Bosch Rexroth IndraControl XFE01.1-SY-01 Operating Instructions Manual Download Page 1

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IndraControl

XFE01.1-SY-01

Safety Extension Module

Operating Instructions
R911376654

Edition 03

Summary of Contents for Rexroth IndraControl XFE01.1-SY-01

Page 1: ...IndraControl XFE01 1 SY 01 Safety Extension Module Operating Instructions R911376654 Edition 03 ...

Page 2: ...ts reserved also regarding any disposal exploitation reproduction editing distribution as well as in the event of applications for industrial property rights Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract All rights are reserved with respect to the content of this d...

Page 3: ...instructions 4 3 2 Explaining signal words and safety alert symbol 5 3 3 Symbols used 6 3 4 Explaining the signal alert symbol on the device 6 4 Intended use 6 5 Spare parts and accessories 8 5 1 Accessories 8 5 2 Wear parts 8 6 Ambient conditions 8 7 Technical data 11 7 1 Voltage supply 11 7 2 Safety related characteristic values 12 7 3 Dimensions and weight 12 8 Standards 13 8 1 Standards used 1...

Page 4: ... the control and for the extension modules 27 10 5 4 24 V voltage supply 28 10 5 5 Grounding 29 10 5 6 Shielding 30 11 Commissioning 30 12 Device description 31 12 1 Memory card 32 12 2 Operating and error displays 32 12 2 1 Conf pushbutton 33 12 2 2 LED display 33 12 2 3 LED on XD1 plug 35 13 Troubleshooting and debugging 35 13 1 General information 35 14 Maintenance 35 15 Ordering information 37...

Page 5: ...sal 38 16 1 General information 38 16 2 Return 38 16 3 Packaging 38 17 Service and support 38 Index 41 IndraControl XFE01 1 SY 01 Safety Ex tension Module III Table of Contents R911376654_Edition 03 Bosch Rexroth AG ...

Page 6: ...IV IndraControl XFE01 1 SY 01 Safety Ex tension Module Bosch Rexroth AG R911376654_Edition 03 ...

Page 7: ...ng this documentation Presales Aftersales Selection Mounting assembly installation Engineering Commissioning Operation Decommissioning Product phases Target groups Activities Design engineer Programmer Technologist Process specialist Select Prepare Design Construct Mechanic electrician Unpack Mount Install Programmer Commissioning engineer Parameterize Program Configure Simulate Technologist Proce...

Page 8: ...nd regulations 1 4 Scope This operating instruction applies to the Safety extension module with the type code XFE01 1 SY 01 For the type code specifications refer to chapter 15 Ordering information on page 37 1 5 Related documents Title Description IndraWorks 14VRS SafeLogic Project Configuration R911341694 Application Description This documentation is intended as guideline when creating a safety ...

Page 9: ...e manufacturer on how to perform the mechanical and electrical installation safely and on how to commission it at the power supply unit Tab 1 2 Related documents If a documentation is not available please contact the Bosch Rexroth Service 1 6 Customer feedback Customer requests comments or suggestions for improvement are of great importance to us Please email your feedback on the documentations to...

Page 10: ...acturing country 14 Company address 15 Certification stamp TÜV Rheinland 16 CE conformity marking 17 Graphic symbol of the equipment Fig 2 1 Exemplary type plate 2 3 Scope of delivery Safety extension module IndraControl XFE01 1 SY 01 24 V power connector XA CN01 Bus base module XA BS11 for IndraControl extension modules Safety instructions 3 Using safety instructions 3 1 Structure of the safety i...

Page 11: ...5 6 2006 The signal word draws attention to the safety instruction and indicates the risk potential The safety alert symbol triangular safety reflector with exclamation marks preceding the signal words Danger Warning Caution indicates hazards for persons DANGER In case of non compliance with this safety instruction death or serious injury will occur WARNING In case of non compliance with this safe...

Page 12: ...XFE01 1 SY 01 is used to securely process logic signals of periphery components sensors according to the sequential program and to provide logic signals for periphery components actuators The sequential program can be freely programmed using the Engineering system Even though the control system was developed manufactured and tested according to the safety standards and certified by an accredited t...

Page 13: ...ture protection class humidity EMC specified in this documentation Also refer to chapter 6 Ambient conditions on page 8 A typical area of application of the Safety extension module IndraControl XFE01 1 SY 01 is the implementation of safety related controls for Handling and mounting systems Food and packaging machines Printing and processing machines Machine tools Compactors Foundry and rolling tec...

Page 14: ...o 85 C Relative humidity 10 to 95 condensing not permitted 10 to 95 condensing not permitted Contamination level 2 acc to DIN EN 61131 2 2 acc to DIN EN 61131 2 Air pressure and Operating altitude 86 kPa to 106 kPa up to 2 000 m above sea level 55 kPa to 106 kPa Up to 4 700 m above sea level Degree of protection IP 20 acc to DIN EN 60529 IP 20 acc to DIN EN 60529 Warning if internal temperature is...

Page 15: ... Q 60 dB μV M Tab 6 3 Electromagnetic operating conditions Testing noise emission acc to EN 61000 6 4 ESD standard Test acc to DIN EN 61000 4 2 Air discharge up to 8 kV criterion A Contact discharge up to 4 kV criterion A ESD Increased noise level Air discharge up to 8 kV criterion FS Contact discharge up to 6 kV criterion FS Electromagnetic HF field standard Test acc to DIN EN 61000 4 3 80 MHz 1 ...

Page 16: ...terruptions every 10 s interruption period of 10 ms Voltage dips short interruptions and voltage fluctuations at DC mains inputs Increased requirements 24 V DC supply voltage 1 40 UT rated voltage for 10 ms 2 0 UT rated voltage for 20 ms Voltage deviation of 15 to 20 3 attempts period of 10 s Tab 6 4 Electromagnetic operating conditions Testing electromagnetic compatibility acc to EN 61000 6 2 as ...

Page 17: ...d into the housing and installation compartments must at least comply with the degree of protection IP 54 according to DIN EN 60529 The device shall be provided in a suitable fire enclosure in the end use application This is a product that corresponds to the limit values of the emitted interference of class A industrial environments but not of class B residential area and small enterprises When us...

Page 18: ...rdware error tolerance HFT 1 Category Category 4 DIN EN ISO 13849 1 PFH average frequency of a dangerous failure per hour 4 5 10 10 1 h PFDavg average probability of a dangerous failure in case of request 3 9 10 5 Service life TM 20 years DIN EN ISO 13849 no proof test required MTTFd mean time to failure 2 500 years DCavg average diagnostic coverage 99 high Types of failure If the internal diagnos...

Page 19: ...DIN EN 60204 1 2007 A1 2009 AC 2010 in extracts EN 60204 1 2006 A1 2009 AC 2010 IEC 60204 1 2005 modified CEI 60204 1 2005 modifiée Safety of machinery Electrical equipment of machines Part 1 General requirements DIN EN 61131 1 2004 IEC 61131 1 2003 CEI 611311 2003 Programmable controllers Part 1 General information DIN EN 61131 2 2008 Corr 2009 IEC 61131 2 2007 Corr 2008 CEI 61131 2 2007 Corr 200...

Page 20: ...ystems DIN EN ISO 13849 1 2016 06 EN ISO 13849 1 2015 12 Safety of machinery Safety related parts of control systems Part 1 General principles for design DIN EN ISO 13849 2 2013 EN ISO 13849 2 2012 Safety of machinery Safety related parts of control systems Part 2 Validation DIN EN 61326 3 1 2008 BER 2009 IEC 61326 3 1 2008 CEI 61326 3 1 2008 Electrical equipment for measurement control and labora...

Page 21: ...8 2 TÜV certificate Fig 8 1 TÜV certificate IndraControl XFE01 1 SY 01 IndraControl XFE01 1 SY 01 Safety Ex tension Module 15 45 Standards R911376654_Edition 03 Bosch Rexroth AG ...

Page 22: ...ollowing directives Machinery directive 2006 42 EC EMC directive 2014 30 EC Loss of CE conformity due to modifications at the device CE marking applies only to the device upon delivery After modifying the device verify the CE conformity 16 45 Standards IndraControl XFE01 1 SY 01 Safety Ex tension Module Bosch Rexroth AG R911376654_Edition 03 ...

Page 23: ...rogrammable controllers 2008 B1 2009 IEC 61131 2 Part 2 Equipment requirements and tests 2007 DIN EN 61000 6 2 Electromagnetic compatibility EMC 2006 B1 2011 IEC 61000 6 2 Part 6 2 Generic standards Immunity for industrial environments 2005 DIN EN 61000 6 4 Electromagnetic compatibility EMC 2011 IEC 61000 6 4 Part 6 4 Generic standards Emission standard for industrial environments 2006 A1 2010 DIN...

Page 24: ... the machine is the prerequisite for a compliance with the EMC directive Please refer to the Rexroth documentation of the respective product for limit values and standards to be complied with The assembly and installation conditions described in this documentation have to be complied with The tests have been carried out at an installation in accordance with the system on a test site that complies ...

Page 25: ...61010 1 12 UPDATE Edition 3 CSA C22 2 NO 61010 2 201 14 Edition 1 Approved under UL file no E210730 Loss of UL CSA conformity due to modifications at the device UL and CSA marking applies only to the device upon delivery After modifying the device verify the UL and the CSA conformity IndraControl XFE01 1 SY 01 Safety Ex tension Module 19 45 Standards R911376654_Edition 03 Bosch Rexroth AG ...

Page 26: ...position 1 2 3 Voltage supply Memory card slot Attached bus base module Fig 9 1 Interfaces of the Safety extension module 20 45 Interfaces IndraControl XFE01 1 SY 01 Safety Ex tension Module Bosch Rexroth AG R911376654_Edition 03 ...

Page 27: ...draControl XFE01 1 SY 01 This memory card is used to save user specific data boot application logbooks devices and application as well as user management data For the position of the microSD slot refer to fig 9 1 Interfaces of the Safety extension module on page 20 If the SD card is removed during operation the control goes into the safe state i e the error response time IndraControl XFE01 1 SY 01...

Page 28: ...equired safety measures against electrostatic discharge ESD acc to EN 61340 5 1 when operating the Safety extension module Mounting location The extension module has the degree of protection IP 20 and is thus intended for use in a closed control cabinet or control box terminal box of the degree of protection IP 54 or higher 22 45 Mounting demounting and electric installation IndraControl XFE01 1 S...

Page 29: ...arantee the correct fastening of the control and the modules connected to them on the mounting rail and they are used as lateral end elements Do not wire cables parallel to motor cables over a long distance or other strong interference sources to avoid coupling of interferences The LED displays may not be hidden Wire all connecting cables in loops Use strain reliefs for all cables Keep the maximum...

Page 30: ...til all latchings are safely closed see A in the following figure 2 Move the first IndraControl extension bus base module see B to the right and connect the IndraControl extension bus base module with the bus base module of the control see D in the following figure 3 Move the other IndraControl extension bus base modules to the right until all bus base modules are connected to each other see C in ...

Page 31: ...nect the control including its components from voltage Removing extension modules from top hat rail 1 Remove the left end clamp 2 Use a suitable tool e g slotted screwdriver and put it first into the upper and then into the lower disengaging mechanism base latch of the control and disengage the control see A in the following figure The base latches are locked in the open position 3 Remove the exte...

Page 32: ...be ensured by the specified measures connection to protective conductor insulation etc Danger of material damage due to incorrect mounting or electric installation NOTICE Any dangerous system states which might cause material damage must be prevented Protection upon direct and indirect contact must be ensured by the specified measures connection to protective conductor insulation etc 26 45 Mountin...

Page 33: ... of the control also have to comply with the criteria of safety separated circuits The same external power supply unit has to supply the 24 V voltage supply of the XMx control and the extension modules Bridge the cables between the power connectors XD1 10 5 3 Voltage supply for the control and for the extension modules The voltage supply for the control and the extension modules is supplied via th...

Page 34: ...he XD1 plugs of the XMxx control and then bridge the cables to the power connectors XD1 of the extension modules Dimensioning the voltage supply Observe the maximum currents when dimensioning the voltage supply A voltage between 20 4 V and 28 8 V has to be applied directly at the device This voltage range also has to be maintained if there are variations in line voltage e g caused by different loa...

Page 35: ...l S20 I O modules are at least provided with one FE spring metal clip at their lower side creating an electric connection to the mounting rail while mounting If necessary provide the top hat rail with a separate grounding connection Voltage jumper The voltage jumper FE functional earth is routed from the control through all connected IndraControl S20 modules This ensures that these terminals are g...

Page 36: ...missioning The product cannot be operated upon delivery It has to be parameterized or programmed The documentations providing information on the commissioning and project configuration are listed in chapter 1 5 Related documents on page 2 An incorrect commissioning can cause fatal immaterial and material damages WARNING Ensure that a qualified person checks documents and releases the system in whi...

Page 37: ...e supply microSD slot with microSD card Attached bus base module Fig 12 1 Safety extension module IndraControl XFE01 1 SY 01 IndraControl XFE01 1 SY 01 Safety Ex tension Module 31 45 Device description R911376654_Edition 03 Bosch Rexroth AG ...

Page 38: ...o logbooks devices and application are stored on a memory card and also remain if the power supply fails 12 2 Operating and error displays Fig 12 2 Display and operating elements 32 45 Device description IndraControl XFE01 1 SY 01 Safety Ex tension Module Bosch Rexroth AG R911376654_Edition 03 ...

Page 39: ...D is on during the initialization phase If the LED is still on after the initialization approx 1 min or if the LED is permanently switched on at runtime integrated self tests determined a fatal error e g hardware error The Safety extension module IndraControl XFE01 1 SY 01 is then probably defective and has to be replaced Contact the Bosch Rexroth Service Tab 12 1 LEDs to display operational readi...

Page 40: ...employees Tab 12 2 Operating state display of the Safety extension module IndraControl XFE01 1 SY 01 LED Color and status Description Mod Off No power supply present or no CSos configuration loaded Green flashing Standby state Green Normal operation Red flashing Error that can be eliminated Red Error that cannot be eliminated Red green flashing Self test or configuration Net Off No power supply pr...

Page 41: ... the display LED and the pushbutton refer to chapter 12 2 Operating and error displays on page 32 Repairs at the device by the customer are not permitted Exceptions are maintenance works listed in the chapter Maintenance For further information in the event of repair please contact the Bosch Rexroth Service 14 Maintenance Only the maintenance works at the device listed in this chapter are permitte...

Page 42: ...ervice personnel is allowed to exchange the memory card For the position of the memory card refer to fig 12 1 Safety extension module IndraControl XFE01 1 SY 01 on page 31 To replace the memory card proceed as follows 1 Disconnect the complete system from voltage This includes the IndraControl XMxx control The Safety extension module IndraControl XFE01 1 SY 01 is connected to this control 2 Secure...

Page 43: ...on interface CX Function type HW Design 1 Sercos Master 01 Design Type 1 PCIe 01 Type 2 S20 02 Type of construction Ext board slip on B Ext card flitting C Ext module stackable E Extension type Function extension F Device type 2 Device type 1 IO Box X Type short description 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 1 Note 1 Function type SY only available with function Safety 01 Fig 15 1 Type code of the Safe...

Page 44: ...e products free of charge to the following address Bosch Rexroth AG Electric Drives and Controls Bürgermeister Dr Nebel Straße 2 97816 Lohr Germany 16 3 Packaging The packaging material consists of cardboard plastics wood or styrofoam Packaging material can be recycled anywhere For ecological reasons please do not return empty packages 17 Service and support Our worldwide service network provides ...

Page 45: ...ne numbers refer to the sales office addresses on the internet Preparing information To be able to help you more quickly and efficiently please have the following information ready Detailed description of malfunction and circumstances Type plate specifications of the affected products in particular type codes and serial numbers Your contact data phone and fax number as well as your e mail address ...

Page 46: ...40 45 IndraControl XFE01 1 SY 01 Safety Ex tension Module Bosch Rexroth AG R911376654_Edition 03 ...

Page 47: ...s 35 Error display 32 F Feedback 3 Functional earth 29 G Grounding 29 H Hazard warnings 4 Helpdesk 38 Hotline 38 I Intended use 6 Interfaces 20 L LEDs on XD1 plug 35 M Maintenance 35 Maintenance notes 36 Memory card 8 32 MTTFd 12 O Operating display 32 Ordering data 38 Ordering information 37 P Packaging 38 PELV 11 Performance level PL 12 PFDavg 12 PFH 12 Potential equalization 29 Power supply uni...

Page 48: ...pare parts 8 Standards 13 Suggestions 3 Support 38 Symbols 6 T Target groups 1 Technical data 11 Troubleshooting 35 TÜV certificate 15 Type code 37 Type plate 3 4 U UL CSA certified 19 Use intended 6 V Voltage jumper 29 Voltage supply 11 27 W Warnings 4 Weight 12 X XD1 LED 35 42 45 Index IndraControl XFE01 1 SY 01 Safety Ex tension Module Bosch Rexroth AG R911376654_Edition 03 ...

Page 49: ...IndraControl XFE01 1 SY 01 Safety Ex tension Module 43 45 R911376654_Edition 03 Bosch Rexroth AG ...

Page 50: ...44 45 IndraControl XFE01 1 SY 01 Safety Ex tension Module Bosch Rexroth AG R911376654_Edition 03 ...

Page 51: ...Notes IndraControl XFE01 1 SY 01 Safety Ex tension Module 45 45 ...

Page 52: ...ectric Drives and Controls P O Box 13 57 97803 Lohr Germany Bgm Dr Nebel Str 2 97816 Lohr Germany Phone 49 9352 18 0 Fax 49 9352 18 8400 www boschrexroth com electrics R911376654 R911376654 DOK CONTRL SL SY XFE IT03 EN P ...

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