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Safety Instructions for Electric Drives and Controls

Application Description

|

R-IB IL INC-PAC

Electric Drives |

Bosch Rexroth AG

and Controls

2.1.3

Warning Symbols and Degrees of Hazard Seriousness

The safety instructions describe the following degrees of hazard seriousness. The

degree of hazard seriousness informs about the consequences resulting from

non-compliance with the safety instructions:

2.1.4

Hazards by Improper Use

Warning sym-

bol

Signal word

Degree of hazard seriousness acc. to

ANSI Z 535.4-2002

Danger

Death or severe bodily harm will occur.

Warning

Death or severe bodily harm may occur.

Caution

Minor or moderate bodily harm or material damage

may occur.

Fig. 2-1

Hazard classification (according to ANSI Z 535)

High electric voltage and high working current! Risk of death or se-
vere bodily injury by electric shock!

Observe the safety instructions!

Dangerous movements! Danger to life, severe bodily harm or mate-

rial damage by unintentional motor movements

!

Observe the safety instructions!

High electric voltage because of incorrect connection! Risk of

death or bodily injury by electric shock!

Observe the safety instructions!

Health hazard for persons with heart pacemakers, metal implants

and hearing aids in proximity to electrical equipment!

Observe the safety instructions!

Hot surfaces on device housing! Danger of injury! Danger of burns!

Observe the safety instructions!

DANGER

DANGER

WARNING

WARNING

CAUTION

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Summary of Contents for Rexroth Inline Series

Page 1: ...ion Description Electric Drives and Controls Pneumatics Service Linear Motion and Assembly Technologies Hydraulics Configuring and Installing the Rexroth Inline Product Range for INTERBUS R911317023 Edition 01 ...

Page 2: ...hereof without express authority are forbidden Offenders are liable for the payment of damages All rights reserved in the case of patent award or listing of a registered design DIN 34 1 Validity The specified data is for product description purposes only and may not be deemed to guarantee unless expressly confirmed in the contract All rights are reserved with respect to the content of this documen...

Page 3: ...ovements 8 2 2 4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting 10 2 2 5 Protection Against Contact with Hot Parts 10 2 2 6 Protection During Handling and Mounting 11 2 2 7 Battery Safety 11 2 2 8 Protection Against Pressurized Systems 12 3 Integration of Inline Into the INTERBUS System 13 3 1 The INTERBUS System 13 3 2 Example Topology of an INTERBUS System 1...

Page 4: ... I O Terminals 40 8 2 1 Inline Station Devices 40 8 2 2 System Restrictions 41 8 3 Selecting Accessories 43 8 3 1 Power Supplies 43 8 3 2 End Clamps and Labeling Fields 43 8 3 3 Minimizing Interference 43 8 4 Installing an Inline Station 44 8 5 Connecting the Bus Coupler 45 8 6 Checking the Installation 45 8 7 Software Configuration for INTERBUS 46 8 8 Addressing 46 8 9 Startup 46 9 Technical Data...

Page 5: ...Protection 53 11 1 Disposal 53 11 1 1 Products 53 11 1 2 Packaging Materials 53 11 2 Environmental Protection 53 11 2 1 No Release of Hazardous Substances 53 11 2 2 Materials Contained in the Products 53 11 2 3 Recycling 54 12 Service Support 55 12 1 Helpdesk 55 12 2 Service Hotline 55 12 3 Internet 55 12 4 Helpful Information 55 ...

Page 6: ...Table of Contents 6 6 Bosch Rexroth AG Electric Drives Inline Application Description and Controls ...

Page 7: ...iate use In such cases the guarantee and the right to payment of damages resulting from inappropriate use are for feited The user alone carries all responsibility of the risks Before using Rexroth products make sure that all the pre requisites for appropriate use of the products are satisfied Personnel that in any way shape or form uses our products must first read and understand the relevant safe...

Page 8: ...system may only be operated under the assembly installation and ambient conditions as described here temperature system of protection humidity EMC requirements etc and in the position specified In residential areas as well as in business and commercial areas Class A devices may be used with the following note This is a Class A device In a residential area this device may cause radio interferences ...

Page 9: ...s documentation Read the operating maintenance and safety instructions in your language before commissioning the machine If you find that you cannot completely un derstand the documentation for your product please ask your supplier to clarify Proper and correct transport storage assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe op eration...

Page 10: ...ndards and carry out the required measures modifica tions and complements Commissioning of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations safety specifications and standards of the application Operation is only permitted if the national EMC regulations for the application are met The ins...

Page 11: ...ion Minor or moderate bodily harm or material damage may occur Fig 2 1 Hazard classification according to ANSI Z 535 High electric voltage and high working current Risk of death or se vere bodily injury by electric shock Observe the safety instructions Dangerous movements Danger to life severe bodily harm or mate rial damage by unintentional motor movements Observe the safety instructions High ele...

Page 12: ...s with voltages of more than 50 volts Contact with parts conducting voltages above 50 volts can cause personal danger and electric shock When operating electrical equipment it is unavoidable that some parts of the units conduct dangerous voltage Risk of injury by improper handling Risk of bodily injury by bruis ing shearing cutting hitting or improper handling of pressurized lines Observe the safe...

Page 13: ...tage on the ca pacitors before beginning to work to make sure that the equipment is safe to touch Never touch the electrical connection points of a component while power is turned on Install the covers and guards provided with the equipment properly before switching the device on Before switching the equipment on cover and safe guard live parts safely to prevent contact with those parts A residual...

Page 14: ...nction of sensors encoders and monitoring devices defective components software or firmware errors These errors can occur immediately after equipment is switched on or even after an unspecified time of trouble free operation The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives Regarding personal safety especially the dan ger of bodily...

Page 15: ...perator Verify that the emergency stop works before commissioning Do not operate the device if the emergency stop switch is not working Isolate the drive power connection by means of an emergency stop circuit or use a safety related starting lockout to prevent unintentional start Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone Additionally se...

Page 16: ...les can be given Those with metal implants or metal pieces as well as with hearing aids must consult a doctor before they enter the areas described above Otherwise health hazards may occur Hot surfaces at motor housings on drive controllers or chokes Danger of injury Danger of burns Do not touch surfaces of device housings and chokes in the proximity of heat sources Danger of burns Do not touch ho...

Page 17: ...ing Bodily injury by bruising shearing cutting hitting Observe the general construction and safety regulations on handling and mounting Use suitable devices for mounting and transport Avoid jamming and bruising by appropriate measures Always use suitable tools Use special tools if specified Use lifting equipment and tools in the correct manner If necessary use suitable protective equipment for exa...

Page 18: ...ply systems supply lines or connections can cause injuries or material damage Environmental protection and disposal The agents used to operate the product might not be economically friendly Dispose of ecologically harmful agents separately from other waste Observe the local regula tions in the country of assembly Risk of injury by improper handling of pressurized lines Do not attempt to disconnect...

Page 19: ... controls all devices of an INTERBUS ring From the master all devices are connected to the bus system Each device has two separate lines for data transmission one for forward data transfer and one for return data transfer This eliminates the need for a return line from the last device to the first device which is necessary in a simple ring system The forward and return lines run in one bus cable F...

Page 20: ...DI 8 IN LB LB OUT U LS U LS FLM DI 8 FLM DI 8 IN LB LB OUT U LS U LS BK IB BK IB U LS OUT BUS BUS LB OUT U LS FLM AI IN LB LB OUT U LS U LS FLM DIO 8 FLM DIO 8 IN LB LB OUT U LS U LS Fieldline Modular M12 station D E DIO 8 4 DIO 8 4 UL Fieldline Modular M8 devices 1 RUN FAIL RUN PROG MRESET STP RDY RUN BSA FAIL PF PRG LNK ACT 100 10 100 RESET INLINE CONTROL ILC 370 PN 2TX IB Ord No 2876915 xxxxxxx...

Page 21: ...e I O modules with communications power Refreshing the data signal repeater function Electrical isolation of the bus segments Connecting or disconnecting the local bus via firmware Connecting or disconnecting the outgoing remote bus via firmware If necessary indicating errors via a floating alarm output e g buzzer light signal Remote bus The remote bus connects the controller board with the remote...

Page 22: ...ble and compact station structure without unnecessary reserve installation space 8 slot terminals These terminals provide a fast and effective station structure for larger stations Functional orientation of the switch box or control cabinet The modular structure makes it possible to assemble standard function blocks in advance Parts of the system can be started up independently of one another This...

Page 23: ...ranch terminal 0 Bus couplers 1 Terminal with remote bus branch 2 Branch terminal 3 Fieldline Modular M8 devices Incoming remote bus Outgoing remote bus 1 2 D DO2 1 2 D DO2 1 2 D DI8 1 2 1 2 1 2 BA RC UL RD TR US UM 1 2 D DO8 1 2 1 2 1 2 RC RD D RB T LD Remote bus branch 7427A005 A 1 2 D DO2 1 2 D DI2 1 2 D DI2 1 2 D DI8 1 2 1 2 1 2 BA RC UL RD TR US UM 1 2 D DO8 1 2 1 2 1 2 B C 0 1 0 0 2 3 3 3 BA...

Page 24: ...e Chapter Number of devices on page 20 Versions The product range offers terminals for all automation tasks Bus couplers for connecting the Inline station to the INTERBUS remote bus The remote bus uses copper technology Terminals with remote bus branch for opening a remote bus branch The remote bus branch uses copper technology Supply terminals for supplying the supply voltages and segmenting the ...

Page 25: ...selected to connect to the INTERBUS remote bus via a copper connection The INTERBUS remote bus is then connected via an Inline connector or a D SUB connector Functions A bus coupler is used to amplify signals repeater function it divides the system into segments and enables the outgoing remote bus and or the connected station to be switched on or off during operation An Inline bus coupler forms th...

Page 26: ...rotects the station against ESD pulses and the user against dangerous contact voltages Fuse protection The bus coupler is protected against polarity reversal and surge voltage for the supplied voltages Functional earth ground connection The terminal is grounded when it is snapped onto the grounded DIN rail via the FE spring on the bottom of the terminal This spring is connected to the FE potential...

Page 27: ... units Potential areas Fig 4 2 to Fig 4 4 show the electrical isolation in the bus coupler The internal wiring is not important here It is shown in the terminal specific data sheet In Fig 4 2 to Fig 4 4 the graphic symbols are not explained because they are not important for indicating the electrical isolation For an explanation of the graphic symbols please refer to the corresponding data sheet o...

Page 28: ... unit Fig 4 3 Electrical isolation in the R IBS IL 24 BK T U PAC bus coupler one power supply unit Potential areas A Area for incoming remote bus B Area for outgoing remote bus C Area for functional earth ground FE capacitive D Area for functional earth ground FE E Area for the bus coupler supply UBK from which the communications power UL and analog terminal supply UANA are generated not isolated ...

Page 29: ...nalog terminal is supplied from the analog circuit UANA The 24 V supply US UM is only looped through the analog terminal and is available again at the next terminal If the supply voltages UBK and UM US are supplied separately at the bus coupler power terminal the I O circuit of an analog terminal is electrically isolated from the 24 V voltages UM and US Fig 4 4 Electrical isolation in the bus coup...

Page 30: ...dules do not count as Inline station modules Terminals with remote bus branch can only be placed directly behind a bus coupler or a terminal with remote bus branch This means that there must be no INTERBUS devices no terminals with protocol chip ID code between the bus coupler and the terminal with remote bus branch Fig 4 5 Terminal with remote bus branch Observe any restrictions for your bus coup...

Page 31: ...l terminals For a general overview of the terminals with a function description of the product groups please refer to the DOK CONTRL ILSYSINS AW EN P application description The following product groups area described Bus couplers and terminals with remote bus branch Power segment and accessory terminals Input output terminals Incoming remote bus Outgoing remote bus 1 2 D DO2 1 2 D DO2 1 2 D DI8 1...

Page 32: ...ion and Controls 4 3 Typical Structure of an Inline Station Fig 4 7 Example station The example Inline station shown in Fig 4 7 consists of the following elements 1 End bracket 2 Bus coupler or control terminal 3 Terminals for the 24 V DC area e g I O terminal 4 End plate end of the station 7427A002 3 2 1 1 4 ...

Page 33: ... the jumper contacts on the side for each circuit The arrangement of the potential jumpers and information about current and voltage distribution on the potential jumpers The connection of the supply voltages 5 1 1 Bus Coupler Supply You must connect the supply voltage UBK bus coupler supply to a bus coupler The voltages for the logic circuit UL and the supply of the terminals for analog signals U...

Page 34: ...1 S2 2 BC Bus coupler in conjunction with a power terminal if required UBK Bus coupler supply supply for bus coupler generates UANA and UL UM Main supply I O supply in the main circuit US Segment supply I O supply in the segment circuit UANA I O supply for analog terminals UL Communications power Local bus Data jumper for the local bus Ground GND for the supply voltages UM and US Noiseless ground ...

Page 35: ... used which supplies the supply voltage UM2 Using a jumper the segment voltage US for segment S2 1 is tapped from the main voltage UM2 at this terminal Segment S2 2 Segment terminal R IB IL 24 SEG PAC provides the segment voltage US via a switch Output terminals installed here can therefore be switched externally Examples of errors and their effects 1 In this example structure a short circuit in s...

Page 36: ...potential and data routing for the 24 V voltage area begins at the bus coupler For further information please refer to the DOK CONTRL ILSYSINS AW EN P application description Please refer to the circuit diagram of the terminal to see which jumpers are provided for a terminal and how they are internally connected The circuit diagram is shown in the terminal specific data sheet ...

Page 37: ... V bus coupler supply UBK 24 V supply in the main circuit UM 24 V supply in the segment circuit US If UM and US are not supplied at the bus coupler Implement the 24 V supplies in the main circuit UM via a directly connected power terminal The 24 V supplies in the segment circuit US can also be implemented at this power terminal or an additional segment terminal As a rule all the information in the...

Page 38: ...he INTERBUS remote bus is connected to a bus coupler Bus couplers are available for connecting the remote bus using copper or fiber optic technology Remote bus using copper technology The bus cables are shielded cables They are connected via an Inline connector with shield connection or via a D SUB connector Connection via an Inline connector is the same as the connection of shielded cables via a ...

Page 39: ...inal is operating correctly if all of its green LEDs are on Status The status indicators yellow display the status of the relevant input output and the connected device Extended diagnostics Some Inline terminals have extended diagnostics A short circuit or overload of the sensor supply is indicated for each input If a short circuit occurs at an output each channel is diagnosed individually Informa...

Page 40: ...ng remote bus connection established OFF Incoming remote bus connection faulty RD 3 Yellow LED Remote bus disabled ON Outgoing remote bus interface disabled OFF Outgoing remote bus interface not disabled LD 4 Red or yellow LED Local bus disabled ON yellow Local bus disabled ON red Isolated disconnection of local bus after error OFF Local bus not disabled UL 5 Green LED Bus coupler supply communica...

Page 41: ...fter the flashing terminal cannot be addressed e g loose contact at the bus interface terminal before the flashing terminal has failed another terminal was snapped on during operation not permitted OFF Communications power is not present RC 2 Green LED Remote bus connection remote bus check ON Incoming remote bus connection established OFF Incoming remote bus connection faulty RD 3 Yellow LED Remo...

Page 42: ...ror diagnostics When the system is operating correctly the green LEDs on the bus coupler and the other terminals remain lit Fig 7 4 detail A For general information about the indicators on other terminals please refer to the DOK CONTRL ILSYSINS AW EN P application description For specific information about a particular terminal please refer to the terminal specific data sheet 1 R IBS IL 24 BK T U ...

Page 43: ...4 Hz C Bus error slow medium fast 2 2 2 2 ˆ U D L D U L U S U 2 2 2 2 2 D D 8 2 2 2 2 U ˇ 2 2 D D 2 2 2 D D 2 2 D D 8 2 2 2 2 2 D D 2 2 U ˇ 2 4 5 B C A 5 5 2 0 0 5 4 Error Short circuit at terminal 4 R IB IL 24 DO 2 2A PAC Effect Controller Error message to the control system peripheral fault Bus coupler Indicators remain unchanged Terminal 4 Green D LED flashes at 2 Hz Other terminals Remain unch...

Page 44: ...Diagnostic and Status Indicators 38 58 Bosch Rexroth AG Electric Drives Inline Application Description and Controls ...

Page 45: ...ll terminals according to the instructions in the DOK CONTRL ILSYSINS AW EN P application description Switch on the supply voltage of the control or computer system Switch on the supply voltages of the Inline station The initialization of the bus system now begins 8 1 Task Example project 1 You want to acquire signals from twelve digital 4 wire sensors each with 50 mA current consumption at 24 V i...

Page 46: ...irements met Possible terminals 4 wire technology 12 channels DI 4 DI 16 No DI 2 DI 8 Yes 1 x DI 8 and 2 x DI 2 Requirements met Possible terminals Short circuit proof Diagnostics via INTERBUS SEG No No SEG F Yes No SEG F D Yes Yes Requirements met Possible terminals Load current up to 0 5 A Reserve DO 2 2A No 2 A not required DO 4 Yes No DO 8 DO 16 Yes Yes Requirements met Possible terminals Load...

Page 47: ...t the permissible current load of the potential jumper US is not exceeded In this case the number of power terminals to be used depends on the arrangement of the terminals Observe the current consumption of each device at the individual potential jumpers when configuring an Inline station This data can be found in the terminal specific data sheets Terminal block Number Current consumption at UL te...

Page 48: ... The structure with an additional power terminal is considered below R IBS IL 24 BK T U PAC R IB IL 24 DO 2 2A PAC R IB IL 24 DO 2 2A PAC R IB IL 24 DO 2 2A PAC R IB IL 24 DO 4 PAC R IB IL 24 SEG F D PAC R IB IL 24 DI 8 PAC R IB IL 24 DI 2 PAC R IB IL 24 DI 2 PAC R IB IL TEMP 2 RTD PAC US UM 4 A 1 2 A 4 A 2 A 0 4 A 0 1 A 0 1 A R IBS IL 24 BK T U PAC R IB IL 24 DO 2 2A PAC R IB IL 24 DO 2 2A PAC R ...

Page 49: ...le Current consumption in the example project on page 41 8 3 2 End Clamps and Labeling Fields Two end clamps are needed to secure an Inline station on the DIN rail Mount these on both sides of the Inline station to keep it from moving from side to side Depending on the mounting position Bosch Rexroth recommends SUB M01 ENDHALTER MNR R911170685 end clamps for mounting on a horizontal DIN rail snapp...

Page 50: ...line station Personal injury when working on live components Before setting up an Inline station or inserting a terminal ensure that the entire station is disconnected from the power Make sure the entire station is reassembled before switching the power back on CAUTION Observe the current consumption of each device at the individual potential jumpers when configuring an Inline station This data ca...

Page 51: ...ig 8 3 Bus coupler connectors Safe grounding To ensure reliable grounding of the Inline station ground the bus coupler via the FE connection Connect the terminal points for the FE connection to a grounded PE terminal 8 6 Checking the Installation The following points should be checked before the system is switched on or in the event of an error 1 Are all the system restrictions observed See Chapte...

Page 52: ...ether have a modular design and are based on international standards which means that even complex applications can be implemented easily Software can be used to perform the following tasks Automated planning and configuration of Inline stations Inline Builder Network and device configuration IndraWorks Application programming IndraWorks System visualization IndraWorks System diagnostics IndraWork...

Page 53: ...x or later Number of data words 256 maximum Transmission speed 500 kbps or 2 Mbps Transmission reliability CR check hamming distance 4 Protocol IEC 61158 Number of devices Total number of bus devices 512 maximum Number of remote bus devices 254 maximum Number of PCP devices 62 maximum firmware version 4 4x or later 126 maximum firmware version 4 6x or later Number of remote bus levels 16 maximum D...

Page 54: ...observe the power supply through the bus couplers power terminals and segment terminals as well as the current consumption of each device Data transfer Protocol IEC 61158 INTERBUS 2 wire 500 kbps or 2 Mbps Transmission speed 500 kbps or 2 Mbps Transmission Inline data jumpers Test voltages Isolating distance Test voltage Technology for 24 V Area up to 60 V DC 5 V supply incoming remote bus 5 V sup...

Page 55: ... limit parameters are Maximum of 63 devices Maximum current consumption at UL 2 A Maximum current consumption at UANA 0 5 A Maximum current consumption at US and UM total current 8 A Order of the terminals Please observe the information in the DOK CONTRL ILSYSINS AW EN P application description 10 1 2 Voltage Failure Diagnostics There are various ways to diagnose a voltage failure PF on the contro...

Page 56: ...power terminal During this process the 24 V power supply units on the low voltage side must not be connected with one another Fig 10 1 shows the electrical isolation A connection between GND of the supply voltage and functional earth ground may only be implemented at one point in the station point A If ground GND of the bus coupler supply voltage were also connected to functional earth ground elec...

Page 57: ... maximum power dissipation The maximum power dissipation is specified in the terminal specific data sheet In the permissible operating temperature range the power dissipation of the housing can be dependent on or independent of the ambient temperature If the power dissipation of the housing depends on the ambient temperature a permissible working point must be defined Permissible working point Dep...

Page 58: ...Examples and Tips 52 58 Bosch Rexroth AG Electric Drives Inline Application Description and Controls ...

Page 59: ...hr am Main Germany 11 1 2 Packaging Materials The packaging materials consist of cardboard wood and polystyrene These ma terials can be easily recycled in any municipal recycling system For ecological reasons please refrain from returning the empty packages to us 11 2 Environmental Protection 11 2 1 No Release of Hazardous Substances Our products do not contain any hazardous substances which may b...

Page 60: ...rder to recycle the metal in the best possible way the products must be disassembled into individual modules Metals contained in electric and electronic modules can also be recycled by means of special separation processes The synthetic materials remaining after these processes can be thermally recycled If the products contain batteries or rechargeable batteries these batteries are to be removed a...

Page 61: ...333 88 26 or 49 0 172 660 04 06 Hotline numbers for other countries can be found in the addresses of each region see below 12 3 Internet Additional notes regarding service maintenance and training as well as the cur rent addresses of our sales and service offices can be found on http www boschrexroth com Outwith Germany please contact our sales service office in your area first 12 4 Helpful Inform...

Page 62: ...Service Support 56 58 Bosch Rexroth AG Electric Drives R IB IL INC PAC Anwendungsbeschreibung and Controls ...

Page 63: ...Notes Application Description Inline Electric Drives Bosch Rexroth AG 57 58 and Controls ...

Page 64: ...CONTRL ILSYSPRO AW01 EN P R911317023 Bosch Rexroth AG Electric Drives and Controls P O Box 13 57 97803 Lohr Germany Bgm Dr Nebel Str 2 97816 Lohr Germany Tel 49 0 93 52 40 0 Fax 49 0 93 52 48 85 www boschrexroth com electrics ...

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