Bosch Rexroth IndraControl VDP 80.1 User Manual
Electric Drives
and Controls Pneumatics
Hydraulics
Linear Motion and
Assembly Technologies
Rexroth IndraControl VDP 80.1
Machine Operator Panel
Operator Display
Project Planning Manual
Service
R911329156
Edition 03
Bosch Rexroth AG DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel 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 80.1
Machine Operator Panel
Operator Display
Project Planning Manual
DOK-SUPPL*-VDP*80.1***-PR03-EN-P
RS-8dae182ab4c72dfa0a6846a001085cac-1-en-US-7
This documentation
contains a detailed description of the standard interface of
the HMI operator panel.
Edition
Edition 01 06.2009 First edition
Edition 02 03.2010 Modifications implemen‐
Edition 03 04.2011 Modifications implemen‐
Release Date Notes
ted
ted
© Bosch Rexroth AG 2011
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 a. Main, Germany
Phone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85
http://www.boschrexroth.com/
Machine Tool System Development, PeSc (SyMu/PiGe)
This document has been printed on chlorine-free bleached paper.
DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Bosch Rexroth AG I/61
Table of Contents
Table of Contents
Page
1 About this Documentation.............................................................................................. 3
1.1
1.2 Required and Supplementing Documentations...................................................................................... 3
1.2.1 Selecting.............................................................................................................................................. 3
1.2.2 Configuring.......................................................................................................................................... 3
1.2.3 Commissioning.................................................................................................................................... 4
1.2.4 Operating............................................................................................................................................. 4
1.2.5 Maintenance........................................................................................................................................ 5
1.3 Representing Information....................................................................................................................... 5
1.3.1 Safety Instructions............................................................................................................................... 5
2 Important Instructions on Use ....................................................................................... 7
2.1 Appropriate Use ..................................................................................................................................... 7
2.1.1 Introduction.......................................................................................................................................... 7
2.1.2 Areas of Application and Use.............................................................................................................. 7
2.2 Inappropriate Use................................................................................................................................... 8
Validity of the Documentation................................................................................................................. 3
3 Safety Instructions for Electric Drives and Controls....................................................... 9
3.1 Definitions of Terms................................................................................................................................ 9
3.2 General Information.............................................................................................................................. 10
3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 10
3.2.2 Requirements for Safe Use............................................................................................................... 10
3.2.3 Hazards by Improper Use.................................................................................................................. 11
3.3 Instructions with Regard to Specific Dangers....................................................................................... 13
3.3.1 Protection Against Contact With Electrical Parts and Housings........................................................ 13
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 14
3.3.3 Protection Against Dangerous Movements....................................................................................... 14
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 16
3.3.5 Protection Against Contact With Hot Parts........................................................................................ 16
3.3.6 Protection During Handling and Mounting......................................................................................... 17
3.3.7 Battery Safety.................................................................................................................................... 17
3.3.8 Protection Against Pressurized Systems........................................................................................... 18
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 18
4 Dimensions, Installation and Wiring ............................................................................ 21
4.1 Dimensions........................................................................................................................................... 21
4.2 Section.................................................................................................................................................. 26
4.3 System Installation Environment.......................................................................................................... 26
4.4 Grounding the VDP 80.1....................................................................................................................... 27
4.5 Technical Data...................................................................................................................................... 27
4.5.1 Display............................................................................................................................................... 27
4.5.2 Weight............................................................................................................................................... 28
4.5.3 Standards.......................................................................................................................................... 28
II/61
Table of Contents
Bosch Rexroth AG DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Page
Applied Standards.......................................................................................................................... 28
CE Conformity Marking.................................................................................................................. 28
UL Approval.................................................................................................................................... 28
5 Design.......................................................................................................................... 31
5.1
5.2 Operating Elements.............................................................................................................................. 33
Overview............................................................................................................................................... 31
6 Connections and Interfaces......................................................................................... 35
6.1 Interface Connection of HMI Operator Panel Power Supply................................................................ 35
6.2 Interface Connection Data exchange .................................................................................................. 35
6.3 USB Interface....................................................................................................................................... 36
6.4 Connecting the Extended IO Interface.................................................................................................. 37
6.5 Interface Connection of Handwheel Unit.............................................................................................. 39
6.6 Emergency Stop in Interface for Handwheel Unit................................................................................. 44
6.7 Handwheel extended interface (only Universal operator panel) .......................................................... 46
7 Universal HMI Panel.................................................................................................... 49
7.1 Labeling Strips...................................................................................................................................... 49
7.2 Labeling the Labeling Strips................................................................................................................. 49
8 Order Information......................................................................................................... 51
8.1 Type Designation Code........................................................................................................................ 51
8.2 Connecting Cables............................................................................................................................... 51
9 Accessory.................................................................................................................... 53
9.1 Hand-Held Terminal VCH02 Handwheel.............................................................................................. 53
10 Service and Support.................................................................................................... 57
Index............................................................................................................................ 59
DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Bosch Rexroth AG 3/61
About this Documentation
1 About this Documentation
1.1 Validity of the Documentation
project planning manual describes the HMI operator control panel of the
This
CNC "IndraMotion MTX micro" of Bosch Rexroth. The manual contains speci‐
fications regarding hardware and interfaces as well as instructions for connect‐
ing the operator display and the machine operator panels to turning and milling
machines.
This documentation supports the user during the phase
● "mounting".
1.2 Required and Supplementing Documentations
1.2.1 Selecting
Documentation titles with type designation codes and parts numbers
Rexroth IndraMotion MTX micro xxVRS System Description
DOK-MTXMIC-SYS*DES*V12-PRxx-EN-P, R911334369
This
documentation
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
DOK-SUPPL*-VDP*80.1***-PRxx-EN-P, R911329156
This documentation contains a detailed description of the standard interfaced of the HMI operator panel.
Rexroth IndraDrive Drive Controllers HCQ, HCT
DOK-INDRV*-HCQ-T+HMQ-T-PRxx-EN-P , R911324185
provides a system overview and describes the product properties of the Rexroth IndraMotion MTX micro.
xx Respective version or edition
Fig.1-1: MTX micro documentation overview - Selecting
1.2.2 Configuring
Documentation titles with type designation codes and parts numbers
Rexroth IndraMotion MTX micro xxVRS Functional Description
DOK-MTXMIC-NC*FUNC*V12-RExx-EN-P, R911334357
This documentation provides information on basic commissioning steps and available functions of the control.
Rexroth IndraMotion MTX micro xxVRS Machine Parameters
DOK-MTXMIC-MA*PAR**V12-RExx-EN-P, R911334365
This documentation describes the design and adjustment of the parameters available.
Rexroth IndraMotion MTX xxVRS PLC Interface
DOK-MTX***-PLC*INT*V12-PRxx-EN-P, R911334381
This documentation describes interface signals and program function blocks for the integrated PLC.
xx Respective version or edition
Fig.1-2: MTX micro documentation overview - Configuring
4/61
Bosch Rexroth AG DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
About this Documentation
1.2.3 Commissioning
Documentation titles with type designation codes and parts numbers
Rexroth IndraMotion MTX micro Easy Setup for Standard Turning and Milling Machines
DOK-MTXMIC-EASY*******-COxx-EN-P, R911332281
This documentation
initial commissioning with handling instructions and examples.
Rexroth IndraWorks xxVRS Software Installation
DOK-IWORKS-SOFTINS*V12-COxx-EN-P, R911334396
This documentation describes the IndraWorks installation.
Rexroth IndraWorks xxVRS Engineering
DOK-IWORKS-ENGINEE*V12-APxx-EN-P, R911334388
This documentation
instructions on how to work with IndraWorks and how to operate the oscilloscope function.
Rexroth IndraMotion MTX xxVRS Commissioning
DOK-MTX***-STARTUP*V12-COxx-EN-P, R911334377
This documentation
sioning and configuration of the axes and the user interface as well as the PLC data are described.
Rexroth IndraWorks xxVRS IndraLogic 2G Programming Instruction
DOK-IWORKS-IL2GPRO*V12-APxx-EN-P, R911334390
This documentation describes the PLC programming tool IndraLogic 2G and its application. It includes the basic usage, first
steps, visualization, menu items and editors.
Rexroth IndraWorks 12VRS Basic Libraries IndraLogic 2G
DOK-IL*2G*-BASLIB**V12-LIxx-EN-P, R911333835
This documentation describes the system-comprehensive PLC libraries.
provides an overview of the components of the IndraMotion MTX micro control system and supports the
describes the application of IndraWorks in which the Rexroth Engineering tools are integrated. It includes
describes the commissioning of the IndraMotion MTX control. Apart from a complete overview, commis‐
xx Respective version or edition
Fig.1-3: MTX micro documentation overview - Commissioning
1.2.4 Operating
Documentation titles with type designation codes and parts numbers
Rexroth IndraMotion MTX micro xxVRS Standard NC Operation
DOK-MTXMIC-NC*OP***V12-APxx-EN-P, R911334373
This documentation describes the MMI operating software of the IndraMotion MTX micro.
Rexroth IndraMotion MTX micro xxVRS Programming Manual
DOK-MTXMIC-NC**PRO*V12-RExx-EN-P, R911334361
The following documentation provides information about the standard programming of the Rexroth IndraMotion MTX control
micro.
DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Bosch Rexroth AG 5/61
About this Documentation
Rexroth IndraMotion MTX xxVRS Standard NC Cycles
DOK-MTX***-NC*CYC**V12-PRxx-EN-P, R911334375
This documentation
control.
Rexroth IndraMotion MTX xxVRS Block Pre-Run
DOK-MTX***-BLK*RUN*V12-APxx-EN-P, R911334379
This documentation
end user.
describes the application of the standard cycles of the different technologies for Rexroth IndraMotion MTX
explains to the machine manufacturer how to setup the "Block pre-run" function at the machine for the
xx Respective version or edition
Fig.1-4: MTX micro documentation overview - Operating
1.2.5 Maintenance
Documentation titles with type designation codes and parts numbers
Rexroth IndraMotion MTX xxVRS Diagnostic Messages
DOK-MTX***-DIAGMES*V11-RExx-EN-P, R911332311
This documentation provides an overview on errors, warnings and messages within the Rexroth IndraMotion MTX control.
xx Respective version or edition
Fig.1-5: MTX micro documentation overview - Maintenance
1.3 Representing Information
1.3.1 Safety Instructions
The meaning of different warning symbols and signal words in the safety in‐
structions for electric drive and controls can be found under 3.4 Explanation of
signal words and the signal graphics, page 18.
6/61
Bosch Rexroth AG DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
2 Important Instructions on Use
2.1 Appropriate Use
Bosch Rexroth AG 7/61
Important Instructions on Use
2.1.1
Introduction
Bosch Rexroth products represent state-of-the-art development and manufac‐
turing. The products are tested prior to delivery to ensure operating safety and
reliability.
WARNING
The products are intended for use in the industrial sector and can only be used
for the
intended purpose, personal injury and material damages can occur.
Before using Bosch Rexroth products, ensure that all the prerequisites for ap‐
propriate use of the products are complied with:
● Anyone using
● If the products take the form of hardware, their original state may not be
● Do not mount damaged or faulty products or use them in operation.
● It has to be ensured that the products have been installed as described in
intended purpose. If products are used for any other purpose than the
In case of damages arising from inappropriate use, Bosch Rexroth
as manufacturer
liable and does not compensate for damages. Furthermore, Bosch
Rexroth cannot be held liable for any claims for damages. The user
bears all risks arising from the inappropriate use of the products.
Bosch Rexroth products in any way has to read and under‐
stand the relevant safety instructions and be familiar with the appropriate
use.
modified, i.e., no structural changes are permitted. It its not permitted to
decompile software products or to modify the source codes.
the relevant documentation.
Personal injury and material damages can re‐
sult from inappropriate use of the products!
does not assume any warranty, cannot be held
2.1.2 Areas of Application and Use
The VDP 80.1 of Bosch Rexroth is an operator and visualization display.
The VDP 80.1 can only be used with the attachments and acces‐
sories specified
specified may neither be attached nor connected. The same applies
to cables and wires.
The unit can only be operated with the configurations and compo‐
nent combinations explicitly specified in this documentation and
only with the software and firmware specified in the appropriate
functional description.
Typical area of application of the VDP 80.1:
● Machine tools
operator display VDP 80.1 may only be operated under the assembly and
The
installation conditions, in the specified position of application and under the
listed ambient conditions (temperature, degree of protection, humidity, EMC
etc.) specified in this documentation.
in this documentation. Components that are not
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Important Instructions on Use
Bosch Rexroth AG DOK-SUPPL*-VDP*80.1***-PR03-EN-P
2.2 Inappropriate Use
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Using the
operating conditions other than the conditions described in the documentation
and the specified technical data, is defined as "inappropriate use".
The VDP 80.1 cannot be used if
● subjected to conditions that do not comply with the specified ambient con‐
● Furthermore, the operator display shall not be used for applications not
VDP 80.1 outside the above-referenced areas of application or under
ditions. Operation under water, under extreme temperature fluctuations or
extreme maximum temperatures is not permitted.
expressly approved of by Bosch Rexroth. Also note the information in the
general safety instructions!
DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Bosch Rexroth AG 9/61
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
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,
documentation comprises the entire documentation used to inform
10/61
Safety Instructions for Electric Drives and Controls
Bosch Rexroth AG DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel 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
placed on the market.
is a person installing, commissioning or using a product which has been
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*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Safety Instructions for Electric Drives and Controls
concept in which measures of risk reduction for personal safety depend
on electrical, electronic or programmable control systems.
● The information
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.
given in the application documentation with regard to the
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 11/61
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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Bosch Rexroth AG DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Safety Instructions for Electric Drives and Controls
● 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!
DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Safety Instructions for Electric Drives and Controls
Bosch Rexroth AG 13/61
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
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.
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.
electric shock. When operating components of the electric drive
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Bosch Rexroth AG DOK-SUPPL*-VDP*80.1***-PR03-EN-P
Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Safety Instructions for Electric Drives and Controls
● 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 minimum cross sec‐
tion according to the table below. With an outer conductor cross section
smaller than 10 mm2 (8 AWG), the alternative connection of two equip‐
ment grounding conductors is allowed, each having the same cross
section as the outer conductors.
Cross section outer con‐
ductor
1.5 mm2 (16 AWG)
2.5 mm2 (14 AWG) 2 × 2.5 mm2 (14 AWG)
4 mm2 (12 AWG) 2 × 4 mm2 (12 AWG)
6 mm2 (10 AWG) 2 × 6 mm2 (10 AWG)
10 mm2 (8 AWG)
16 mm2 (6 AWG)
25 mm2 (4 AWG)
Minimum cross section equipment grounding conductor
Leakage current ≥ 3.5 mA
1 equipment grounding
conductor
10 mm2 (8 AWG)
16 mm2 (6 AWG)
2 equipment grounding con‐
ductors
2 × 1.5 mm2 (16 AWG)
-
-
-
35 mm2 (2 AWG)
50 mm2 (1/0 AWG) 25 mm2 (4 AWG)
70 mm2 (2/0 AWG) 35 mm2 (2 AWG)
... ... ...
Fig.3-1: Minimum Cross Section of the Equipment Grounding Connection
-
-
-
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:
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Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Safety Instructions for Electric Drives and Controls
● 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.
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.
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Safety Instructions for Electric Drives and Controls
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Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
● The standard equipment motor
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.
holding brake or an external holding brake
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.
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Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
Safety Instructions for Electric Drives and Controls
● 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.
● 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
falling!
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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.
Environmental protection and disposal! The batteries contained in
the product
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.
are considered dangerous goods during land, air, and
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Rexroth IndraControl VDP 80.1 Machine Operator Panel Operator Display
3.3.8 Protection Against Pressurized Systems
According to
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
falling!
the information given in the Project Planning Manuals, motors and
Environmental protection and disposal! The agents (e.g., fluids)
used to
Dispose of agents harmful to the environment separately from other
waste. Observe the national regulations of your country.
operate the product might not be environmentally friendly.
3.4 Explanation of Signal Words and the Safety Alert Symbol
The
Safety Instructions in the available application documentation contain spe‐
cific signal words (DANGER, WARNING, CAUTION or NOTICE) and, where
required, a safety alert symbol (in accordance with ANSI Z535.6-2006).
The signal word is meant to draw the reader's attention to the safety instruction
and identifies the hazard severity.
The safety alert symbol (a triangle with an exclamation point), which precedes
the signal words DANGER, WARNING and CAUTION, is used to alert the
reader to personal injury hazards.
DANGER
In case of non-compliance with this safety instruction, death or serious injury
will occur.
WARNING
In case of non-compliance with this safety instruction, death or serious injury
could occur.
CAUTION
In case of non-compliance with this safety instruction, minor or moderate injury
could occur.
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