Bosch Rexroth IndraControl VDP 16.1, Rexroth IndraControl VDP 40.1, Rexroth IndraControl VDP 60.1 Project Planning Manual
Electric Drives
and Controls Pneumatics
Service
Linear Motion and
Assembly Technologies
Hydraulics
Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revision
Copyright
Validity
Published by
Note
Rexroth IndraControl
VDP 16.1/40.1/60.1
Operator Display
Project Planning Manual
DOK-SUPPL*-VDP16/40/60-PR03-EN-P
RS-3819577ef0bf23a20a6846a0007da7dd-1-en-US-5
This documentation describes the displays IndraControl VDP 16.1, VDP 40.1
and VDP 60.1 as well as the Y-repeaters available as accessories.
Edition Release Date Notes
120-2100-B368-01/EN 06.2004 First edition
120-2100-B368-02/EN 01.2005 Second edition
120-2100-B368-03/EN 05.2010 Third edition
© Bosch Rexroth AG, 2004
Copying this document, giving it to others and the use or communication of the
contents thereof without express authority, are forbidden. Offenders are liable
for the payment of damages. All rights are reserved in the event of the grant of
a patent or the registration of a utility model or design (DIN 34-1).
The specified data is for product description purposes only and may not be
deemed to be guaranteed unless expressly confirmed in the contract. All rights
are reserved with respect to the content of this documentation and the availa‐
bility of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr am Main, Germany
Phone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85
http://www.boschrexroth.com/
Development Control Platform HB (CS)
This document has been printed on chlorine-free bleached paper.
DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
Bosch Rexroth AG I/69
Table of Contents
Table of Contents
Page
1 System Presentation...................................................................................................... 5
1.1 Brief Description of the VDP 16.1, VDP 40.1 and VDP 60.1 Operator Displays ................................... 5
1.2 Variants................................................................................................................................................... 5
1.2.1 Characteristic Features....................................................................................................................... 5
1.2.2 Displays with Foil Keyboard................................................................................................................ 6
1.2.3 Displays with Touch Screen................................................................................................................ 6
1.2.4 VDP 16.1 Variants............................................................................................................................... 6
VDP 16.1 - Variants.......................................................................................................................... 6
1.2.5 VDP 40.1 - Variants............................................................................................................................. 7
1.2.6 VDP 60.1............................................................................................................................................. 8
1.3 Accessories............................................................................................................................................ 9
1.4 Commissioning....................................................................................................................................... 9
2 Important Instructions on Use ..................................................................................... 11
2.1 Appropriate Use ................................................................................................................................... 11
2.1.1 Introduction........................................................................................................................................ 11
2.1.2 Areas of Use and Application............................................................................................................ 11
2.2 Inappropriate Use................................................................................................................................. 12
3 Safety Instructions for Electric Drives and Controls .................................................... 13
3.1 Definitions of Terms.............................................................................................................................. 13
3.2 General Information.............................................................................................................................. 14
3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 14
3.2.2 Requirements for Safe Use............................................................................................................... 14
3.2.3 Hazards by Improper Use.................................................................................................................. 15
3.3 Instructions with Regard to Specific Dangers....................................................................................... 16
3.3.1 Protection Against Contact with Electrical Parts and Housings......................................................... 16
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 17
3.3.3 Protection Against Dangerous Movements....................................................................................... 17
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 19
3.3.5 Protection Against Contact With Hot Parts........................................................................................ 19
3.3.6 Protection During Handling and Mounting......................................................................................... 19
3.3.7 Battery Safety.................................................................................................................................... 20
3.3.8 Protection Against Pressurized Systems........................................................................................... 20
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 21
4 Technical Data............................................................................................................. 23
4.1 Front Panel .......................................................................................................................................... 23
4.2 Voltage Supply...................................................................................................................................... 23
4.3 Ambient Conditions............................................................................................................................... 24
4.4 Standards............................................................................................................................................. 24
4.4.1 Used Standards................................................................................................................................. 24
4.4.2 CE Marking........................................................................................................................................ 25
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Table of Contents
4.4.3 UL/CSA Certified............................................................................................................................... 25
4.5 Wear Parts............................................................................................................................................ 26
4.6 Compatibility Test................................................................................................................................. 26
Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
Page
Declaration of Conformity .............................................................................................................. 25
Note for the Machine Manufacturer................................................................................................ 25
5 Dimensions and Installation......................................................................................... 27
5.1 Housing Dimensions............................................................................................................................. 27
5.1.1 Housing Dimensions VDP 16.1......................................................................................................... 27
5.1.2 Housing Dimensions VDP 40.1......................................................................................................... 29
5.1.3 Housing Dimensions VDP 60.1......................................................................................................... 31
5.2 Housing Dimensions of the Y-Repeater............................................................................................... 31
5.3 Installation ............................................................................................................................................ 32
5.3.1 Installation Notes............................................................................................................................... 32
5.3.2 Mounting Cut-out............................................................................................................................... 32
5.3.3 Mounting Dimensions VDP 16.1........................................................................................................ 34
5.3.4 Mounting Dimensions VDP 40.1........................................................................................................ 35
5.3.5 Mounting Dimensions VDP 60.1........................................................................................................ 35
6 Display and Operating Components............................................................................ 37
6.1 Backlight Switch-off.............................................................................................................................. 37
6.1.1 General Information........................................................................................................................... 37
6.2 Operating and Error Displays............................................................................................................... 37
6.3 Foil Keyboard........................................................................................................................................ 38
6.3.1 System Requirements....................................................................................................................... 38
6.3.2 Position of the Buttons....................................................................................................................... 39
6.3.3 VDP 16.1 Keys and VDP 40.1 Keys.................................................................................................. 39
Function and Operating Keys (F... + OP...).................................................................................... 39
Use of an External Keypad............................................................................................................. 39
M-Keys........................................................................................................................................... 40
6.3.4 Keys VDP 60.1.................................................................................................................................. 41
Function and Special Keys (F... + S...)........................................................................................... 41
M-Keys .......................................................................................................................................... 42
Alphanumeric Block........................................................................................................................ 43
6.4 Touch Screen....................................................................................................................................... 43
6.5 LEDs at the Y-Repeater........................................................................................................................ 43
7 Interfaces..................................................................................................................... 45
7.1 Interfaces at the VDP............................................................................................................................ 45
7.1.1 View on the Connector Panel............................................................................................................ 45
7.1.2 General Information........................................................................................................................... 45
7.1.3 Overview............................................................................................................................................ 45
7.1.4 S3/S4 Rotary Switch.......................................................................................................................... 46
Overview......................................................................................................................................... 46
7.1.5 DC 24 V Voltage Supply.................................................................................................................... 46
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Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
7.1.6 XUSB Interfaces................................................................................................................................ 47
7.1.7 G4 Display Interface.......................................................................................................................... 48
7.1.8 Combined Keyboard/Mouse Interface............................................................................................... 48
7.1.9 Mouse Interface................................................................................................................................. 48
7.1.10 PROFIBUS DP Interface................................................................................................................... 49
7.2 Intefaces at the Y-Repeater.................................................................................................................. 50
7.2.1 View on the Connector Panels.......................................................................................................... 50
7.2.2 Description of the Interfaces - Overview............................................................................................ 51
7.2.3 Connection of the Y-Repeater (Block Diagram)................................................................................ 51
7.2.4 G4 Display Interfaces........................................................................................................................ 51
7.2.5 Digital 24 V Input (Changeover Input)............................................................................................... 52
Bosch Rexroth AG III/69
Table of Contents
Page
8 Maintenance................................................................................................................ 55
8.1 General Information.............................................................................................................................. 55
8.2 LCD Display.......................................................................................................................................... 55
8.3 Connecting two VDPs via the Y-Repeater............................................................................................ 56
9 Software....................................................................................................................... 57
9.1 Touch Screen Software........................................................................................................................ 57
10 Environmental Protection and Disposal ...................................................................... 59
10.1 Environmental Protection...................................................................................................................... 59
10.2 Disposal................................................................................................................................................ 59
11 Ordering Information.................................................................................................... 61
11.1 Type Designation Code........................................................................................................................ 61
11.1.1 General Information........................................................................................................................... 61
11.2 VDP 16.1.............................................................................................................................................. 61
11.3 VDP 40.1.............................................................................................................................................. 62
11.4 VDP 60.1.............................................................................................................................................. 63
11.5 Accessories.......................................................................................................................................... 64
11.5.1 Y-Repeater........................................................................................................................................ 64
11.5.2 Connecting Cable to Control Cabinet PC IPC 40.2........................................................................... 64
12 Service and Support.................................................................................................... 65
Index............................................................................................................................ 67
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Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
Bosch Rexroth AG 5/69
System Presentation
1 System Presentation
1.1 Brief Description of the VDP 16.1, VDP 40.1 and VDP 60.1 Operator Displays
The VDP 16.1/40.1/60.1 operator displays are passive operator and visualiza‐
tion terminals. They form a PC-based operator terminal when used with a
control cabinet PC (IPC) equipped with a G4 display interface. At present, the
IPC 40.2, VSB 40.1 or VPB 40.1 devices are available as control cabinet PCs.
While the VDP 16.1, VDP 40.1 and VDP 60.1 displays are mounted in the door
of the control cabinet or on a bracket with little mounting depth, the control
cabinet PC (IPC) can for example be mounted in the control cabinet. Data is
transmitted between control cabinet PC and VDP 16.1/40.1/60.1 operator dis‐
play via G4 display interface.
Y-repeater
A Y-repeater is an accessory to connect VDP devices to a control cabinet PC
(see chapter 11.5 "Accessories" on page 64). The Y-repeater can be used
to connect two VDP devices to a control cabinet PC (IPC).
1.2 Variants
1.2.1 Characteristic Features
The displays are available as differnet variants, see type designation code in
chapter 11.1 "Type Designation Code" on page 61. They differ in display size
and touch screen capability.
VDP 16.1 BB - BK
Customized design for Bosch - AC -
Display 304.8 mm TFT (12")
Touch screen Yes Yes No
Keys (foil keyboard) No No 16 machine
Fig.1-1: Characteristic features of the VDP 16.1 devices
VDP 40.1 BE - BI
Customized design for Bosch AG
Display 381 mm TFT (15")
Touch screen Yes Yes No
Keys (foil keyboard) No No 16 machine
function keys
function keys
Fig.1-2: Characteristic features of the VDP 40.1 devices
VDP 60.1 BL
Display 304.8 mm (12")
Touch screen No
Keys (foil keyboard) Machine function keys and alphanumeric keys
Fig.1-3: Characteristic features of the VDP 60.1 devices
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System Presentation
Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
1.2.2 Displays with Foil Keyboard
The front panel with foil keyboard consists of a 4 mm thick aluminum panel with
beveled edges covered by a chemical resistant polyester foil with embossed
keys. Machine functions keys are integrated in the application-oriented function
keypad.
1.2.3 Displays with Touch Screen
The front panel with touch screen allows to operate the application software via
the touch-sensitive surface of the display without keyboard and mouse.
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
Operate the touch screen only with your finger or with a touch pen.
1.2.4 VDP 16.1 Variants
VDP 16.1 - Variants
VDP 16.1BB with touch screen
NOTICE
Danger of destruction of the touch screen if
operated with inappropriate objects (e.g.
screwdriver).
Fig.1-4: VDP 16.1 with touch screen
VDP 16.1AC with touch screen, without front USB, customized Bosch design
Principally, they differ from the standard variant in its rounded edges, the miss‐
ing USB connection and the different mounting dimensions.
DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
VDP 16.1BK with keypad and 16 M-keys, standard variant
Bosch Rexroth AG 7/69
System Presentation
Fig.1-5: VDP 16.1 with foil keyboard
1.2.5 VDP 40.1 - Variants
VDP 40.1BE with touch screen
Fig.1-6: VDP 40.1 with touch screen
VDP 40.1AG with touch screen, without front USB, customized Bosch design
Principally, they differ from the standard variant in its rounded edges, the miss‐
ing USB connection and the different mounting dimensions.
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Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
System Presentation
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
VDP 40.1BI with foil keyboard and 16 machine function keys, standard variant
1.2.6 VDP 60.1
Fig.1-7: VDP 40.1 with foil keyboard
VDP 60.1BL with foil keyboard, 16 machine function keys, alphanumeric keys
and 12" display
Fig.1-8: VDP 60.1 with foil keyboard
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Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
1.3 Accessories
Using the Y-repeater (VAC01.1S-YG4-EXTN) provided as accessory part, two
VDP displays can be connected to a control cabinet PC (IPC). The Y-repeater
can be cascaded. Therefore, three or more VDPs can be connected to a control
cabinet PC.
1.4 Commissioning
Mount the device properly, see also chapter 5.3 "Installation " on page 32.
Connect the device to the de-energized control cabinet PC (IPC); then connect
the 24 V supply voltage.
Bosch Rexroth AG 9/69
System Presentation
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Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
2 Important Instructions on Use
2.1 Appropriate Use
2.1.1 Introduction
Rexroth products represent state-of-the-art developments and manufacturing.
They are tested prior to delivery to ensure operational safety and reliability.
Bosch Rexroth AG 11/69
Important Instructions on Use
WARNING
The products are designed for the use in an industrial environment and may
therefore only be used for the intended purpose. If they are not used as inten‐
ded, situations causing personal injury as well as material damage can occur.
Rexroth disclaims as manufacturer any warranty, liability or dam‐
ages occurring due to inappropriate use of the products. Further‐
more, Rexroth is not paying any compensation. The user is
responsible for any risks resulting from inappropriate use of the
products.
Before using Rexroth products, the following requirements must be met to en‐
sure appropriate use of the products:
● Anyone handling one of the Rexroth products in any way has to read and
understand the respective safety-related guidelines as well as the instruc‐
tions on appropriate use.
● Hardware products have to remain in their original state, i. e. no modifi‐
cation regarding the design is allowed. Software products must not be
decompiled and their source codes must not be modified.
● Damaged or faulty products must not be implemented or put into opera‐
tion.
● It must be ensured that the products are installed as specified in the doc‐
umentation.
Physical injury and material damage might re‐
sult from an inappropriate use of the products!
2.1.2 Areas of Use and Application
The Rexroth VDP 16.1/40.1/60.1 displays are passive operating and visuali‐
zation terminals forming a PC-based machine operating terminal when used
with an industrial PC.
NOTICE
The VDP 16.1/40.1/60.1 displays may exclusively be used with the accessories
and add-on components specified in this documentation. Components not
named expressly mentioned must neither be mounted nor connected. The
same applies to cables and conduits.
The products may only be operated with the expressly stated configurations
and component combinations as well as with the software and firmware which
is given and specified in the respective functional description.
Typical areas of application of the VDP 16.1/40.1/60.1 are:
Danger of destruction of the device if not ex‐
pressly stated accessories, add-on compo‐
nents and other components, cables, conduits,
software and firmware is used.
12/69
Important Instructions on Use
Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
● Handling systems and assembly systems
● Packaging and food processing machines
● Printing machines and paper converting machines
● Machine tools
● Wood processing machines
The VDP 16.1/40.1/60.1 operator displays may only be operated under the as‐
sembly conditions and installation conditions, in the specified position of appli‐
cation and under the specified ambient conditions (temperature, degree of
protection, humidity, EMC etc.) given in this documentation.
2.2 Inappropriate Use
The application of VDP 16.1/40.1/60.1 that are not within the specified areas
of application or under operating conditions deviating from the operating con‐
ditions and technical data specified in the documentation is considered as
"inappropriate".
VDP 16.1/40.1/60.1 must not be used if ...
● it is exposed to operating conditions that do not fulfill the ambient condi‐
tions specified. For instance, operation under water, in case of extreme
variations of temperature or in extreme maximum temperatures is not al‐
lowed.
● the intended applications have not expressly been allowed by Rexroth. It
is imperative that you also note the information given in the general notes
on safety!
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
Bosch Rexroth AG 13/69
Safety Instructions for Electric Drives and Controls
3 Safety Instructions for Electric Drives and Controls
3.1 Definitions of Terms
Application Documentation
Component
Control System
Device
Electrical Equipment
Electric Drive System
Installation
Machine
Manufacturer
Product
Project Planning Manual
Qualified Persons
Application documentation comprises the entire documentation used to inform
the user of the product about the use and safety-relevant features for config‐
uring, integrating, installing, mounting, commissioning, operating, maintaining,
repairing and decommissioning the product. The following terms are also used
for this kind of documentation: User Guide, Operation Manual, Commissioning
Manual, Instruction Manual, Project Planning Manual, Application Manual, etc.
A component is a combination of elements with a specified function, which are
part of a piece of equipment, device or system. Components of the electric drive
and control system are, for example, supply units, drive controllers, mains
choke, mains filter, motors, cables, etc.
A control system comprises several interconnected control components placed
on the market as a single functional unit.
A device is a finished product with a defined function, intended for users and
placed on the market as an individual piece of merchandise.
Electrical equipment encompasses all devices used to generate, convert, trans‐
mit, distribute or apply electrical energy, such as electric motors, transformers,
switching devices, cables, lines, power-consuming devices, circuit board as‐
semblies, plug-in units, control cabinets, etc.
An electric drive system comprises all components from mains supply to motor
shaft; this includes, for example, electric motor(s), motor encoder(s), supply
units and drive controllers, as well as auxiliary and additional components, such
as mains filter, mains choke and the corresponding lines and cables.
An installation consists of several devices or systems interconnected for a de‐
fined purpose and on a defined site which, however, are not intended to be
placed on the market as a single functional unit.
A machine is the entirety of interconnected parts or units at least one of which
is movable. Thus, a machine consists of the appropriate machine drive ele‐
ments, as well as control and power circuits, which have been assembled for
a specific application. A machine is, for example, intended for processing,
treatment, movement or packaging of a material. The term "machine" also cov‐
ers a combination of machines which are arranged and controlled in such a way
that they function as a unified whole.
The manufacturer is an individual or legal entity bearing responsibility for the
design and manufacture of a product which is placed on the market in the in‐
dividual's or legal entity's name. The manufacturer can use finished products,
finished parts or finished elements, or contract out work to subcontractors.
However, the manufacturer must always have overall control and possess the
required authority to take responsibility for the product.
Examples of a product: Device, component, part, system, software, firmware,
among other things.
A project planning manual is part of the application documentation used to
support the sizing and planning of systems, machines or installations.
In terms of this application documentation, qualified persons are those persons
who are familiar with the installation, mounting, commissioning and operation
of the components of the electric drive and control system, as well as with the
hazards this implies, and who possess the qualifications their work requires. To
comply with these qualifications, it is necessary, among other things,
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Safety Instructions for Electric Drives and Controls
Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
1) to be trained, instructed or authorized to switch electric circuits and devices
safely on and off, to ground them and to mark them
2) to be trained or instructed to maintain and use adequate safety equipment
3) to attend a course of instruction in first aid
User
A user is a person installing, commissioning or using a product which has been
placed on the market.
3.2 General Information
3.2.1 Using the Safety Instructions and Passing Them on to Others
Do not attempt to install and operate the components of the electric drive and
control system without first reading all documentation provided with the product.
Read and understand these safety instructions and all user documentation prior
to working with these components. If you do not have the user documentation
for the components, contact your responsible Bosch Rexroth sales partner. Ask
for these documents to be sent immediately to the person or persons respon‐
sible for the safe operation of the components.
If the component is resold, rented and/or passed on to others in any other form,
these safety instructions must be delivered with the component in the official
language of the user's country.
Improper use of these components, failure to follow the safety instructions in
this document or tampering with the product, including disabling of safety de‐
vices, could result in property damage, injury, electric shock or even death.
3.2.2 Requirements for Safe Use
Read the following instructions before initial commissioning of the components
of the electric drive and control system in order to eliminate the risk of injury
and/or property damage. You must follow these safety instructions.
● Bosch Rexroth is not liable for damages resulting from failure to observe
the safety instructions.
● Read the operating, maintenance and safety instructions in your language
before commissioning. If you find that you cannot completely understand
the application documentation in the available language, please ask your
supplier to clarify.
● Proper and correct transport, storage, mounting and installation, as well
as care in operation and maintenance, are prerequisites for optimal and
safe operation of the component.
● Only qualified persons may work with components of the electric drive and
control system or within its proximity.
● Only use accessories and spare parts approved by Bosch Rexroth.
● Follow the safety regulations and requirements of the country in which the
components of the electric drive and control system are operated.
● Only use the components of the electric drive and control system in the
manner that is defined as appropriate. See chapter "Appropriate Use".
● The ambient and operating conditions given in the available application
documentation must be observed.
● Applications for functional safety are only allowed if clearly and explicitly
specified in the application documentation "Integrated Safety Technolo‐
gy". If this is not the case, they are excluded. Functional safety is a safety
DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
concept in which measures of risk reduction for personal safety depend
on electrical, electronic or programmable control systems.
● The information given in the application documentation with regard to the
use of the delivered components contains only examples of applications
and suggestions.
The machine and installation manufacturers must
– make sure that the delivered components are suited for their individ‐
ual application and check the information given in this application
documentation with regard to the use of the components,
– make sure that their individual application complies with the appli‐
cable safety regulations and standards and carry out the required
measures, modifications and complements.
● Commissioning of the delivered components is only allowed once it is sure
that the machine or installation in which the components are installed
complies with the national regulations, safety specifications and standards
of the application.
● Operation is only allowed if the national EMC regulations for the applica‐
tion are met.
● The instructions for installation in accordance with EMC requirements can
be found in the section on EMC in the respective application documenta‐
tion.
The machine or installation manufacturer is responsible for compliance
with the limit values as prescribed in the national regulations.
● The technical data, connection and installation conditions of the compo‐
nents are specified in the respective application documentations and must
be followed at all times.
National regulations which the user must take into account
● European countries: In accordance with European EN standards
● United States of America (USA):
– National Electrical Code (NEC)
– National Electrical Manufacturers Association (NEMA), as well as
local engineering regulations
– Regulations of the National Fire Protection Association (NFPA)
● Canada: Canadian Standards Association (CSA)
● Other countries:
– International Organization for Standardization (ISO)
– International Electrotechnical Commission (IEC)
Bosch Rexroth AG 15/69
Safety Instructions for Electric Drives and Controls
3.2.3 Hazards by Improper Use
● High electrical voltage and high working current! Danger to life or serious
injury by electric shock!
● High electrical voltage by incorrect connection! Danger to life or injury by
electric shock!
● Dangerous movements! Danger to life, serious injury or property damage
by unintended motor movements!
● Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electric drive systems!
● Risk of burns by hot housing surfaces!
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Safety Instructions for Electric Drives and Controls
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Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
● Risk of injury by improper handling! Injury by crushing, shearing, cutting,
hitting!
● Risk of injury by improper handling of batteries!
● Risk of injury by improper handling of pressurized lines!
3.3 Instructions with Regard to Specific Dangers
3.3.1 Protection Against Contact with Electrical Parts and Housings
This section concerns components of the electric drive and control
system with voltages of more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal
danger and electric shock. When operating components of the electric drive
and control system, it is unavoidable that some parts of these components
conduct dangerous voltage.
High electrical voltage! Danger to life, risk of injury by electric shock or serious
injury!
● Only qualified persons are allowed to operate, maintain and/or repair the
components of the electric drive and control system.
● Follow the general installation and safety regulations when working on
power installations.
● Before switching on, the equipment grounding conductor must have been
permanently connected to all electric components in accordance with the
connection diagram.
● Even for brief measurements or tests, operation is only allowed if the
equipment grounding conductor has been permanently connected to the
points of the components provided for this purpose.
● Before accessing electrical parts with voltage potentials higher than 50 V,
you must disconnect electric components from the mains or from the pow‐
er supply unit. Secure the electric component from reconnection.
● With electric components, observe the following aspects:
Always wait 30 minutes after switching off power to allow live capacitors
to discharge before accessing an electric component. Measure the elec‐
trical voltage of live parts before beginning to work to make sure that the
equipment is safe to touch.
● Install the covers and guards provided for this purpose before switching
on.
● Never touch electrical connection points of the components while power
is turned on.
● Do not remove or plug in connectors when the component has been pow‐
ered.
● Under specific conditions, electric drive systems can be operated at mains
protected by residual-current-operated circuit-breakers sensitive to uni‐
versal current (RCDs/RCMs).
● Secure built-in devices from penetrating foreign objects and water, as well
as from direct contact, by providing an external housing, for example a
control cabinet.
DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
Safety Instructions for Electric Drives and Controls
High housing voltage and high leakage current! Danger to life, risk of injury by
electric shock!
● Before switching on and before commissioning, ground or connect the
components of the electric drive and control system to the equipment
grounding conductor at the grounding points.
● Connect the equipment grounding conductor of the components of the
electric drive and control system permanently to the main power supply at
all times. The leakage current is greater than 3.5 mA.
● Establish an equipment grounding connection with a copper wire of a
cross section of at least 10 mm2 (8 AWG) or additionally run a second
equipment grounding conductor of the same cross section as the original
equipment grounding conductor.
Bosch Rexroth AG 17/69
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock
Protective extra-low voltage is used to allow connecting devices with basic in‐
sulation to extra-low voltage circuits.
On components of an electric drive and control system provided by Bosch
Rexroth, all connections and terminals with voltages between 5 and 50 volts
are PELV ("Protective Extra-Low Voltage") systems. It is allowed to connect
devices equipped with basic insulation (such as programming devices, PCs,
notebooks, display units) to these connections.
Danger to life, risk of injury by electric shock! High electrical voltage by incorrect
connection!
If extra-low voltage circuits of devices containing voltages and circuits of more
than 50 volts (e.g., the mains connection) are connected to Bosch Rexroth
products, the connected extra-low voltage circuits must comply with the re‐
quirements for PELV ("Protective Extra-Low Voltage").
3.3.3 Protection Against Dangerous Movements
Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:
● Improper or wrong wiring or cable connection
● Operator errors
● Wrong input of parameters before commissioning
● Malfunction of sensors and encoders
● Defective components
● Software or firmware errors
These errors can occur immediately after equipment is switched on or even
after an unspecified time of trouble-free operation.
The monitoring functions in the components of the electric drive and control
system will normally be sufficient to avoid malfunction in the connected drives.
Regarding personal safety, especially the danger of injury and/or property dam‐
age, this alone cannot be relied upon to ensure complete safety. Until the
integrated monitoring functions become effective, it must be assumed in any
case that faulty drive movements will occur. The extent of faulty drive move‐
ments depends upon the type of control and the state of operation.
18/69
Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Safety Instructions for Electric Drives and Controls
Dangerous movements! Danger to life, risk of injury, serious injury or property
damage!
A risk assessment must be prepared for the installation or machine, with its
specific conditions, in which the components of the electric drive and control
system are installed.
As a result of the risk assessment, the user must provide for monitoring func‐
tions and higher-level measures on the installation side for personal safety. The
safety regulations applicable to the installation or machine must be taken into
consideration. Unintended machine movements or other malfunctions are pos‐
sible if safety devices are disabled, bypassed or not activated.
To avoid accidents, injury and/or property damage:
● Keep free and clear of the machine’s range of motion and moving machine
parts. Prevent personnel from accidentally entering the machine’s range
of motion by using, for example:
– Safety fences
– Safety guards
– Protective coverings
– Light barriers
● Make sure the safety fences and protective coverings are strong enough
to resist maximum possible kinetic energy.
● Mount emergency stopping switches in the immediate reach of the oper‐
ator. Before commissioning, verify that the emergency stopping equip‐
ment works. Do not operate the machine if the emergency stopping switch
is not working.
● Prevent unintended start-up. Isolate the drive power connection by means
of OFF switches/OFF buttons or use a safe starting lockout.
● Make sure that the drives are brought to safe standstill before accessing
or entering the danger zone.
● Additionally secure vertical axes against falling or dropping after switching
off the motor power by, for example,
– mechanically securing the vertical axes,
– adding an external braking/arrester/clamping mechanism or
– ensuring sufficient counterbalancing of the vertical axes.
● The standard equipment motor holding brake or an external holding brake
controlled by the drive controller is not sufficient to guarantee personal
safety!
● Disconnect electrical power to the components of the electric drive and
control system using the master switch and secure them from reconnec‐
tion ("lock out") for:
– Maintenance and repair work
– Cleaning of equipment
– Long periods of discontinued equipment use
● Prevent the operation of high-frequency, remote control and radio equip‐
ment near components of the electric drive and control system and their
supply leads. If the use of these devices cannot be avoided, check the
machine or installation, at initial commissioning of the electric drive and
control system, for possible malfunctions when operating such high-fre‐
quency, remote control and radio equipment in its possible positions of
normal use. It might possibly be necessary to perform a special electro‐
magnetic compatibility (EMC) test.
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
DOK-SUPPL*-VDP16/40/60-PR03-EN-P
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
Safety Instructions for Electric Drives and Controls
Bosch Rexroth AG 19/69
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐
ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors
or permanent magnets of electric motors represent a serious danger to persons
with heart pacemakers, metal implants and hearing aids.
Health hazard for persons with heart pacemakers, metal implants and hearing
aids in proximity to electric components!
● Persons with heart pacemakers and metal implants are not allowed to
enter the following areas:
– Areas in which components of the electric drive and control systems
are mounted, commissioned and operated.
– Areas in which parts of motors with permanent magnets are stored,
repaired or mounted.
● If it is necessary for somebody with a heart pacemaker to enter such an
area, a doctor must be consulted prior to doing so. The noise immunity of
implanted heart pacemakers differs so greatly that no general rules 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.
3.3.5 Protection Against Contact With Hot Parts
Hot surfaces of components of the electric drive and control system. Risk of
burns!
● Do not touch hot surfaces of, for example, braking resistors, heat sinks,
supply units and drive controllers, motors, windings and laminated cores!
● According to the operating conditions, temperatures of the surfaces can
be higher than 60 °C (140 °F) during or after operation.
● Before touching motors after having switched them off, let them cool down
for a sufficient period of time. Cooling down can require up to 140 mi‐
nutes! The time required for cooling down is approximately five times the
thermal time constant specified in the technical data.
● After switching chokes, supply units and drive controllers off, wait 15 mi‐
nutes to allow them to cool down before touching them.
● Wear safety gloves or do not work at hot surfaces.
● For certain applications, and in accordance with the respective safety reg‐
ulations, the manufacturer of the machine or installation must take meas‐
ures to avoid injuries caused by burns in the final application. These
measures can be, for example: Warnings at the machine or installation,
guards (shieldings or barriers) or safety instructions in the application
documentation.
3.3.6 Protection During Handling and Mounting
Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!
● Observe the relevant statutory regulations of accident prevention.
● Use suitable equipment for mounting and transport.
● Avoid jamming and crushing by appropriate measures.
20/69
Safety Instructions for Electric Drives and Controls
Bosch Rexroth AG DOK-SUPPL*-VDP16/40/60-PR03-EN-P
● Always use suitable tools. Use special tools if specified.
● Use lifting equipment and tools in the correct manner.
● Use suitable protective equipment (hard hat, safety goggles, safety shoes,
safety gloves, for example).
● Do not stand under hanging loads.
● Immediately clean up any spilled liquids from the floor due to the risk of
slipping.
3.3.7 Battery Safety
Batteries consist of active chemicals in a solid housing. Therefore, improper
handling can cause injury or property damage.
Risk of injury by improper handling!
● Do not attempt to reactivate low batteries by heating or other methods (risk
of explosion and cauterization).
● Do not attempt to recharge the batteries as this may cause leakage or
explosion.
● Do not throw batteries into open flames.
● Do not dismantle batteries.
● When replacing the battery/batteries, do not damage the electrical parts
installed in the devices.
● Only use the battery types specified for the product.
Rexroth IndraControl VDP 16.1/40.1/60.1 Operator Display
Environmental protection and disposal! The batteries contained in
the product are considered dangerous goods during land, air, and
sea transport (risk of explosion) in the sense of the legal regulations.
Dispose of used batteries separately from other waste. Observe the
national regulations of your country.
3.3.8 Protection Against Pressurized Systems
According to the information given in the Project Planning Manuals, motors and
components cooled with liquids and compressed air can be partially supplied
with externally fed, pressurized media, such as compressed air, hydraulics oil,
cooling liquids and cooling lubricants. Improper handling of the connected sup‐
ply systems, supply lines or connections can cause injuries or property damage.
Risk of injury by improper handling of pressurized lines!
● Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐
sion).
● Observe the respective manufacturer's operating instructions.
● Before dismounting lines, relieve pressure and empty medium.
● Use suitable protective equipment (safety goggles, safety shoes, safety
gloves, for example).
● Immediately clean up any spilled liquids from the floor due to the risk of
slipping.
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