extinguishes If the new rechargeable battery pack has not been charged there will not be sufficient UPS protection to effect a controlled shutdown of the PC Therefore install fully charged batteries if at all possible ...

Page 84: ...on cards and have them installed by a specialist 8 3 1 Installing an expansion card 1 Switch off the supply voltage If required unplug all connectors 2 Wait until the UPS has switched off the power supply the UPS LED on the front illuminates red until the UPS switches off the IPC power supply 3 Open the housing 4 Remove the mounting screw holding the slot cover 5 Insert the expansion card and secu...

Page 85: ... to a system reboot the functions based on the newly aded card are not available there may be several reasons for this D The card is not properly seated in the PCI or ISA slot contacts D The software driver for the card has not been installed or its installation is faulty D IRQ interrupt conflict with other PC hardware components D The software for the card has not been installed CAUTION Destructi...

Page 86: ...7 IRQ9 IRQ10 IRQ11 IRQ14 IRQ15 PCI PnP ISA EISA Default PCI PnP ISA slot DMA The PCI Plug and Play Setup BIOS menu provides for the permanent selection of a DMA channel for Legacy ISA cards BIOS selection DMA Channel 0 DMA Channel 1 DMA Channel 2 DMA Channel 3 DMA Channel 4 DMA Channel 5 DMA Channel 6 DMA Chan nel 7 PnP ISA EISA Default PnP When using the PCL Software PLC the use of DMA channels m...

Page 87: ...o called legacy ISA cards must be permanently set BIOS selection IRQ 3 4 5 7 9 10 11 15 Option Available Reserved Default Available ISA slot UMB You can use the The Advanced Menu PCI Configuration sub menu PCI PNP ISA UMB Region Exclusion BIOS submenu to reserve a specific block in upper memory for ISA legacy cards BIOS selection C800 CBFF CC00 CFFF D000 D3FF D400 D7FF D800 DBFF DC00 DFFF Option A...

Page 88: ...Maintenance and Replacement 8 16 1070 073 822 104 02 06 GB Notes ...

Page 89: ...n software 9 1 BIOS software The IPC requires the BIOS software for its initial boot process to enable it to find and start an operating system which provides a more user friendly and comfortable platform for running the application software The PCs are equipped with the following licensed BIOS software D IPC 200 MHz AMIBIOS by American Megatrends version LEU1R129 or higher IPC 266 MHz PhoenixBios...

Page 90: ...als D D D provided 9 3 1 Bosch PCL software PLC The installation of the Bosch PCL Software PLC adds the capabilities of a programmable logic controller to the IPC IPC300 The Bosch PCL Software PLC encompasses the following components D PCL expansion card for PCI bus D Installation diskette with PCL application program Interconnection When connected to other PLC components e g I O rack via a field ...

Page 91: ...ications between the operator interface and the Typ3 osa controller utilize the TCP IP protocol via the Ethernet connection between the IPC IPC300 and the osa master module of the controller IPC IPC300 with Typ3 osa operating software D osa master L w Ethernet connection D osa plc D osa fms D osa dc I O e g osa rack 4 containing Ethernet Typ3 osa controller possibly other devices in the Ethernet n...

Page 92: ...istical information MDA PDA about the entire system IPC IPC300 with Typ3 osa operating software Ethernet Typ3 osa Additional devices in Ethernet network as required ËËËËË PLC I O IPC IPC300 with PLC and MADAP Studio PROFIBUS DP other PROFIBUS I O devices D B IO K DP16DO D B IO M DP D Decentr I O RM65M 16DP PROFIBUS DP Ethernet Ethernet network Main computer Ethernet Ethernet PROFIBUS DP PROFIBUS D...

Page 93: ...m 10 m X11 length 2 5 m 5 m 10 m 1070 083 117 1070 083 116 1070 080 771 1070 918 793 1070 919 258 1070 918 794 1070 920 456 1070 920 457 1070 920 271 1070 083 120 1070 083 119 1070 080 744 Connecting cables IPC300 with Pentium I to BF312T LCD rigid cable length 2 5 m 5 m 10 m 15 m X11 length 2 5 m 5 m 10 m 15 m 1070 920 456 1070 921 385 1070 921 384 1070 921 070 1070 083 120 1070 083 119 1070 080 ...

Page 94: ...Package for In dustrial PC with 2 GB Iomega Jaz drive 1070 084 267 10 3 Spare Parts Designation Order no Fuses 6 3 A 5x20 medium time lag for 24 VDC power 1 25 A 5x20 medium ti me lag for 230 VAC power 10 A 5x20 quick blow for battery pack 1070 900 850 1070 900 839 1070 904 575 Battery pack for USP Connecting cable for bat tery pack in preparation 1070 080 517 Hard disk 6 4 GB w spring suspension ...

Page 95: ...isk GB Gigabyte HD Hard Disk IDE Interface for Hard Disk Drive CD ROM Drive etc ISA Industrial Standard Architecture bus system for PCs KBD Keyboard LCD Liquid Crystal Display LPT Line Printer MB Megabyte MTB Machine control panel PCI Peripheral Component Interconnect bus system for PCs RAM Random Access Memory SPP Standard Parallel Port TFT Thin Film Transistor UPS Uninterruptible Power Supply VG...

Page 96: ... 1 electrical connections 230 115 VAC power supply 5 8 24 V power supply 5 5 electrostatically sensitive devices ESD 1 6 Emergency STOP devices 1 5 EPP A 1 ESD electrostatically sensitive devices 1 6 ESD earthing wrist strap 1 6 ESD protection 1 6 ESD work station 1 6 Ethernet connection 6 10 expansion slots 8 12 BIOS settings 8 14 layout 8 13 External CRT monitor BIOS settings 6 16 external monit...

Page 97: ...reening information 5 2 Shutdown Delay Time 3 11 software 9 1 spare parts 1 5 specifications 2 2 SPP A 1 standard operation 1 1 standards compatibility 2 5 storage temperature 2 4 system overview 2 1 T temperature 2 4 temperature monitoring 3 1 TFT A 1 TFT display resolution 6 11 trademarks 1 7 U uninterruptible power supply 3 2 UPS program 3 4 UPS A 1 UPS functionality 3 2 UPS program configurati...

Page 98: ...mp Control option 3 7 Exit command 3 5 Hide command 3 5 Run as Service option 3 8 Run as User Task 3 8 Shutdown Count option 3 8 Smart Shutdown command 3 6 Start command 3 5 Stop command 3 5 UPSplus Mode command 3 8 USB 6 7 utilities 9 1 V Versions 2 1 VGA A 1 VGA port 6 16 vibration resistance 2 4 video adapter CRT 6 16 setting resolution on IPC 6 11 setting resolution on IPC300 6 14 X X11 power ...

Page 99: ...utomationstechnik Antriebs und Steuerungstechnik Postfach 11 62 D 64701 Erbach Fax 49 0 60 62 78 4 28 1070 073 822 104 02 06 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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