Bosch Rexroth IPC, IPC300 Connectivity Manual

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Page 1

Industrial PC

IPC / IPC300 Connectivity Manual

Antriebs- und Steuerungstechnik

Edition

104

Page 2

Industrial PC

IPC / IPC300 Connectivity Manual

1070 073 822-104 (02.06) GB

E 1999 – 2002

by Bosch Rexroth AG, Erbach / Germany

Reproduction or distribution by any means subject to our prior written permission.

Discretionary charge 6.–

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Contents

1 Safety Instructions 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Standard operation 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Qualified personnel 1–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Safety markings on components 1–3 . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Safety instructions in this manual 1–4 . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Safety instructions concerning the described product 1–5 . . . . . . . .

1.6 Documentation, software release and trademarks 1–7 . . . . . . . . . . .

2 IPC System Overview 2–1 . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Versions 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Specifications 2–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Expansion slots 2–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Rechargeable battery pack 2–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Operating conditions 2–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Standards compatibility 2–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

3 Security Functions 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Temperature monitoring function 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Uninterruptible power supply (UPS) 3–2 . . . . . . . . . . . . . . . . . . . . . . . .

3.3 UPS program 3–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Functions 3–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Operating and configuring UPSplus (Windows95) 3–5 . . . . . . . . . . .

3.3.3 Operating and configuring UPSNT (WindowsNT) 3–9 . . . . . . . . . . . .

4 Installation 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Installed positions and clearances 4–2 . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 IPC / IPC300 dimensioned drawings 4–3 . . . . . . . . . . . . . . . . . . . . . . .

4.3 Installing IPC / IPC300 in mounting frame 4–4 . . . . . . . . . . . . . . . . . .

5 Electrical Connections 5–1 . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Protective Earth conductor (PE) & screening information 5–2 . . . . .

5.2 Interference suppression information 5–3 . . . . . . . . . . . . . . . . . . . . . .

5.3 Power supplies 5–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 24VDC power supply 5–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 230/115 VAC power supply 5–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents

6 Interfaces, Ports & Connectors 6–1 . . . . . . . . . . . . . . . .

6.1 Overview 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 COM1 through COM4 serial ports 6–3 . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Pin assignments 6–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2 COM1 through COM4 settings 6–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 LPT1 parallel port 6–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Ethernet connection 6–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Display interfaces 6–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5.1 BF2xxT for IPC 6–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5.2 BF3xxT for IPC300 6–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5.3 External CRT monitor for IPC / IPC300 6–16 . . . . . . . . . . . . . . . . . . . . .

6.6 X11 power supply connection 6–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Keyboard connector 6–19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Mouse port 6–21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 LED Display 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Maintenance and Replacement 8–1 . . . . . . . . . . . . . . . .

8.1 Fuse protection 8–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Replacing the hard disk 8–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.1 Replacing the CD-ROM drive 8–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.2 Replacing the 3.5” floppy disk 8–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.3 Replacing the battery pack 8–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Expansion cards 8–12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.1 Installing an expansion card 8–12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.2 BIOS settings for IPC 8–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.3 BIOS settings for IPC300 8–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Software 9–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 BIOS software 9–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Operating system and utilities 9–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 Application software 9–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3.1 Bosch PCL (software PLC) 9–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3.2 Typ3 osa (CNC operating software) 9–3 . . . . . . . . . . . . . . . . . . . . . . .

9.3.3 MADAP Studio (automatic system diagnostics) 9–4 . . . . . . . . . . . . .

10 Order numbers 10–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 IPC / IPC300 10–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 Accessories 10–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 Spare Parts 10–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Appendix A–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 Abbreviations A–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Index A–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 Safety Instructions

Before you start working with the Bosch Rexroth IPC / IPC300 Industrial PC, we recommend that you thoroughly familiarize yourself with the contents of this manual. Keep this manual in a place where it is always accessible to all users.

1.1 Standard operation

This manual contains information required for the proper use of this product. However, for reasons of structural clarity, the manual cannot provide exhaustive details regarding all available combinations of functional options. Similarly, it is not feasible to consider every conceivable integration or operating scenario within the confines of this manual.

The described industrial PCs serve as operating and visualization units for Bosch Rexroth proprietary application software running on Microsoft Windows NT 4.0 operating systems. They are intended as control platforms for testing, adjustment and assembly station applications.

While it is possible in principle to operate other proprietary operating systems or application software on the industrial PCs, the occurrence of unexpected effects, even with Bosch Rexroth applications, cannot be entirely ruled out. With this type of nonstandard operation, Bosch Rexroth shall not assume any liability for either hardware and/or software.

Safety Instructions

1–1

The products described hereunder D were developed, manufactured, tested and documented in accordance

with the relevant safety standards. In standard operation, and provided that the specifications and safety instructions relating to the project phase, installation and correct operation of the product are followed, there should arise no risk of danger to personnel or property.

D are certified to be in full compliance with the requirements of the

D COUNCIL DIRECTIVE 89/336/EEC of May 3rd 1989 on the approx-

imation of the laws of the Member States relating to electromagnetic compatibility, 93/68/EEC (amendments of Directives), and 93/44/EEC (relating to machinery)

D COUNCIL DIRECTIVE 73/23/EEC (electrical equipment designed for

use within certain voltage limits)

D Harmonized standards EN 50081-2 and EN 50082-2

D are designed for operation in an industrial environment (Class A

emissions). The following restrictions apply:

D Direct connection to the public low-voltage power supply is prohibited. D Connection to the medium and/or high-voltage system must be pro-

vided via transformer.

The operation of Class A devices in private residences, in business or small-industry settings is permitted only if their operation does not produce undue interference with other devices.

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. This is a Class A device. In a residential area, this device may cause

radio interference. In such case, the user may be required to introduce suitable countermeasures, and to bear the cost of the same.

The prerequisites for trouble-free service and and safe operation of the described products are proper transport, handling and storage, placement, installation, plus careful operation of the equipment.

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1–2

Safety Instructions

1.2 Qualified personnel

This instruction manual is designed for specially trained personnel. The relevant requirements are based on the job specifications as outlined by the ZVEI and VDMA professional associations in Germany. Please refer to the following German-Language publication:

Weiterbildung in der Automatisierungstechnik Publishers: ZVEI and VDMA Maschinenbau Verlag Postfach 71 08 64 60498 Frankfurt/Germany

This instruction manual is designed specifically for system planners and PC specialists. They require special knowledge of configuration and start-up of electrical equipment.

Interventions in the hardware and software of our products not described in this instruction manual may only be performed by our skilled personnel.

Unqualified interventions in the hardware or software or non-compliance with the warnings listed in this instruction manual or indicated on the product may result in serious personal injury or damage to property.

Installation and maintenance of the products described hereunder are the exclusive domain of trained electricians as per IEV 826-09-01 (modified) who are familiar with the contents of this manual.

Trained electricians are persons of whom the following is true: D They are capable, due to their professional training, skills and expertise,

and based upon their knowledge of and familiarity with applicable technical standards, of assessing the work to be carried out, and of recognizing possible hazards.

D They possess, subsequent to several years’ experience in a comparable

field of endeavour, a level of knowledge and skills that may be deemed commensurate with that attainable in the course of a formal professional education.

With regard to the foregoing, please read the information about our comprehensive training program.

You find the latest information on training courses, teachware and training systems on our website http://www.boschrexroth.de. The professional staff at our Didactic Center Erbach will be pleased to provide detailed information. You may contact the center by telephone at (+49) 6062 78-600.

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1.3 Safety markings on components

DANGER! High voltage!

DANGER! Corrosive battery acid!

CAUTION! Electrostatically sensitive devices (ESD)!

Disconnect mains power before opening!

Safety Instructions

1–3

Lug for connecting PE conductor only! Screened conductor only!

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1–4

Safety Instructions

1.4 Safety instructions in this manual

DANGEROUS ELECTRICAL VOLTAGE

This sym b o l warns of the presence of a dangerous electrical voltage. In- sufficient or lacking compliance with this warning can result in personal

injury.

DANGER

This symbol i s u s e d w h e r ever insufficient or lacking observance of this instruction can result in personal injury.

CAUTION

This symbol is used wherever insufficient or lacking observance of instructions can result in damage to equipment or data files.

. This symbol is used to alert the user to an item of special interest.

L This asterisk symbol indicates that the manual is describing an activity which

the user will be required to perform.

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1.5 Safety instructions concerning the described product

DANGER Fatal injury hazard through ineffective Emergency-STOP devices! Emergency-STOP safety devices must remain effective and accessible during all operating modes of the system. The release of functional locks imposed by Emergency-STOP devices must never be allowed to cause an uncontrolled system restart! Before restoring power to the system, test the Emergency-STOP sequence!

DANGER Retrofits or modifications may interfere with the safety of the products described hereunder!

Safety Instructions

1–5

The consequences may be severe personal injury or damage to equipment or the environment. Therefore, any system retrofitting or modification utilizing equipment components from other manufacturers shall require express approval by Bosch Rexroth.

DANGEROUS ELECTRICAL VOLTAGE Unless described otherwise, maintenance procedures must always be carried out only while the system is isolated from the power supply. During this process, the system must be blocked to prevent an unauthorized or inadvertent restart.

If measuring or testing procedures must be performed on active systems, these must be carried out by trained electricians.

CAUTION Only Bosch Rexroth-approved spare parts may be used!

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CAUTION Danger to the module! All ESD protection measures must be observed when using the module! Prevent electrostatic discharges!

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1–6

Safety Instructions

Observe the following protective measures for electrostatically sensitive devices (ESD)!

D The personnel responsible for storage, transport and handling must be

trained in ESD protection.

D ESDs must be stored and transported in dedicated protective packaging. D Out of principle, ESDs may be handled only at special ESD work stations

equipped for this particular purpose.

D Personnel, work surfaces and all devices and tools that could might come

into contact with ESDs must be on the same potential (e.g., earthed).

D An approved earthing wrist strap must be worn. It must be connected to

the work surface via a cable with integrated 1 MW resistor.

D ESDs may under no circumstances come into contact with objects sus-

ceptible to accumulating an electrostatic charge. Most items made of plastic belong to this category.

D When installing ESDs in or removing them from an electronic device, the

power supply of the device must be switched OFF.

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1.6 Documentation, software release and trademarks

Documentation

The present manual provides the user with comprehensive information about operation and configuration of the IPC / IPC300 Industrial PC.

Overview of available documentation Part no.

IPC, IPC300 Connectivity Manual 1070 073 812 1070 073 822

Safety Instructions

German English

1–7

Release

Trademarks

BF2xxT / BF3xxT Control Panel Connectivity Manual

1070 073 814 1070 073 824

. In this manual the floppy disk drive always uses drive letter A:, and the

hard disk drive always uses drive letter C:.

Special keys or key combinations are shown enclosed in pointed brackets:

D Named keys: e.g., <Enter>, <PgUp>, <Del> D Key combinations (pressed simultaneously): e.g., <Ctrl> + <PgUp>

Information on the software version for Windows95 or WindowsNT can be obtained by:

1. Clicking with the right mouse button on the “My Computer” icon (”Workplace”) on the desktop

2. Select “Properties” menu option

All trademarks referring to software that is installed on Bosch Rexroth products when shipped from the factory represent the property of their respective owners.

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At the time of shipment from the factory, all installed software is protected by copyright. Software may therefore be duplicated only with the prior permission of the respective manufacturer or copyright owner.

MS-DOSr and Windowst are registered trademarks of Microsoft Corporation.

PROFIBUSr

is a registered trademark of the PROFIBUS Nutzerorganisa-

tion e.V. (user organization).

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1–8

Notes:

Safety Instructions

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2 IPC System Overview

The Bosch IPC and IPC300 each comprise a powerful industrial PC with additional components (e.g., UPS, temperature monitoring unit, safe shutdown of the operating system, up to 6 expansion cards with PCI and ISA slot), all of which exceed the standard of an industrial PC.

The physical contruction is very compact and service-friendly, providing t h e suitability for industrial applications:

D High degree of failure resistance (e.g., shock and vibration-proof

cushioned hard disk, UPS uninterruptible power supply), and

D Simple maintenance

In accordance with requirements, the IPC / IPC300 is supplied with installed Microsoft Windows 95B or Windows NT4.0 operating system and appropriate Bosch Rexroth application software (refer to Section 9.3).

2.1 Versions

IPC System Overview

2–1

The IPC and IPC300 are available in two equipment versions accommodating different power supplies:

D 230/115 V D 24 V

. The 230/115 V

version

version also has a 24 VDC input (X10_1) which is not

functional, however.

230/115 V

24 V

version

version CD-ROM drive

Expansion slots

230/115 V

3.5” Floppy disk

1070 073 822-104 (02.06) GB

24 V

+ –

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2–2

IPC System Overview

2.2 Specifications

PC feature IPC IPC300

Interl Pentium processor or compatible CPU (socket 7) with Intel MMXT

Second level cache 512 kB 512 kB RAM MIN 64 MB

Hard disk > 2.1 GB IDE (spring-cushion mount,

CD-ROM drive 32 X (or higher) 32-fach (min.) Floppy Disk High-density 3.5 in./1.44 MB High-density 3.5 in./1.44 MB Free expansion slots 4x PCI / 2x ISA or

Power supply (2 versions)

UPS (Uninterruptible Power Supply)

Temperature monitoring unit With warning function & safe shutdown With warning function & safe shutdown 4 LEDs Display of essential operating statuses Display of essential operating statuses Standard interfaces 4x serial (RS-232,

technology

y 200 MHz or y 266 MHz* y 266 MHz

optional 400 MHz PentiumT III

min 64 MB

MAX 128 MB or 256 MB*

w/ Autopark function)

3x PCI / 3x ISA 230/115 VAC (at 50/60 Hz) or

24 VDC Via internal battery Via internal battery

of which 1x optional RS-485/422), 1x parallel, PS/2 keyboard, PS/2 mouse, VGA

max. 256 MB > 2.1 GB IDE (federnd gelagert,

mit Autopark-Funktionalität)

4x PCI / 2x ISA or 3x PCI / 3x ISA

230/115 VAC (at 50/60 Hz) or 24 VDC

4x serial (RS-232, of which 1x optional RS-485/422), 1x parallel, PS/2 keyboard, PS/2 mouse, VGA

Enhanced interfaces Ethernet,

LVDS video transmission (touch screen signals via COM2),

power supply for control panel. Weight Approx. 8 kg Approx. 8 kg IPC dimensions 19 in. housing:

448 x 132 x 256 mm

(19 in. x 3U x 256 mm) Operating system Microsoft Windows 95B / Windows NT4.0 Microsoft Windows NT 4.0

* Due to processor phase-out, the IPC subject to concurrent modification to 266 MHz / MAX 256 MB.

Ethernet, Gigabit video transmission including touch screen signals, power supply for control panel.

19”-Gehäuse: 448 x 132 x 256 mm (19 in. x 3U x 256 mm)

. All specifications are subject to change as a result of technological de-

velopments. This also means that components providing higher than the specified performance (e.g., a faster processor) may be integrated in the devices without explicit reference in this documentation.

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2.3 Expansion slots

IPC System Overview

Six expansion slots are provided for expansion cards:

D 3 PCI bus slots D 2 ISA bus slots D 1 PCI or ISA bus slot (combination slot)

CAUTION Possible damage to or application software PC through the use of non-approved expansion cards. Use only approved expansion cards which have been installed by authorized specialists.

For more information on installing expansion cards, refer to Section 8.3.

2–3

2.4 Rechargeable battery pack

The IPC and IPC300 feature an integrated rechargeable battery pack (2 series-connected 6V batteries).

In the presence of a power failure, the battery pack facilitates a controlled and safe shutdown of the PC operating system, as described in Section 3.2, “UPS Functions”. Loss of data held in PC RAM is thus prevented.

The rechargeable battery pack must be replaced if it no longer accumulates a sufficient charge. Refer also to Section 8.2.3.

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2–4

IPC System Overview

2.5 Operating conditions

Temperature

The IPC and IPC300 are designed for continuous (24 hours/day) operation. The display backlight can be switched off. Unless stated otherwise in specific sections, these specifications apply:

Storage temperature

D –20°C to +60°C

Ambient temperature

D +5°C to +45°C Ambient temperatures apply to installation described in Section 4.

Temperature fluctuations of up to 3°C per minute are permitted.

Relative humidity

Atmospheric pressure

Protection Category ratings

CAUTION Excessive operating temperature! Do not expose the PC to direct sunlight or other sources of heat radiation!

Climate class 3K3, as per EN 60529; condensation not permitted.

To DIN 60204, when operating at altitudes up to 2000 m above sea level.

IP00 Control cabinets and installation compartments for the control panels must conform to IP 54 rating (dust filters upstream of air intake and exhaust):

CAUTION Conditions hazardous to the product! The ambient air must be free of electrically conductive pollutants (e.g., acids, alkali, corrosives, salts, metallic vapours, etc.). Air intake and exhaust filters must be serviced at regular intervals.

Vibration resistance, operating

Impact resistance

Frequency range: 10 to 150 Hz Amplitude: 0.075 mm at 10 to 57 Hz Acceleration: 1 g at 57 to 150 Hz

to EN 60068-2-6

15 g as per DIN IEC 68-2-27, no functional impediment.

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2.6 Standards compatibility

The IPC and IPC300 system components are certified to comply with the following standards:

D EN 60 204–1 Electrical systems on machines D EN 50 081–2 Basic specification for interference emission

D EN 50 082–2 Basic technical standard, interference resistance

D EN 60 742 Tranformer for 24 V power supply, protective se-

D EN 60 950 Overvoltage category II D EN 61 131 Requirements w/ respect to 24 V outputs D EN 61 131–2 Requirements w/ respect to 24 V power supply D EN 418 Machine safety, Emergency-STOP devices D EN 60 529 Protection categories (incl. housings and instal-

D EN 60 068–2–6 Vibration test D EN 60 068–2–27 Impact test D .IS.114 “X-ray Radiation” Directive, as per Official Fede-

IPC System Overview

(industrial environment)

paration

lation compartments)

ral Gazette

2–5

. The CE licensing requirements have been fulfilled for all IPC and

IPC300 shipped from the factory. However, the subsequent insertion of additional expansion cards will necessitate a supplementary CE certification.

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2–6

Notes:

IPC System Overview

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3 Security Functions

Each PC is equipped with a temperature monitoring function and an uninterruptible power supply (UPS). The UPS only works in conjunction with a battery pack.

3.1 Temperature monitoring function

The ambient air of the IPC must not exceed +45°C (see Section 2.5). To ensure operational reliability , a temperature monitoring function measures the internal housing temperature.

A temperature warning, occurring at internal housing temperatures exceed- ing 50°C, manifests itself as follows:

D via the flashing “Temp” LED at the front panel of the housing. D via a message window displayed by the operating system.

This message must also be interpreted by all PC applications, and by I/O processes in particular. Bosch Rexroth application programs are in full compliance with this requirement.

Security Functions

3–1

The descibed temperature monitor can be disabled by means of the following program:

D UPS D UPS

See also Section 3.3. If temperatures in the housing exceed 65°C, the IPC will be shut down and

switched off via the UPS logic circuit (see Section 3.2).

DANGER Inadvertent machine movements. Always ensure that temperatures remain within the noncritical range. In the case of application-sensitive procedures, ensure that machine movements are terminated in a controlled fashion in the event that the temperature monitoring function disables the operator terminal.

for Windows 95

plus

for Windows NT 4.0

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3–2

Security Functions

3.2 Uninterruptible power supply (UPS)

In the event of a power failure exceeding 800 ms in duration, or of an internal housing temperature in excess of 65°C (refer to Section 3.1, above), the UPS logic integrated in the power supply is activated, effecting a safe operating system shutdown procedure backed up by the internal rechargeable battery (”battery pack”). Power interruptions of shorter durations are bridged by the battery pack. For an IPC300 running with the Windows NT operating system, power interruptions of up t o 5 seconds in length may be permitted before the USP logic circuit activates.

Please note:

D To allow the rechargeable battery pack to attain its full charge capacity,

the IPC must remain powered up for a minimum of 5 hours subsequent to initial start-up. Sufficient USP protection cannot be ensured during this charging period.

D IPC only:

Frequent On/Off cycling of power tends to cause rapid discharge of the battery pack. You should never cycle the power more often than 4 times in succession. The battery pack must again be fully recharged thereafter.

D The UPS locgic function requires hard disk capacity for intermediate

datza storage. Ensure that the hard disk never fills up completely.

D Check and verify whether or not the preset Delay Time of 30 seconds

selected in the UPS Dialog window will allow the safe shutdown of all application programs, or whether the interval must be increased.

Voltage drops below 800 ms duration

Operating voltage

Operating voltage restored within 800 ms

IPC is not shut down,

Operating system

loaded

(standard

operation)

not loaded

as operating voltage interruption < 800 ms

DANGER If there are no batteries in the unit, or if the batteries are defective or discharged, the IPC will RESET without warning after a voltage dip in excess of 20 ms! Possible consequences are uncontrolled machine movements or loss of data. Each time the PC is booted up, observe UPS program messages indicating that the battery pack may be discharged. This test is run during each PC boot phase.

Voltage drops below 800 ms duration are bridged by the battery pack, and do not trigger the UPS logic circuit.

t0 t1 < 800 ms

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Page 21

Voltage drops between 800 ms and 60 s duration

In the event of a voltage drop in excess of 800 ms, the operating system will initiate a safe shutdown of the operating system after a preselected delay time.

D If the mains power is restored within a 5-second interval (short break), the

USP will remain disabled (IPC300 only with appropriate settings).

D If the mains power is restored within the next 60 seconds, the USP will

interrupt the operating voltage for another 8 seconds (up to t3), and then again restart the operating system.

Security Functions

3–3

Operating voltage

Operating system

loaded

(standard operation) not loaded

t0t1 = 800 ms

Mains voltage failure Mains voltage available

Shutdown of the application program

Delay Time, adjustable

Voltage interruption in excess of 60 seconds

After approx. 60 sec the UPS internally switches off the power supply.

Mains voltage failure

Operating system shutdown

Operating voltage interrupted for 8 seconds

Operating system startup

< 60 sec

= t2 + 8 sec

Operating voltage

Operating system

loaded

(standard

operation)

not loaded

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UPS deenergizes power supply

Shutdown of the application program

Operating system shutdown

Delay Time, adjustable

t0t1 = 800 ms t4 = t1 + 60 sec

. For the procedures required to adjust the Delay Time with the

“UPS also “UPS

” supplementary software, see page LEERER MERKER. See

plus

for IPC” (page 3–10), or “UPSNT for IPC300” (page 3–13).

Page 22

3–4

Security Functions

3.3 UPS program

3.3.1 Functions

The “UPS

” or “UPSNT” uninterruptible power supply program controls

plus

and monitors the integrated uninterruptible power supply (UPS). The program also checks the function of the battery pack, and controls temperature monitoring of the system. In the case of the IPC300, the program also monitors fan functions and internal operating voltages.

Depending on the type of IPC and its operating system, one of the following is installed:

D UPS D UPS D UPS

for IPC with Windows 95

plus

for IPC with Windows NT

for IPC300 with Windows NT

The UPS program is always connected to the UPS via the COM4 serial port. The occurrence of a voltage drop/interruption causes the UPS program to

respond as follows: D By sending, within a preselected interval (Delay Time = max. 50

seconds), a signal to all active applications, facilitating their safe shutdown by the user / operator or via special application routines.

D By following the expiration of the Delay Time by shutting down the operat-

ing system. Once the UPS power monitoring function has been triggered, aborting the system shutdown routine is no longer possible.

Closing all active applications prevents data loss in the event of a sudden voltage interruption. If the mains voltage has not been restored, the UPS switches off the IPC power supply after a maximum 60 seconds (see disconnect conditions in Section 3.2).

CAUTION Loss of data through manual restart! Note that the USP switches off the operator terminal in any case. For thus reason, once the operating system has been shut down, the “Restart” dialog button must not be selected. In the case of voltage interruptions below 60 seconds, the operating system is restarted automatically.

The operator cannot access the UPS

or UPSNT program during standard

plus

operation. Operation and settings are not possible without special access rights (as User or Administrator), and not until the operating system has been restarted.

. Parameter values set in UPS

or UPSNT may not be changed without

plus

prior consultation with Bosch Rexroth AG.

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Page 23

Security Functions

3–5

3.3.2 Operating and configuring UPS

. The full complement of the procedural steps described below is avail-

able only during the initial installation, or in the event that the program was started by a user with special access privileges.

Start / Stop

Select the UPS menu option in the main window, and double-click Start.

(Windows95)

plus

Hide

Exit

Simple operating menu

Subsequent to the initial installation or after a Stop command, the program is again started with this command. Once the start has been successful, the main window disappears after approx. 2 seconds, and a symbol is added to the task bar.

The USP program is exited by selecting the Stop menu command.

Hides the main window of the program, and adds a symbol to the task bar. The command is not available while the program is stopped.

Exits the entire program, and terminates an ongoing monitoring event.

Click the right mouse button to open a simple operating menu listing the important functions of the program.

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Page 24

3–6

Security Functions

Configuration

This dialogue defines the start and runtime characteristics of UPS monitoring. To allow possible changes to take effect, the UPS program must be stopped and restarted.

COM Port

UPS Shutdown Parameter

The UPS program is always connected to the UPS via the COM4 serial port.

Brute Shutdown

Upon receipt of the shutdown signal from the UPS, the shutdown command for the Windows operating system is issued without delay. This causes the immediate termination of all active aplications, followed by the shutdown of Windows.

Smart Shutdown

Upon receipt of the shutdown signal from the UPS, the preset Delay Time starts to elapse.

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Page 25

Security Functions

3–7

Delay Time This interval is defined as a value between 0 and 50 seconds, by which the

shutdown of Windows will be delayed. The intervening period is used to

dispatch a Request To Close message to all active windows. The user can avail himself of this time for the purpose of saving his data. Upon expiry of the Delay T ime, all application programs will be terminated without prior security query!

When setting the Delay Time, observe that there must be sufficient time to effect a safe shutdown of the operating system (closing and backing up Windows system files), i.e., between the end of the Delay Time and the expiry of the 60 seconds after the shutdown signal. If the interval is too short, the shutdown process will be interrupted because the UPS disrupts the mains power . This may cause loss of data in some circumstances.

CAUTION Upon expiry of the Delay Time, the operating system is shut down without prior security query . Unsecured data belonging to open applications will be lost.

Advanced Controls

Enable Accu Test

When this check box is checked, the system performs a test of the battery pack during each restart.

In the case of a faulty battery pack (e.g., defective battery pack, cable break, plug not connected), battery monitoring is disabled. The UPS program continues only with its temperature monitoring function. If temperature monitoring has not been enabled, the UPS program will be terminated.

Enable Temp Control

When this checkbox is checked, the ambient temperature is monitored on a continuous basis. Excessive temperatures will produce the following warning message:

1070 073 822-104 (02.06) GB

Subsequent to a temperature warning, the UPS program is again enabled. During the reactivation interval of approx. 2 seconds, no power monitoring takes place although the battery pack is fully functional.

Page 26

3–8

Info

Security Functions

Disable Auto Power Off

This option disables both the USP monitoring function and the power-off delay for the power supply:

D A voltage interruption will cause the PC to shut down immediately. D After a normal shutdown, the wait interval of approx. 60 seconds prior to

the shutdown of the power supply is omitted.

Although this function reduces the wait times during startups and software installations, it must always be disabled during standard operation!

CAUTION Loss of data! Activation of this checkbox no longer makes a safe shutdown possible in the event of a power failure. The device switches off instantly!

Shutdown Count

The displayed value shows how often the system was shut down by UPS, i.e. how many charging cycles the battery has been subjected to. More details regarding after how many charging cycles it is necessaary to replace the rechargebale batteries is contained in section 8.2.3.

plus

Mode

UPS

Default button

There are two operating modes for the UPS

program:

plus

Run as Service

The program is started as part of the Windows 95 startup, and remains active until Windows 95 is again terminated. Changing user logins have no influence on the program’s characteristics. The user in unable to stop the program or terminate monitoring. Although he would be able to access the active program via the Setup dialog and change parameter values, these changes would not take effect until Windows 95 has been restarted.

Run as User Task

The program is started as part of a user login routine, and is terminated upon logout. The user has full control over all UPS program functions.

Selecting this button returns all settings to their default values. These are:

D COM port: COM4 D Smart Shutdown, Delay Time: 50 sec D Enable Accu Test: enabled D Enable Temp Control: enabled D Disable Auto Power Off: disabled D Run UPS

as Service: enabled

plus

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Page 27

3.3.3 Operating and configuring UPSNT (WindowsNT)

. Operation requires Administrator privileges!

Start / Stop

The UPS If the service is to be stopped, ended or restarted (e.g., during a reinstallation

or update procedure), select Services Manager in the system control (see icon below, to the left of UPS

program is automatically started with WindowsNT.

Control).

Security Functions

3–9

The status of the UPSNT service is displayed in the Services Manager of WindowsNT:

D UPS D UPS

The marked entry of the UPS

stopped: No entry in Status column

started: Started entry in Status column

service is started and stopped via the Start

and Stop buttons, respectively.

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Page 28

3–10

Security Functions

Configuration – UPSNT for IPC

To configure the UPS

program, select UPS NT Control in the control

panel (see illustration below).

. The UPS

program always runs as a Windows NT service. Changing

user logins have no influence on this characteristic. A user without Administrator privileges is neither able to terminate the program nor stop the monitoring function.

COM Port

. To allow new parameter values to take effect subsequent to their

modification, the UPS program must be stopped and restarted. This may be accomplished by restarting the computer, or with the aid of the Services Manager.

The UPS program is always connected to the UPS via the COM4 serial port.

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Advanced Controls

Security Functions

3–11

Shutdown Delay Time This interval is defined as a value between 0 and 45 seconds, by which the

shutdown of Windows will be delayed. The intervening period is used to

CAUTION Upon expiry of the Delay Time, the operating system is shut down without prior security query . Unsecured data belonging to open applications will be lost.

Enable Accu Test

When this check box is checked, the system performs a test of the battery pack during each restart.

Enable Temp Control

When this checkbox is checked, the ambient temperature is monitored on a continuous basis. Excessive temperatures will produce a temperature warning message.

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3–12

Info

Security Functions

Disable Auto Power Off

This option disables both the USP monitoring function and the power-off delay for the power supply:

D A voltage interruption will cause the PC to shut down immediately. D After a normal shutdown, the wait interval of approx. 60 seconds prior to

the shutdown of the power supply is omitted.

Although this function reduces the wait times during startups and software installations, it must always be disabled during standard operation!

CAUTION Loss of data! Activation of this checkbox no longer makes a safe shutdown possible in the event of a power failure. The device switches off instantly!

Shutdown Count

Default button

Selecting this button returns all settings to their default values. These are:

D COM port: COM4 D Shutdown Delay Time: 30 sek D Enable Accu Test: enabled D Enable Temp Control: enabled D Disable Auto Power Off: disabled

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Page 31

Configuration – UPSNT for IPC300

To configure the UPS

program, select UPS NT Control in the control

panel (see illustration below).

Security Functions

3–13

. The UPS

program always runs as a Windows NT service. Changing

user logins have no influence on this characteristic. A user without Administrator privileges is neither able to terminate the program nor stop the monitoring function.

COM Port

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. To allow new parameter values to take effect subsequent to their

modification, the UPS is automatically stopped and restarted. No monitoring function is enabled during this interval (5 to 10 sec).

The UPS program is always connected to the UPS via the COM4 serial port.

Page 32

3–14

Security Functions

Advanced Controls

Shutdown Delay Time This interval is defined as a value between 0 and 45 seconds, by which the

shutdown of Windows will be delayed. The intervening period is used to

CAUTION Upon expiry of the Delay Time, the operating system is shut down without prior security query . Unsecured data belonging to open applications will be lost.

Enable Startup Battery Test

When this check box is checked, the system performs a test of the battery pack during each restart. Upon detection of an error, the red LED “UPS” flashes and an error message is generated (”Accu Test failed! The Accu is not installed or empty!”) and distributed throughout the system. The UPS program continues to operate.

The battery test is automatically repeated after 12 hours:

D If no error is found, automatic test repetition in 12-hour intervals ensues. D Upon detection of an error, the red LED “UPS” flashes and an error mess-

age is generated and distributed throughout the system, and no further battery test is performed.

Error messages from the battery test are also stored in the Windows NT Application Event Log.

Enable Temp Control

When this checkbox is checked, the ambient temperature is monitored on a continuous basis. Excessive temperatures will produce the temperature warning message “Board Temperature high! Check System!”.

The power monitoring function is retained even after a temperature warning. Upon detection of an error, the red LED “Temp” flashes.

Temperature warning messages are also stored in the Windows NT Application Event Log.

Enable Fan Control

When this checkbox is activated, the integrated housing fans are monitored in the IPC300 with Pentium I (266 MHz) and the housing and processor fans are monitored in the IPC300 with Pentium III (400 MHz). In the event of an error, the red LED “Temp” flashes and the following message is generated and distributed throughout the system: “FAN failure! Check System!”

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Page 33

Security Functions

Enable Voltage Control

When this checkbox is activated, internal supply voltages are monitored. In the event of an error, the green LED “Vout” extinguishes and the following message is generated and distributed throughout the system: “Board Voltage failure! Check System!”.

Disable Auto Power Off

CAUTION Loss of data! Activation of this checkbox no longer makes a safe shutdown possible in the event of a power failure. The device switches off instantly!

This option disables both the USP monitoring function and the power-off delay for the power supply:

D A voltage interruption will cause the PC to shut down immediately. D After a normal shutdown, the wait interval of approx. 60 seconds prior to

the shutdown of the power supply is omitted.

Although this function reduces the wait times during startups and software installations, it must always be disabled during standard operation!

3–15

Command

No Powerdown on Shortbreak

When this checkbox has been activated, interruptions in the power supply of up to 5 seconds are permitted without affecting ongoing operations. Only in the case of power interruptions lasting in excess of 5 seconds will the UPS logic be started and the safe shutdown of the system initiated.

This dialog box provides for the linking and activation of an executable program (*.exe; *.bat) which is to be started and executed after the initilaization of the shutdown. This is helpful in situations where applications failing to respond to the systemwide messagesmust be backed up and terminated. To this end, appropriate housekeeping and termination programs can be entered and activated in this dialog. If there are several programs, or if the programs require transfer parameters, they must be combined in a batch file and then entered.

. The entry itself may not contain any invocation parameters, and the de-

clared program itself must not initiate a shutdown!

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Page 34

3–16

Default button

Health Monitor

Security Functions

Selecting this button returns all settings to their default values. These are:

D COM port: COM4 D Shutdown Delay Time: 30 sec D Enable Startup Battery Test: enabled D Enable Temp Control: enabled D Enable Fan Control: enabled D Enable Voltage Control: enabled D Disable Auto Power Off: disabled D No Powerdown on Shortbreak: enabled D Execute Command File: disabled

This dialog section indicates the current readings for internal voltages, battery voltage, system temperature and fan functions. The Battery Voltage reading is updated only after a battery test. The battery test occurs automatically after a system start, and in 12-hour intervals thereafter; it can also be initiated by pressing the Test Battery button.

D The LED illuminates red when the voltage reading of the battery voltage

measured under load is low.

D The LED illuminated green when the battery pack is fully functional.

Info

. Excessive repetitions of the battery test will discharge the battery

pack. Never perform more than 5 battery tests within a 24-hour period.

The following applies to Fan Speed monitoring:

D Red LED: Fan at standstill, or fan speed is too low or too high. D Green LED: Fan is working properly.

Pressing the StopAutoRefresh button disables the automatic updating of measured readings, and the legend on the button changes to AutoRefresh. Pressing the AutoRefresh button again enables automatic measurement updating, again changing the legend on the button to StopAutoRefresh.

Shutdown Count

. Windows NT stores all important events under the following:

VERWALTUNG " EREIGNISANZEIGE " PROTOKOLL/ANWENDUNG

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Page 35

4 Installation

Installation

When installing the Bosch IPC / IPC300, refer to the information on standards compatibility and operating conditions in Sections 2.6 and 2.5.

DANGER The operational reliability of components designed to be installed in housings or control cabinets will be severely impeded if they are used or operated without having first been installed. Therefore, do not use or operate the IPC until it has been installed.

4–1

. Note

D The use of silicon-based sealing compounds, adhesives and insu-

lating agents is prohibited.

D Ensure that the installation is maintenance-friendly, i.e., that it

provides unrestricted access to connections, cables and fuses.

D Precede all installation procedures by writing down the information

on equipment rating plates. In the event that rating plates are hidden from view as a result of the installation, you will still have quick access to this information whenever required.

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Page 36

4–2

Installation

4.1 Installed positions and clearances

Housing: 19 in. rack module, protection category IP00 (EN 60529) Weight: Approx. 8 kg (w/o expansion cards)

Installed pos.: Horizontal Installation

type:

IPC installation clearances

Installation premises to provide a min. of IP54 rating.

50 mm, Top

Front = Connection side

Side clearance = 50 mm

IPC300 installation clearances

Front = Connection side

Side clearance = 50 mm

50 mm, Rear

. Please note that the integrated CD-ROM drive may be operated in a

horizontal position only. For this reason the IPC must be installed in a horizontal position.

D When installing the IPC / IPC300, ensure that the connection side of the

respective unit remains easily accessible.

D Because it must be possible to verify the operating status of the unit at

any time, the LED displays must not be concealed in any way.

D Provide adequate ventilation, and ensure that cables are routed with a

minimum clearance of 50 mm (top, bottom and rear).

D Allow for connecting loops in all cable routings; provide strain relief for all

cables.

D Maintain suitably large distances from sources of interference.

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Page 37

4.2 IPC / IPC300 dimensioned drawings

IPC

482.6 (= 19”)

Installation

Mounting hole

4–3

132.5

57.2

37.7

256.2

8.4

465.9

445

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Page 38

4–4

IPC300

Installation

Mounting hole

482.6 (= 19”)

132.5

265.5

57.2

37.7

8.4

18.8

6.8

465.9

445

4.3 Installing IPC / IPC300 in mounting frame

L Construct a 19 in. mounting frame with fasteners for the 4 holes in the front

panel of the IPC or IPC300.

L Insert the IPC or IPC300 into the mounting frame from the front. L Using 4 suitable mounting screws, attach the unit to the mounting frame.

5 6

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Page 39

5 Electrical Connections

Please note that, with respect to all electrical connections, the terminal connection plans and work instructions provided by the machine manufacturer shall always be binding!

The system planner is also charged with providing and planning for the integration and implementation of required components, such as Emergency-STOP circuits, mains switches, etc., in accordance with the current state of the art and at the highest level of safety attainable.

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

Observe the following to prevent functional failures: D Provide for isolated 24 VDC and 0 V terminal bars inside the control cabi-

net. With regard to cable routing, maintain a minimum distance of 10 cm (4 in.) from all power cables.

D Design the overall system power circuits in a manner ensuring the simul-

taneous startup of operating terminals and other industrial components, such as CNC and PLC.

Electrical Connections

5–1

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Page 40

5–2

Electrical Connections

5.1 Protective Earth conductor (PE) & screening information

DANGER Dangerous conditions, functional failures and equipment damage on machine plant caused by substandard potential equalization or screening properties between system components!

Potential equalization currents may not flow across the screening of interface cables.

L The protective earthing conductors (earthing connections) of the system

must be arranged in a tightly meshed grid. All components, control cabinet housings and doors, including the mounting plate, must be earthed.

L The potential equalization lines / PE lines of all system components shall be

kept as short as possible, thus providing low-resistance connections.

L Install the PE lines, preferably electroconductively, on the mounting plate in

the control cabinet. Both sides of the insulated installed PE rails must be connected to the mounting plate with max. 20 cm long, adequately dimensioned copper bands. Position the PE lines so that the length of the outgoing protective earth conductor connections to the individual modules in the control cabinet does not exceed 1 m.

L When specifying the PE wiring, ensure sufficiently dimensioned cross-sec-

tion. In this regard, also observe EN 60204, Part 1 (max. electrical resistance and testing PE wiring installations).

L If at all possible, apply screening connections on both ends of a cable. L Ensure that equipotential equalization currents do not flow across the inter-

face signal lines via the shielded conductors. Therefore, before switching on the IPC for the first time , ensure that the potential equalization between devices which are to be connected is correct. Do not forget the interfaces which connect devices to each other at different locations (irrespective of distance or power supply).

DANGER Dangerous shock currents due to poor PE connections! The effectiveness of PE connections must not be impeded by mechanical, chemical or electrochemical influences. Connections must be permanent and tight.

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Page 41

5.2 Interference suppression information

When designing t he m achine p lant, o bserve a nd c omply w ith g overning r egulations and statutory law with regard to interference suppression on individual components. This will increase the operational safety of the entire system.

DANGER Dangerous conditions, functional failures and equipment damage on the machine plant caused by substandard EMC measures or line transient interference!

Install signal voltage cables only at a sufficient distance from highvoltage cables (e.g., motor power cables). If this is not possible, separate metallic cable channels must be used.

The following sections are designed to provide you with a brief overview of possible interference suppression measures in the control cabinet. Among these are, for example:

D Filters D Spark quenching circuits D Damping of inductive switching peaks D Limitation of switching voltage of high-speed semiconductors D Screening

Electrical Connections

5–3

To ensure optimum suppress interference, all of these components should be taken into consideration because they are most effective when working in combination. In principle, interference suppression should be implemented as follows:

D Apply suppression measures as close to the source of interference as

possible.

D Use only components that are identified as interference suppressors. D Limit leakage currents in accordance with safety regulations. D Provide touch guards. D Prevent vibration fatigue breakage by providing secure mechanical

support for interference suppressors.

To ensure that interference suppression measures are successful, electrical symmetry or asymmetry must also be taken into consideration. Besides symmetrical interference voltage components which occur between mains connection cables, there are also asymmetrical interference voltages caused, for example, by capacitive coupling of the source of interference to the mains. The following diagram shows a standard interference suppression circuit. The asymmetrical interference voltages are discharged to the housing via

. C

damps the symmetrical interference.

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Mains

Page 42

5–4

Electrical Connections

Interference suppression examples

Suppression of contacts: (Alternating current, direct current, offset DC current)

a) b) c)

VDR

to b) For sensitive contacts, residual current when contact open! to c) Voltage-dependent resistance, residual current when contact open!

Suppression of an inductive load: (Motors, solenoid, relay and contactor coils)

a) b) c) d)

−

VDR

to c) For relay, drop-off delay. to d) For relay , defined drop-off delay. to e) Must be optimized for inductance!

Suppression example – mains input:

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Page 43

5.3 Power supplies

Electrical Connections

5–5

5.3.1 24V

power supply

X10_1 24 VDC power connection (w/ integrated 24 VDC power supply)

Alternative to 230/115 VAC power connection. All internally required voltages are provided by a DC/DC converter.

Weidmüller push-lock terminal, MSTB 1.5, 4-pin

Max. conductor cross-sect.: 1.5 mm

X10_1

++––

21 3 4

Rated voltage UN: 24 VDC ; +20%, –15% Residual ripple at UN: See diagram below Interference / surge immunity: U Current draw at UN: max. 5 A Input fuse: 6.3 A (5x20) medium time-lag Reverse polarity protection: Via decoupling diode. Polarity reversal will blow

input fuse.

(see next page)

Pin Signal

1 24V

2 3 4

= 35 V (at t < 100 ms)

max

24V 0V

DANGEROUS ELECTRICAL VOLTAGE The 24 VDC input voltage must satisfy the requirements of ”protec- tive separation”!

Safety transformer, as per EN 60742

L1 L2 L3

+ 24V

400V +5%

400V

400V −5%

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Page 44

5–6

Electrical Connections

Offset AC components of the type produced by an unregulated rotary current bridge circuit without smoothing, with a ripple factor of 5% (refer to DIN 40110/10.75, Section 1.2), are permissible. As an upper voltage limit, this produces a maximum absolute value of 30.2 V and, as a minimum voltage limit, the minimum absolute value of 18.5 V.

1.05.28.8 V = 30.2 V

Upper limit 28.8 V

0.866.30.2 V = 26.1 V

1.05.20.4 V = 21.4 V Lower limit

0.866.21.4 V = 18.5 V

20.4 V

cos (30 ) = 0.866

30 el

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Page 45

Electrical Connections

5–7

Cross-sections dependent on current draw, but MIN 4 At greater current draw, use 2 x 4 mm

IPC

(24 VDC version)

Power supply

L1L2L3

Power supply with safety transformer, as per EN 60742

Max. length 4 m

Cross-sections

dependent on current

draw, but MIN 0.5

24 VDC

(1)

A B

0 V Load24 V Load

(3)

102 (green/yellow)

(blue)

102 (green/yellow)

Earth bar

= Terminal block 4

B = Terminal block 10

: Terminals in isolated arrangement

(2)

X10_1

X11

LVDS

COM2

BF2xxT

Control Panel

X34

LVDS

X33

IPC300

(24 VDC version)

Power supply

X10_1

X11

LCD

BF3xxT

Control Panel

Fan

LCD

X33 X10_1 X10_2

Fan power

(1) Easily removable and visible. (2) Preferred installation of PE terminal bars, i.e., electrically

conductive on the mounting plate. Both ends of PE terminal bars must be connected to mounting plate by means of copper straps of a length not exceeding 200 mm. At minimum, the cross-section of the copper straps must be equal to that of the supply cable.

(3) 0.5 mm

0.75 mm

1.5 mm

, up to 4 m

, up to 6 m

, up to 10 m Distances in excess of 10 m necessitate a separate power supply at the machine!

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Page 46

5–8

Electrical Connections

5.3.2 230/115 VAC power supply

X20 230/115 VACpower connection (w/ integrated AC power supply)

Alternative to 24 VDC power connection. All internally required voltages are produced by the integrated power supply.

CAUTION The supply voltage must satisfy the requirements of Overvoltage Category II. Otherwise, the integrated power supply may be destroyed. Use a separation transformer to generate the 230/115 VAC (refer to next page).

Coupler for non-heating apparatus, 3-pin

Max. conductor crosssection: 1.5 mm

X20

Assignment

N1 PE U2

Rated voltage: 85VAC to 264VAC;

Extended-range input Current draw at U Current draw at U

= 230 VAC: 0.6 A

= 115 VAC: 1.2 A

Inrush current at 230 VAC: 30 A, cold start 25_C

at 115 VAC: 15 A, cold start, 25_C

Input fuse: 1.25 A (5x20) medium time-lag

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Page 47

Electrical Connections

5–9

To utilize neutral conductor ”N”, operator permission is required!

Incoming mains

L1L2L3

PEPEPEPEPE

42 (green/yellow)

min.162 (green/yellow)

162 (green/yellow) 62 (green/yellow) 102 (green/yellow)

PE star-point connection

to control cabinet housing to machine all housing components (PE lug)

PE terminal bar for = V wiring (see Fig. 2)

162 (green/yellow)

Fuses; motor protection switch preferred

400 V

42 (green/yellow)

Transform er, as per EN 60742

230 V

42 (green/yellow)

PEPE N1

IPC (see Fig. 3)

possibly. 230 V fan

Service sockets

L3.1

L1.1

L2.1

e.g., drives

230 VAC power connection via separation transformer

230 V supply

= Terminals in

isolated arrangement

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Page 48

5–10

Electrical Connections

230 VAC

(see previous page)

Cross-sections dependent

on current draw, but MIN

of 0.75

U2 PE N1

IPC

(230/115 VAC version)

Power supply (protective separation to EN 60950)

X20

BF2xxT

Control Panel

X11

LVDS

COM2

X34

LVDS

X33

24 VDC

Cross-sections dependent

on current draw, but MIN

of 0.5

(*)

0.5 mm2, up to 4 m

(*)

0.75 mm2, up to 6 m

, up to 10 m

1.5 mm Distances in excess of 10 m necessitate a separate power supply at the machine!

U2 PE N1

IPC300

(230/115 VAC version)

Power supply (protective separation to EN 60950)

X20

BF3xxT

Control Panel

Fan

X11

LCD

X33 X10_1 X10_2

Fan power

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Page 49

6 Interfaces, Ports & Connectors

6.1 Overview

The following table specifies the installed IPC connector types, as well as their mating connectors.

Interfaces, Ports & Connectors

6–1

Label on housing

IPC IPC300

COM1 Serial port:

COM2 Serial port:

X57 Serial port:

COM3 Serial port:

COM4 – Serial port:

LPT1 Parallel port:

Ethernet Ethernet 10 Base T

USB USB interface Female USB

LVDS – for BF2xxT:

– LCD Gigabit for BF3xxT:

VGA VGA connection for

X11 BF2xxT, BF3xxT:

Keyb PS/2 mini DIN keyboard Female PS/2

Mouse PS/2 mini DIN mouse Female PS/2

As described in Section 5.3: X20 PC power supply:

X10_1 PC power supply:

Interface service Physical

RS-232, IPC: free assignment IPC300:

alternative, X57

RS-232 for touch screen. Without touch screen: IPC: alternative to X57 IPC300: free assignment

RS-485/422: IPC: alternative, COM2 IPC300: alternative to COM1

RS-232, free assignment

RS-232 for UPS logic

Supports SPP, EPP, ECO mode

Network connection

Video transmission

Video transmission and RS-422 for touch screen controller (COM2)

external CRT monitor

Power supply, mouse & keyboard

230/1 15 VAC, alternative to X10_1

24 VDC, alternative to X20

connector

Male DB-9 connector

Female DB-25 connector

Female RJ45, 8-pin

connector, 4-pin Female RJ45,

8-pin Female RJ45,

8-pin

Female VGA HD connector, 15-pin

Female DB-15 connector

mini DIN, 6-pin

Non-heating appliance connector, male

Male Weidmüller push-lock terminal, MSTB 1.5, 4-pin

Mating connector or cable

Female DB-9 connector

Male DB-25 connector (e.g., printer cable)

Male RJ45 connector, 8-conductor, twisted prs.

Male USB, 4-conductor

Male RJ45 connector, 8-conductor, twisted prs.

Male RJ45 connector, 8-conductor, twisted prs., CAT7

Monitor cable w/ male VGA HD connect.,15-pin

Male DB-15 connctor

Keyboard cable w/ male PS/2 mini DIN, 6-pin

Male PS/2 mini DIN, 6-pin

Power cord w/ female non-heating appliance connector

Female Weidmüller push-lock terminal, MSTB 1.5, 4-pin

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Page 50

6–2

Interfaces, Ports & Connectors

Port and connector layout

IPC

. Mouse and keyboard may be connected only if there is neither mouse

nor keyboard connected to the BF2xxT/BF3xxT control panel.

All externally accessed connectors are located on the front panel. All connectors are clearly labelled. In addition, in the IPC300 DIP switches S1 and S3 provide external access.

IPC300

X57 (COM2 RS-485/422) COM2 (RS-232)

S1 S3

DIP switch for display resolution (see page 6–14)

COM1 / X57 switchover, and connecting COM3 with X11 (see page 6–18)

PE lug (M5)

24 VDC

230/1 15 VAC

(on 230/115 V version)

PE lug

24 VDC

230/1 15 VAC

(on 230/115 V version)

PE lug (M6)

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Page 51

6.2 COM1 through COM4 serial ports

6.2.1 Pin assignments

CAUTION Functional failures caused by poor screening! Use only metallic or conductive connector/coupling shells providing large-area screen contact.

COM1 Serial port, freely assignable

Male DB-9 connector Type: RS-232

Cable length: Max. 15 m Cable type: Screened, min. cross-section 0.14 mm Transmission rate: Max. 115200 bps Handshake: Hardware and software handshake (XON, XOFF) Interrupt (IRQ): 4 I/O address: 3F8H or AUTO (recommended) BIOS preset: IPC: Onboard Serial Port1: Auto

Interfaces, Ports & Connectors

IPC300: alternative to X57

IPC300: COM1 is also applied to X57 as an RS-422/485. Parallel operation is not possible.

IPC300: Serial Port A: Enabled

6–3

COM1

RS232

DCD

DTR

GND

DSR

RTS

CTS

Screen applied to metal shell of connector

To peripheral devices

Assignment as an RS-232:

DCD Data Carrier Detect. RCV channel used, for example, by a

connected modem to inform the PC that it is receiving a carrier

signal (active connection). RX Receive Data. Line on which data is received. TX Transmit Data. Line on which data is transmitted to a

peripheral device. DTR Data Terminal Ready. XMIT channel used by the PC to signal

to a connected peripheral device that its interface is switched

on and initialized. DSR Data Set Ready. RCV channel used by the connected periph-

eral device to inform the PC that it is switched on and inilital-

ized. GND Signal Ground

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6–4

Interfaces, Ports & Connectors

RTS Request to Send. RCV channel used by the connected periph-

eral device to signal to the PC that is wishes to transmit data.

CTS Clear to Send. XMIT channel used by the PC to signal to the

connected peripheral device that it is permitted to transmit data.

RI Ring Indicator. Receive line on which a connected modem in-

forms the PC of the presence of an active call.

Screen Contact with housing frame via metallic shell of the D-Sub

connector.

COM2 Serial port, assigned to touch screen

On the IPC, the COM2 port must be connected to the touch screen. On the IPC300, the COM2 is transmitted via the Gigabit bus, making a special data line unnecessary.

In exceptional cases the IPC also permits the use of the COM1 or COM3 port for the touch screen, provided that the BIOS settings are changed to suit.

On the IPC the COM2 is also applied to X57 to provide RS-422/485 service. Parallel operation is not possible, however.

Male DB-9 connector Type: RS-232 Cable length: Max. 15 m Cable type: Screened, min. cross-section 0.14 mm Transmission rate: Max. 115200 bps Handshake: Hardware and software handhsake (XON, XOFF) Interrupt (IRQ): 3 I/O address: 2F8H or AUTO (recommended) BIOS preset: IPC: Onboard Serial Port2: Auto

IPC300: Serial Port B: Enabled

COM2

RS232

DCD

DTR

GND

DSR

RTS

CTS

IPC: to BF2xxT (separate line) IPC300: internally to BF3xxT via LCD

Screen applied to metal shell of connector

Refer to page 6–3 for explanations on pin assignments.

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Page 53

Interfaces, Ports & Connectors

6–5

X57 Serial port used as an RS-485/422, IPC: alternative to COM2

IPC300: alternative to COM1

This port can be assigned only in the event that the COM2 port (IPC) or COM1 port (IPC300) is not used. Parallel operation is not possible. The X57 interface is not suitable as a connection for the touch screen controller of a connected control panel.

Male DB-9 connector Type: RS-485/422 Cable length: Max. 15 m Cable type: Screened, min. cross-section 0.14 mm Transmission rate: Max. 115200 bps Handshake: Hardware and software handshake (X Interrupt (IRQ): 3 (IPC), 4 (IPC300) I/O address: 2F8H (IPC), 3F8H (IPC300), AUTO (recommended) BIOS preset: IPC: Onboard Serial Port 2: AUTO

IPC300: Serial Port A: Enabled

X57

RS485/422

DCD

RXD−

TXD−

DTR

GND

DSR

RXD+

TXD+

, X

To peripheral devices

OFF

)

Settings

Screen applied to metal shell of connector

Assignment as an RS-485/422:

(For more information on pin assignment, see Page 6–3)

DCD as for RS-232 RXD–, RXD+ Receive Data. Line on which data is received. TXD–, TXD+ Transmit Data. Line on which data is transmitted to peripheral. DTR as for RS-232 DSR as for RS-232 GND as for RS-232 RI as for RS-232 Screen as for RS-232

The S3 DIP switch can be used to configure the X57 interface as an RS-485 or RS-422:

D X57 = RS-485 Switch 3 set to ON = TXD is controlled via RTS.

Also, for 2-wire operation, TXD+ must be bridged with RXD+, and TXD– with RXD–.

D X57 = RS-422 Switch 3 set to OFF = TXD always enabled.

ON OFF

1 2345678

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Location of S3: IPC300 = externally accessed, see diagram on page 6–2

IPC = see diagram on page 6–12.

Page 54

6–6

Interfaces, Ports & Connectors

COM3 Serial port, freely assignable

Male DB-9 connector Type: RS-232 Cable length: Max. 15 m Cable type: Screened, min. cross-section 0.14 mm Transmission rate: Max. 115200 bps Handshake: Hardware and software handshake (XON, XOFF) Interrupt (IRQ): 10 I/O address: 3E8H BIOS preset: IPC: Onboard Serial Port3: 3E8h

IPC300: Serial Port C: Enabled

COM3

Refer to page 6–3 for explanations on pin assignments.

COM4 Serial port, assigned to UPS logic

(refer to Section 3.2) COM4 is internally assigned to the uninteruptible power supply (UPS).

On the IPC, COM4 can be used for external applications if the UPS ios not required. On the IPC300, the COM4 is not externally accessible.

Male DB-9 connector Type: RS-232 Cable length: Max. 15 m Cable type: Screened, min. cross-section 0.14 mm Transmission rate: Max. 115200 bps Handshake: Hardware and software handshake (XON, XOFF) Interrupt (IRQ): 11 I/O address: 2E8H (if equipped for free assignment) BIOS preset: IPC: Onboard Serial Port4: 2E8h

IPC300: Serial Port D: Enabled

DCD

DTR

GND

DSR

RTS

CTS

Screen applied to metal shell of connector

To peripheral devices

COM4

DCD

DTR

GND

DSR

RTS

CTS

Screen applied to metal shell of connector

Refer to page 6–3 for explanations on pin assignments.

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Interfaces, Ports & Connectors

USB Serial interface (Universal Serial Bus), currently not supported

The USB interface provides for the connection of up to 128 devices equipped with USB functions.

USB socket, 4-pin

USB

6–7

USB

2143

USB_P

USB1

USB2

USB_M

Screen

PIN Signal

1 USB power supply (max. 500 mA) 2 Data – 3 Data + 4 USB Ground

USB device

Screen applied to metal shell of connector

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Page 56

6–8

Interfaces, Ports & Connectors

6.2.2 COM1 through COM4 settings

Control Panel

For information about setting the communication parameters for serial interfaces, refer to the manual supplied with the installed operating system. Windows 95/NT: Go to Start / Settings / Control Panel, etc.

BIOS

The factory-shipped BIOS settings for COM1 through COM4 have been set to Present.

CAUTION Interrupt (IRQ) and I/O address must correspond to BIOS settings.

In the case of address conflicts regarding COM3/4, e.g., if IRQ 10 or 11 are already in use by other PC expansion cards, free IRQs must be used instead.

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Page 57

6.3 LPT1 parallel port

LPT1 Parallel port for printer, scanner, etc.

Interfaces, Ports & Connectors

Male DB-25 connector Type: SPP (ex works), EPP, ECP Cable length: Max. 3 m Cable type: Screened, min. cross-section 0.14 mm Interrupt (IRQ): 7 I/O address: AUTO or 378H (recommended)

LPT1

6–9

14 25

Interface mode

EPP

SPP

Write

STROBE

Data0

Data1

Data2

Data3

Data4

Data5

Data6

Data7

Intr

ACK

Wait

n.u. n.u. Datastb n.u. n.u. Addrstrb

GND GND

GND GND GND

GND GND

GND

BUSY PAPER out SEL out AUTOFD ERROR INIT SEL in

GND GND

GND GND GND

GND GND

GND

1 2 3 4 5 6 7

8 9 10

11 12 13 14 15 16

17 18 19

20 21 22 23 24 25

max. 3 m

To peripheral device

Screen applied to metal shell of connector

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The parallel port normally runs in the default SPP mode. Provided that suitable peripheral devices are present, it can also be operated in EPP (Enhanced Parallel Port) or ECP (Extended Capabilities Port) mode. The mode is changed in the BIOS settings.

CAUTION Functional failures caused by poor screening! Use only metallic or conductive connector/coupling shells providing large-area screen contact.

Page 58

6–10

Interfaces, Ports & Connectors

6.4 Ethernet connection

Ethernet Network connection

The Ethernet connection allows the PC to communicate on an Ethernet network. To facilitate data communications, the required network protocols (e.g., TCP/IP) must be recognized by the operating system and the network application programs running on the PC.

Female RJ45, 8-pin Type: IPC: Ethernet 10-Base-T

IPC300: Ethernet 10/100BaseTX Cable length: Max. 100 m Cable type: Screened, twisted pair Transmission rate: 10 Mbit/s and/or 100 Mbit/s Interrupt (IRQ): 5 I/O address: 340H

Ethernet RJ45

Ethernet

max. 100 m

TXD+

TXD−

RXD+

RXD−

To network

The driver configuration functions for the network connection can be accessed in the task bar or in the Control Panel under the Network Card symbol. A dialog box provides selections of data transmission speed, e.g., 10 Mbit/s or 100 MBit/s.

. Note that the network card of the remote communication partner must

be able to handle the same data transfer rate.

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Page 59

6.5 Display interfaces

6.5.1 BF2xxT for IPC

LVDS Video transmission

Interfaces, Ports & Connectors

6–11

The video signals are transmitted via the LVDS port. The port has been specifically designed for longer transmission routes and interference-free transmission, and can only be connected to the LVDS port of the BF200T and BF212T control panels.

Female RJ45, 8-pin Cable length: Max. 10 m Cable type: Twisted pair, 8-conductor, screened

Refer to information on premanufactured connecting cables in Section 10.2.

Selecting the display resolution

LVD S

max. 10 m

To BF200T or BF212T

(LVDS)

LVDS

TXCLKOUTP

TXCLKOUTN

TXOUT1P

TXOUT2P

TXOUT2N

TXOUT1N

TXOUT0P

TXOUT0N

The display resolutions must be selected in the connected IPC or rho4 via the S3 DIP switch (see diagram below):

D BF200T (10.4 in. colour display): 640 x 480 pixels, 256000 colours D BF212T (12.1 in. colour display): 800 x 600 pixels, 256000 colours

(factory setting)

To change the factory setting, the mousing cover of the IPC is removed (4 mounting screws), and the settings of segments 7 and 8 on the S3 DIP switch are changed (see diagram below).

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6–12

Interfaces, Ports & Connectors

Battery

Floppy disk CD-ROM drive

Battery

Main board

Hard disk

S3 DIP switch

D 640 x 480 pixels Switches 7,8: ON

1 2345678

ON OFF

D 800 x 600 pixels Switch 7 : OFF

Switch 8 : ON

1 2345678

ON OFF

(Factory setting)

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Page 61

6.5.2 BF3xxT for IPC300

LCD Gigabit interface

Interfaces, Ports & Connectors

6–13

(video transmission and RS-422 for touch screen controller)

The Gigabit interface simultaneously handles the transfer of video signals and and control communications for the touch screen controller (RS-422). On the IPC300 the controller signals are internally connected to COM2. The Gigabit interface has been specifically designed for longer transmission routes and interference-free transmission, and can only be connected to the Gigabit interface on the BF312T and B315T control panel.

Female RJ45, 8-pin Cable length: Max. 15 m, max. 75 m with repeaters Cable type: Twisted pair, 8-pin, screened

Refer to information on premanufactured connecting cables in Section 10.2.

Gigabit

max. 15 m

To BF312T or BF315T

(Gigabit)

LCD

Gigabit data+ (video data+)

Gigabit data− (video data−)

COM Touch: Control signal

COM Touch: TX+

COM Touch: TX−

Control signal, Gigabit receiver

COM Touch: RX+

COM Touch: RX−

GBIT repeater

The use of the Gigabit repeater extends the reach of required connections between the IPC300 and BF3xxT (LCD and X33) by 15 metres per repeater , to a maximum of 75 metres achieved with 4 repeaters. Installs via M4 press-in nuts. Using standard mounting clamps, snap-on installation on a standard DIN rail is also possible. Information on screen resolution settings can be found on page 6-15.

Refer to ordering information in Section 10.2.

94.5 27

GBIT_IN

Press-in nut M4 (2x)

X33

112

GBIT_OUT

X11

43.15

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Page 62

6–14

Interfaces, Ports & Connectors

Setting screen resolution

The display resolution must be selected on the S1 DIP switch (refer to diagram below):

D BF312T (12.1 in. colour display): 800 x 600 pixels D BF315T (15 in. colour display): 1024 x 768 pixels

(factory presets)

S1 S3

Changes are made on the externally accessible switch segments 1 though 8 of the S1 DIP switch:

D 800 x 600 pixels

1 2345678

ON OFF

D 1024 x 768 pixels

(IPC300 with Pentium I / 266 MHz)

1 2345678

ON OFF

(factory setting)

D 1024 x 768 pixels

(IPC300 with Pentium III / 400 MHz)

1 2345678

ON OFF

(factory setting)

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Page 63

Interfaces, Ports & Connectors

6–15

If a Gigabit Repeater is used, the DIP switch has to be configured as follows depending on the connected control panels:

D 800 x 600 Pixel (BF312T)

1 2345678

D 1024 x 768 Pixel (BF315T)

1 2345678

ON OFF

(Einstellung ab Werk)

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Page 64

6–16

Interfaces, Ports & Connectors

6.5.3 External CRT monitor for IPC / IPC300

VGA External monitor port

The VGA port accepts an external monitor (CRT) for operation via the built-in video adapter. The external monitor can be operated in parallel with the operator panel.

D Video RAM: 2 MB

. Note that the external monitor must already be connected at the time

the control terminal is booted up. If this is not the case, the VGA port will not be initialized by the BIOS.

. Inserting a graphics card will disable the integrated video adapter.

Also, on the IPC300, the BIOS setting must be changed.

Female VGA HD, 15-pin Cable length: Max. 1.5 m Cable type: Screened, min. cross-section 0.14 mm Max. resolution: 1280 x 1024 pixels, max. 16 million colours

VGA

max. 1.5 m

RED

GREEN

BLUE

ID2

VGA

GND

RED GND

GREEN GND

BLUE GND

KEY

Digital GND

ID0

ID1

Hsync

Vsync

ID3

1 2 3 4 5

6 7 8 9 10

11 12 13 14 15

Display

Screen applied to metal shell of connector

CRT monitor resolution

After a system restart, the screen resolution of the VGA port always corresponds to the setting of the LVDS or LCD interface. Refer to page 6–11 (LVDS) or page 6–14 (LCD).

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Interfaces, Ports & Connectors

6–17

It should be noted that it is technically possible to bypass the stated resolution and colour settings by changing them in the Control Panel while the IPC or IPC300 is running. However, such changes would again be overwritten during a subsequent system start:

D VGA mode: 640 x 480 pixels, 72 Hz, 24 bit colours D SVGA mode: 800 x 600 pixels, 72 Hz, 24 bit colours D XGA mode: D SXGA:

1024 x 768 pixels, 72 Hz, 16 bit colours 1280 x 1024 pixels, 72 Hz, 8 bit colours

If the VGA port must be permanently set to a resolution which fails to correspond to the selections possible on the LVDS or LCD interface, the connection between LVDS and/or LCD and VGA must be interrupted:

D IPC with S3 DIP switch:

VGA resolution as per BIOS:

Segment 7 : “OFF” Segment 8 : “OFF”

1 2345678

ON OFF

D IPC300 with S1 DIP switch:

VGA resolution as per BIOS:

Segment 5 : OFF Segment 6 : OFF Segment 7 : OFF Segment 8 : OFF

1 2345678

ON OFF

. With these settings, connecting a control panel is no longer possible!

CAUTION Setting incorrect resolutions and colours can destroy your monitor! Observe the specifications applying to your CRT or LCD monitor, and adapt the operating system parameters accordingly.

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Recommended monitors for external use are low-radiation models to TCO95. In addition, you should achieve the desired display resolution at a refresh rate of no less than 72 Hz.

Page 66

6–18

Interfaces, Ports & Connectors

6.6 X11 power supply connection

X11 Power supply, backlight power, mouse and keyboard signals from

control panel

The X11 power supply connection ensures reliable service of the control panel and other components even over extended physical distances. For distances below 1.5 m, mouse and keyboard can also be directly connected to the PC.

The X11 connection provides the following services:

D Operating power to the control panel. IPC: 12 VDC

D Power required for backlight source. D Communication of mouse and keyboard signals

(refer also to Sections 6.7 and 6.8)

D Connection between COM3 and control panel as required. The connec-

tion is configured with the use of the S3 DIP switch and is identical for IPC and IPC300.

COM3 interconnected with X11: S3 switch segments 1 and 2: ON

. IPC300 with Pentium III / 400 MHz only:

Always make sure that segment 4 of the DIP switch S3 is closed (ON) in order to activate the backlight “sleep” function of the BF3xx.

IPC300: 24 VDC

1 2345678

ON OFF

Female DB-15 connector Cable length: IPC: Max. 10 m

IPC300: Max. 15 m, can be extended to 75 m

via repeaters in conjunction with Gigabit

interface (refer to page 6–13) Cable type: Screened, min. cross-section 0.14 mm

Refer to information on premanufactured connecting cables in Section 10.2.

X11

max. 10/15 m

PCC_H PCC_L PCD_H

X11

915

+12V (IPC) / +24V (IPC300)

PCD_L

MSC_H MSC_L

MSD_H MSD_L GND TXD 3 GND

RXD 3

SW_Back

1 2 3

4 5 6 7 8

10 11

12 13 14 15

To control panel

(X33)

Screen applied to metal shell of connector

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Page 67

6.7 Keyboard connector

Keyb PS/2 mini DIN keyboard connector

. Use this connection only if no keyboard is connected to the “KBD” port

Interfaces, Ports & Connectors

6–19

of the control panel. Otherwise, faulty keyboard operation may occur.

Female PS/2 mini DIN, 6-pin Cable length: Max. 1.5 m Cable type: Screened, min. cross-section 0.14 mm BIOS preset:

System Keyboard: Present (IPC only)

(for “Keyb” or “KBD”)

KBD

Screen

Keyboard Data

GND

+5 V

Keyboard Clock

max. 1.5 m

Keyboard

Keyboard adapter

Screen applied to metal shell of DIN plug connector

If the system fails to recognize the keyboard, the interface in the BIOS may have been set to “Absent”, i.e., “Not Connected”. Change the BIOS setting to “Present” (IPC only).

In the event that the MF2 keyboard is equipped with a standard 5-pin DIN plug, you will require a keyboard plug adapter to a female PS/2 Mini DIN connector.

A suitable adapter is approx. 20 cm in length with a DIN connector and a mini DIN coupling on the ends. Connector assignment as per diagram below. These premanufactured adapters are available from computer stores.

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6–20

Interfaces, Ports & Connectors

Adapter für PS/2 connector

ScreenScreen

Mini DIN keyboard connection

PS/2 mini DIN connector (male)

Keyboard Data

GND

+5V

Keyboard Clock

Screen applied to metal shell of DIN plug connector

max. 0.2 m

Standard DIN connector (female)

Screen applied to metal shell of DIN plug connector

MF2 keyboard port

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Page 69

6.8 Mouse port

Interfaces, Ports & Connectors

Mouse PS/2 mouse port

. Use this connection only if no mouse is connected to the “Mouse” port

of the IPC. Otherwise, faulty mouse operation may occur.

Female PS/2 mini DIN, 6-pin Cable length: Max. 1.5 m Cable type: Screened, min. cross-section 0.14 mm Interrupt (IRQ): 12 BIOS preset: IPC: PS/2 Mouse Support: Enabled

6–21

Mouse

max. 1.5 m

Mouse

665

Screen

Mouse Data

GND

+5 V

Mouse Clock

Screen applied to metal shell of DB9 plug connector

Mouse

If the system fails to recognize the PS/2 mouse, the interface in the BIOS may have set to “Disabled”, i.e., “Not Available”. Change the BIOS setting to “Enabled” (IPC only). The operating system will not recognize the insertion of an external mouse after completed startup because the mouse initialization occurs during the boot phase.

. The connected mouse must be PS/2-compatible.

The BIOS normally reserves IRQ12 for the PS/2 mouse. If there are address conflicts, e.g., if IRQ 12 has already been occupied by another PC expansion card, you should change the IRQ of the expansion card to one that is still free.

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6–22

Notes:

Interfaces, Ports & Connectors

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Page 71

7 LED Display

LED Display

7–1

RESET pushbutton

A RESET pushbutton and a horizontal array of 5 LEDs are located on the backside. They have the following functions:

LED Display Meaning Remedial measure

VOut LED green Standard operation –

Temp LED off Standard operation –

UPS LED off Standard operation –

RESET pushbutton Initiates reboot of the PC –

LED green Standard operation – LED off No 230/115VAC mains

power or 24 V sent at power supply

LED off Internal +5 V and +12 V

voltages are not present

LED flashes red

LED red IPC currently in battery

LED flashes red

Control/ Display

Internal housing temp. above 50 °C, shutdown will occur if temperature continues to rise

mode, i.e., no mains power present!

Battery pack discharged, defective or not connected

Meaning Remedial measure

is pre-

Check IPC power supply for power.

Reduce internal IPC housing temperature. Check/verify fan functions.

Restore mains power to IPC. Initiate controlled IPC restart.

Check battery charge. Maintain 5-hour charging cycle!

1070 073 822-104 (02.06) GB

LED red RESET pushbutton has

been pressed

–

Page 72

7–2

Notes:

LED Display

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8 Maintenance and Replacement

The IPC and IPC300 are maintenance-free. However, some components are subject to wear and must be replaced.

Maintenance schedule

Include the following tasks in your maintenance schedule: D At least once a year check that all plug-and-socket and terminal

connections of the components are correctly seated and not damaged. Check that cables are not broken or crushed. Replace damaged parts immediately.

D Check fan and fan filter mats at least once a year.

Clogged and contaminated filter mats reduce the air volumes required for proper ventilation and cooling. Therefore, wash dirty filter mats in soapy water or replace with new mats. Allow washed filter mats to dry thoroughly before reinstalling.

Maintenance and Replacement

8–1

DANGER Risk of injury through rotating fan impeller! Keep hands a n d fingers clear, and do not insert any items into the fan impeller.

D Ensure that the rechargeable batteries (battery pack) are fully functional.

To enesure that the battery pack is tested during each system startup (and afterwards in 12-hour intervals), enable the Battery Test option of the UPS control program.

CAUTION Loss of data! Back up the data from the hard disk at regular intervals .

D Depending on temperature, vibration and daily operating hours, the ser-

vice life of the hard disk may last anywhere between 2.5 and 10 vears. To safeguard application data, and to avoid the necessity of time-intensive new installation of operating system (OS) and application programs following a hard disk replacement, the functional program and OS data on the hard disk should be backed up at regular intervals with the use of the Bosch-supplied “Backup Package for Industrial PC”. This process writes an image of the hard disk to the medium in the Iomega ”Jaz” drive supplied with the package; if a hard disk replacement is required, this image must simply be copied back to the newly installed hard disk. Refer to Section 10.3 for ordering information.

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8–2

Maintenance and Replacement

8.1 Fuse protection

The IPC and IPC300 are equipped with a replaceable power supply fuse:

D 6.3 A (5x20), medium time-lag for 24 VDC power supply D 1.25 A (5x20), medium time-lag for 230 VAC power D IPC: accessible after removal of the CD-ROM drive.

(refer to procedures in Section 8.2.1)

D IPC300: accessible externally at the front panel. Refer to fuse ordering information in Section 10.3.

. In the event that the power supply remains faulty after replacing the

power supply fuse, please contact Bosch Rexroth Service: Telephone: (+49) (0 60 62) 78-888.

CAUTION Loss of data! Service repairs of devices returned by customers do not entail backups of user data. Repaired units are returned with formatted hard disk and newly installed software.

IPC

Mother board

deinstalled CD-ROM drive

Fuse

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IPC300

Maintenance and Replacement

Fuse

8–3

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8–4

Maintenance and Replacement

8.2 Replacing the hard disk

The hard disk is replaced complete with installation frame.

CAUTION Loss of data! Back up all required application data and operating system settings to an external storage medium!

. To safeguard application data, and to avoid the necessity of time–

intensive new installation of operating system (OS) and application programs following a hard disk replacement, the functional program and OS data on the hard disk should be backed up at regular intervals with the use of the Bosch-supplied “Backup Package for Industrial PC” This process writes an image of the hard disk to the medium in the Iomega ”Jaz” drive supplied with the package; if a hard disk replacement is required, this image must simply be copied back to the newly installed hard disk. Please refer to Section 10.3 for ordering information.

Hard disk with holder

Mounting screw for hard disk holder

Data/voltage connection

Motherboard

Hard disk data/voltage connection

1. Switch off the power supply to the unit. If required, unplug all connectors

from the unit.

2. Wait until the UPS has switched off the power supply (the UPS LED on

the front illuminates red until the UPS switches off the IPC power supply).

3. Open the housing.

4. The ribbon cable is secured by a spot of hot glue which must be broken

(cut) for deinstallation. Disconnect the IDE ribbon cable from the hard disk. Unless this cable is defective, disconnecting it from the mainboard will not be required.On the IPC300, this ribbon cable also connects the CD-ROM drive.

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Maintenance and Replacement

5. Loosen the mounting screw on the rear of the housing and remove the hard disk holder complete with hard disk.

6. The new hard disk is always installed with installation frame, and in reverse sequence to that described above.

8–5

. Again, secure the hard disk connector by applying a spot of “hot

glue”.

7. The new hard disk must be declared to the BIOS of the PC. T o access the BIOS menu, press the following keys while the system is booting up:

D IPC: Press <del>. D IPC300: Press the <F2> function key.

IPC: Select the Auto-Detect Hard Disks menu option so that the new hard disk parameters can be recognized by the system. In the Standard-CMOS-Setup menu select PIO-Mode 3 for the hard disk. Exit the BIOS via the Save Settings and Exit option (save hard disk parameters). To do this, press the <Y> button (= Yes).

IPC300: To enable recognition of the new hard disk parameters by the system, go to the main menu, select the Primary Master menu option, followed by the Type = AUTO option. Select Exit Saving Changes (sav- ing new parameter settings) to exit the BIOS menu.

Restart the operating system, and again access the BIOS menu. In the

Primary Master option, set the Type option to User, and the Transfer Mode option to Fast PIO 3.

Select Exit Saving Changes (saving new parameter settings) to exit the BIOS menu.

8. If the IPC operating system fails to start up, interrupt the power supply again for min.10 seconds, and then restart the operating system.

9. If the system still does not start up, check for:

D Proper connection between controller cable and hard disk. D Proper connection of all port connectors and cables. D Presence of operating power.

10.Once the PC has started up properly, the user data and operating system settings for standard operation must be restored.

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8–6

Maintenance and Replacement

8.2.1 Replacing the CD-ROM drive

Mounting screw for CD-ROM

Power connection:

– CD-ROM – Floppy disk

Motherboard

CD-ROM data connection

1. Switch of f the supply voltage to the unit. If required, unplug all connectors.

2. Wait until the UPS has switched off the power supply (the UPS LED on the front illuminates red until the UPS switches off the IPC power supply).

3. Open the housing.

4. Unplug the female connector together with the controller ribbon cable and the female connector for the power supply from the CD-ROM drive. Only a defective cable must be disconnected from the motherboard.

5. Loosen the mounting screw on the front panel.

6. Remove the CD-ROM drive including the carrier plate.

7. Loosen the mounting screws and replace the drive.

8. Installation is in reverse sequence to that described above.

9. When the IPC has started, the CD-ROM drive should be recognized again by the operating system if the drive is of the same type. If another type is installed, the relevant driver software should also be installed. In this case follow the installation instructions of the CD-ROM manufacturer and the Windows95 or WindowsNT 4.0 installation routine.

10.If the CD-ROM drive still cannot be accessed, check for:

D Proper connection between controller cable and CD-ROM drive. D Proper seating of all cables and connectors. D Presence of operating power.

CD-ROM power connection

deinstalled CD-ROM drive

CD-ROM data connection

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8.2.2 Replacing the 3.5” floppy disk

Backplane/Floppy Mounting screws

deinstalled support plate with floppy disk, side panel and backplane

Maintenance and Replacement

8–7

Side panel

Floppy Power connection

Floppy disk

Floppy disk Mounting screws (from below)

Backplane

Floppy Data connection

Power connection:

– CD-ROM – Floppy disk

Motherboard

Backplane/Floppy Mounting screws

1. Switch of f the supply voltage to the unit. If required, unplug all connectors.

2. Wait until the UPS has switched off the power supply (the UPS LED on the front illuminates red until the UPS switches off the IPC power supply).

3. Open the housing.

4. If applicable, remove all expansion cards and all cables connected to these cards.

5. Unplug the female connector together with the controller ribbon cable and the female connector for the power supply from the floppy disk. Only a defective cable must be disconnected from the motherboard.

6. Loosen the two mounting screws on the front panel. Loosen the 4 mounting screws on the backplane and remove the floppy disk together with the side panel, backplane and holder from the side of the housing (as the motherboard is plugged into one of the backplane slots, the backplane must be moved carefully in order to loosen this connection).

7. Loosen the 4 mounting screws on the underside of the floppy disk holder and insert a new drive.

8. Installation is in reverse sequence to that described above.

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8–8

Maintenance and Replacement

9. If you have installed another type (e.g. 3.5” HD 2.88 MB), this must be declared to th e IPC BIOS. To access the BIOS menu, press the following keys while the system is booting up::

D IPC: Press <del> . D IPC300: Press the <F2> function key.

IPC: Go to the Standard SETUP menu option, and select the new floppy disk type. Exit the BIOS via the Save Settings and Exit option (save hard disk parameters). To do this, press the <Y> button (= Yes).

IPC300: Go to the main menu, and select Diskette 1. Select the new floppy disk type. Select Exit Saving Changes (saving new parameter settings) to exit the BIOS menu.

10.If the floppy disk drive cannot be accessed, check for:

D Proper connection between controller cable and flopps disk drive. D Proper seating of all cables and connectors. D Presence of operating power.

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8.2.3 Replacing the battery pack

The rechargeable battery pack must be replaced in the following cases:

D The battery test has failed. D The total number of charging cycles is above the value which depends on

the ambient temperature shown below (refer to the Shutdown Count option in UPS program, Sections 3.3.2 and 3.3.3).

D The red “USV” LED on the front panel is flashing for more than 8 hours

(refer to page 7–1).

Different prerequisites must be met by the IPC and IPC300 to start the charge cycle. That is, whether or not the respective power supply is backed by the rechargeable battery pack after Power-Off.

D IPC: Always after Power-Off D IPC300: After Power-Off only if a controlled shutdown of still-active soft-

A harmful deep-discharge of the battery pack is prevented as long as the IPC or IPC300 is not connected to mains power.

ware is required.

Maintenance and Replacement

8–9

The number of charging cycles that the rechargeable battery pack can withstand and therefore its useful life, depends on the ambient temperature in which the battery pack is used. Ambient temperature here is defined as the one in which the operating terminal is situated, e.g. the temperature in the control cabinet or in the operating housing.

The following table can be used as a guideline:

Ambient temperature Charging cycles Maintenance interval

+ 25 °C 4000 cycles 6 years + 35 °C 2000 cycles 3 years + 45 °C 1000 cycles 1.5 years

. The battery packs used in the IPC/IPC300 are recyclable, and can be

retunred to Bosch Rexroth upon replacement. They must not be disposed of in standard residential refuse.

X19 Battery terminal

Battery connection terminal. The connection may be removed only for the purpose of replacing the battery packs.

1070 073 822-104 (02.06) GB

Terminal strip, 2-oin Cable length: Max. 0.5 m Cable type: Unscreened, min. cross-section 1.5 mm

X19

GND

Battery

Page 82

8–10

Replacing the batteries

Maintenance and Replacement

WARNING Before replacing the battery , back up important data because during the battery replacement procedure, power supply is removed.

1. Before replacing the batteries, switch off the PC and remove the mains plug (230/115 VAC and 24 VDC plug).

2. Open the housing cover

3. Remove the connector with the bipolar cable from battery terminal X19 below the CD-ROM.

4. The battery packs can be replaced when the 4 mounting screws have been removed (cf. figure below).

. Insert the two new battery packs as shown in the figure below. Please

also observe the installation instructions delivered together with the packs.

Battery

Battery retaining screws

Battery

+––

12 +–

Battery pack connector (X19)

CD-ROM drive

5. Plug the connector with the bipolar cable back onto terminal X19. Ensure correct polarity of the batteries.

DANGER Polarity reversal of the rechargeable battery packs will result in an F10A (5x20) fuse being triggered on the power supply module. Further damages might occur. The UPS operating cycle will then no longer be possible.

6. Close the housing cover.

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Maintenance and Replacement

7. Restore power to the system. Observe the “UPS” LED display on the front panel:

D Battery pack already charged: UPS LED Off D Battery pack discharged: UPS LED flashes red

Wait approx. 5 hours until the battery pack is fully charged, and the UPS LED extinguishes.

8–11

. If the new rechargeable battery pack has not been charged, there will

not be sufficient UPS protection to effect a controlled shutdown of the PC. Therefore, install fully charged batteries if at all possible.

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8–12

Maintenance and Replacement

8.3 Expansion cards

The unit provides 6 slots for PCI bus and ISA bus expansion cards :

D 3 PCI bus slots (max. length 180 mm) D 2 ISA bus slots (max. length 175 mm) D 1 combination slot (PCI or ISA bus) (max. length 180 mm)

CAUTION Damage to PC or application software through unauthorized expansion cards. Use only approved expansion cards, and have them installed by a specialist.

8.3.1 Installing an expansion card

1. Switch off the supply voltage. If required, unplug all connectors.

2. Wait until the UPS has switched off the power supply (the UPS LED on the front illuminates red until the UPS switches off the IPC power supply).

3. Open the housing.

4. Remove the mounting screw holding the slot cover.

5. Insert the expansion card, and secure it with the mounting screw.

CAUTION Destruction of expansion card or main board The ISA/PCI combination slot must never be populated with an ISA card and PCI card at the same time!

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Arrangement of expansion slots in the housing

ISA/PCI slot A1

PCI slot A2

PCI slot A3

ISA slot A5

ISA slot A6

Maintenance and Replacement

8–13

PCI slot A4

Slot cover

If the card is Plug-and-Play (PnP) compatible, it is automatically recognized and integrated in the system, provided this creates no hardware conflicts (IRQ, etc.) with other expamnsion cards or connected devices.

In the event that subsequent to a system reboot the functions based on the newly aded card are not available, there may be several reasons for this:

D The card is not properly seated in the PCI or ISA slot contacts. D The software driver for the card has not been installed or its installation is

faulty.

D IRQ (interrupt) conflict with other PC hardware components. D The software for the card has not been installed.

1070 073 822-104 (02.06) GB

CAUTION Destruction of main board or ISA cards through address conflicts (IRQ, memory access, I/O address)! Observe the information provided by the card manufacturer. You may have try out new configuration settings in both BIOS and operating system.

Page 86

8–14

Maintenance and Replacement

8.3.2 BIOS settings for IPC

. IRQ 3, 4, 5, 7, 10, 11, 14 are already occupied, and are therefore no

longer available for PCI and ISA expansion cards!

PCI slot

In the PCI/Plug and Play Setup BIOS menu you can assign an IRQ address to each PCI expansion slot. The number of the IRQ address also defines the priority. If only PnP cards are used, the AUTO setting must be selected.

BIOS selection: PCI Slot1 IRQ Priority, PCI Slot2 IRQ Priority, PCI Slot3 IRQ Priority, PCI Slot4 IRQ Priority: AUTO, 3, 4, 5, 7, 9, 10, 11, 12

Default: AUTO

ISA slot (IRQ)

The IRQ address for non-PnP compatible ISA bus cards (so-called legacy ISA cards) must be permanently set in the PCI/Plug and Play Setup BIOS menu.

BIOS selection: IRQ3, IRQ4, IRQ5, IRQ7, IRQ9, IRQ10, IRQ11, IRQ14, IRQ15: PCI/PnP, ISA/EISA

Default: PCI/PnP

ISA slot (DMA)

The PCI/Plug and Play Setup BIOS menu provides for the permanent selection of a DMA channel for Legacy ISA cards.

BIOS selection: DMA Channel 0, DMA Channel 1, DMA Channel 2 , DMA Channel 3, DMA Channel 4, DMA Channel 5, DMA Channel 6, DMA Channel 7: PnP, ISA/EISA

Default: PnP

. When using the PCL Software PLC, the use of DMA channels may pre-

vent real-time generation.

8.3.3 BIOS settings for IPC300

. IRQ 3, 4, 5, 7, 10, 11, 14 are already occupied, and are therefore no

longer available for PCI and ISA expansion cards!

PCI slot

You can use the The Advanced Menu / PCI Configuration sub menu BIOS submenu to assign an IRQ address to each PCI slot. At the same time, the number of the IRQ also defines a priority. If only PnP cards are used, the AUTO setting must be selected.

BIOS select.: PCI Option: Disabled, Auto, IRQ: 3, 4, 5, 7, 9, 10, 11, 12, 14, 15, Default: AUTO

IRQ line 1, PCI IRQ line 2, PCI IRQ line 3, PCI IRQ line 4

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ISA slot (IRQ)

ISA slot (UMB)

Maintenance and Replacement

8–15

In the The Advanced Menu / PCI Configuration sub menu / PCI/PNP ISA IRQ Resource Exclusion / IRQx BIOS menu the IRQ ad-

dress for for non-PnP compatible ISA bus cards (so-called legacy ISA cards) must be permanently set.

BIOS selection: IRQ:3, 4, 5, 7, 9, 10, 11, 15 Option: Available, Reserved Default: Available

You can use the The Advanced Menu / PCI Configuration sub menu / PCI/PNP ISA UMB Region Exclusion BIOS submenu to reserve a specific

block in upper memory for ISA legacy cards. BIOS selection: C800 - CBFF, CC00 - CFFF, D000 - D3FF, D400 - D7FF,

D800 - DBFF, DC00 - DFFF

Option: Available, Reserved Default: Available

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8–16

Notes:

Maintenance and Replacement

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Page 89

9 Software

9.1 BIOS software

Software

9–1

The IPC / IPC300 features a CD-ROM drive, a 3.5” floppy disk drive and an Ethernet network connection for software installation and backup. Please refer to the documentation of the particular operating system for restoring backup files.

Depending on the intended application, a variety of software programs are installed on the IPC as shipped from the factory:

D BIOS D Operating system D Utility programs D Application software

The IPC requires the BIOS software for its initial boot process to enable it to find and start an operating system which provides a more user-friendly and comfortable platform for running the application software. The PCs are equipped with the following licensed BIOS software:

D IPC (200 MHz): AMIBIOS by American Megatrends,

IPC (266 MHz): PhoenixBios by Phoenix

D IPC300: PhoenixBios by Phoenix

9.2 Operating system and utilities

Operating system Microsoft Windows 95B

UPS utility program UPS

version LEU1R129 (or higher)

Software IPC IPC300

or Microsoft Windows NT4.0

(for Windows 95)

plus

(for Windows NT)

UPS

Microsoft Windows NT4.0

UPS

NTC4

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9–2

Software

9.3 Application software

The following Bosch application software options are available:

Application IPC IPC300

PCL Software PLC D D rho4 Robot controller software D D Typ3 osa CNC operating software D D MADAP Systems operating and

Studio diagnostic software WinSPS PLC programming software D D

WinDP Field bus parameterization for

WinCan Field bus parameterization for CAN bus

TSWIN Programming interface for operating terminals

D = provided

9.3.1 Bosch PCL (software PLC)

The installation of the Bosch PCL Software PLC adds the capabilities of a programmable logic controller to the IPC / IPC300. The Bosch PCL Software PLC encompasses the following components:

D PCL expansion card for PCI bus D Installation diskette with PCL application program

Interconnection

When connected to other PLC components (e.g., I/O rack) via a field bus (PROFIBUS-DP, CAN, InterBus-S), the control panel/IPC becomes a fullfeatured PLC controller.

D D

PROFIBUS-DP

D D

Example:

PCL expansion card

Profibus-DP

PROFIBUS-DP

e.g., EG2/K expansion module for PLC

PLC I/O

RM4-DP or RM2-DP

other PROFIBUS I/O devices:

D Decentr. I/O

RM65M-16DP

D B ~ IO

K-DP16DO

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9.3.2 Typ3 osa (CNC operating software)

The IPC / IPC300 can be used in conjunction with Bosch BF2xxT, BF3xxT control panels as an operating terminal computer for the Bosch Typ3 osa controller series.

Interconnection

Communications between the operator interface and the T yp3 osa controller utilize the TCP/IP protocol via the Ethernet connection between the IPC / IPC300 and the osa master module of the controller.

Software

9–3

IPC / IPC300 with Typ3 osa operating software

BF2xxT or BF3xxT

Keyboard

Ethernet

Typ3 osa controller

possibly other devices in the Ethernet network

Ethernet network

e.g., osa rack 4, containing

osa master L (w/ Ethernet connection)

D osa plc D osa fms D osa dc I/O

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9–4

Software

9.3.3 MADAP Studio (automatic system diagnostics)

The IPC / IPC300 is also used as a visual display terminal for automatic system diagnostics. From any operator station, the system operator can thus receive statistical information (MDA/PDA) about the entire system.

Main computer

EG2/K PLC expansion module

PLC I/O

RM4-DP or RM2-DP

Typ3 osa

PROFIBUS-DP

IPC / IPC300 with Typ3 osa operating software

Ethernet

IPC / IPC300 with PLC and MADAP Studio

Ethernet network

Ethernet

other PROFIBUS I/O devices:

D Decentr. I/O

RM65M-16DP

D B ~ IO

K-DP16DO

D B ~ IO

M-DP

PROFIBUS-DP

Additional devices in Ethernet network, as required

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Ethernet

Page 93

10 Order numbers

10.1 IPC / IPC300

For order numbers with extensions for basic unit, operating system and additional components, refer to the “Control Technology Price List”:

D 1070 072 134 (English)

10.2 Accessories

Designation Order no.

Order numbers

10–1

Connecting cables IPC

Connecting cables IPC300 with Pentium I to BF312T

COM2 (touch screen controller),length 2.5 m

5 m 10 m

LVDS, length 2.5 m

5 m 10 m

LVDS, hi-flex cable

length 2.5 m

5 m 10 m

X11, length 2.5 m

5 m 10 m

LCD, rigid cable

length 2,5 m

5 m 10 m 15 m

X11, length 2,5 m

5 m 10 m 15 m

1070 083 117 1070 083 116

1070 080 771 1070 918 793

1070 919 258 1070 918 794

1070 920 456 1070 920 457 1070 920 271

1070 083 120

1070 083 119

1070 080 744

1070 920 456 1070 921 385 1070 921 384 1070 921 070

1070 083 120

1070 083 119 1070 080 744 1070 079 383

1070 073 822-104 (02.06) GB

Connecting cables IPC300 with Pentium I to BF315T TA

LCD, rigid cable

length 2,5 m

5 m

10 m

X11, length 2,5 m

5 m

10 m

1070 920 456 1070 921 385 1070 921 384

1070 083 120

1070 083 119 1070 080 744

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10–2

Order numbers

Designation Order no.

10.3 Spare Parts

Connecting cables IPC300 with Pentium III to

– BF315T P3 – BF315T P3 TA – BF315T P3 OTA

Repeater for IPC300 Cable extension 15 m, for

Backup Package for Industrial PC

LCD, rigid cable

length 2,5 m

5 m

10 m

LCD, hi-flex cable

length 2,5 m

5 m

10 m

X11, length 2,5 m

5 m

10 m

LCD and X11 with 2 GB Iomega ”Jaz”

drive

1070 920 456 1070 921 385 1070 921 384

1070 922 022 1070 922 021 1070 921 891

1070 083 120

1070 083 119

1070 080 744 1070 079 423

1070 084 267

Designation Order no. Fuses 6.3 A (5x20), medium time-

lag, for 24 VDC power

1.25 A (5x20), medium time-lag, for 230 VAC power

10 A (5x20), quick-blow, for battery pack

Battery pack for USP

Connecting cable for battery pack

Hard disk 6,4 GB,

w/ spring suspension CD-ROM drive 1070 919 420 3,5” Floppy disk drive 1070 920 192 Power supply for 220 VAC power

for 24 VDC power RAM modules IPC: 16 MB

32 MB 64 MB

IPC300: 128 MB

1070 900 850

1070 900 839

1070 904 575

in preparation 1070 080 517

1070 920 880

1070 080 219 1070 080 220

1070 918 970 1070 919 081 1070 920 267

1070 920 459

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Page 95

A Appendix

A.1 Abbreviations

BIOS Basic Initial Operations System CD–ROM Optical storage medium COM x Serial port x CRT Monitor w/ cathode ray tube EPP Enhanced Parallel Port (bidirectional) FD Floppy Disk GB Gigabyte HD Hard Disk IDE Interface for Hard Disk Drive, CD-ROM

Drive, etc.

Appendix

A–1

ISA ”Industrial Standard Architecture” , bus

system for PCs KBD Keyboard LCD Liquid Crystal Display LPT Line Printer MB Megabyte MTB Machine control panel PCI Peripheral Component Interconnect, bus

system for PCs RAM Random Access Memory SPP Standard Parallel Port TFT Thin-Film Transistor UPS Uninterruptible Power Supply VGA Video Graphics Array (graphics standard)

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A–2

Appendix

A.2 Index

Numbers

230/115 VAC power connection, 5–8 24 VDC power connection, 5–5

adapter, MF2 to PS/2 mini DIN (keyboard), 6–19 ambient temperature, 2–4 application software, 9–2

MADAP Studio, 9–4 PCL (software PLC), 9–2 Typ3 osa, 9–3

assembly, 4–4

backing up the hard disk, 8–1, 8–4, 10–2 backlight ”sleep” function, 6–18 battery, terminal, 8–10 battery pack, terminal, 8–9 BIOS, A–1 BIOS settings, external CRT monitor, 6–16 BIOS software, 9–1 Brute Shutdown, option, 3–6

CD–ROM, A–1 COM1, 6–3 COM1–4, settings, operating system, 6–8 COM2, 6–4 COM3, 6–6 COM4, 6–6 connecting cables, 10–1 CRT, A–1

data backup, 8–1 Delay Time, 3–7, 3–14 display

BF2xxT, resolution, 6–11 resolution, BF3xxT, 6–14

documentation, related, 1–7

EEC Council Directive

relating to electromagnetic compatibility, 1–1 relating to electrical equipment for limited voltages, 1–1

electrical connections

230/115 VAC power supply, 5–8

24 V power supply, 5–5 electrostatically sensitive devices (ESD), 1–6 Emergency–STOP devices, 1–5 EPP, A–1 ESD (electrostatically sensitive devices), 1–6 ESD earthing wrist strap, 1–6 ESD protection, 1–6 ESD work station, 1–6 Ethernet connection, 6–10

expansion slots, 8–12

BIOS settings, 8–14

layout, 8–13 External CRT monitor, BIOS settings, 6–16 external monitor, 6–16

floppy disk drive, 1–7

GB, A–1 GBIT repeater, 6–13 Gigabit interface, 6–13

hard disk, replacement, 8–4 hard disk drive, 1–7 hardware, versions, 2–1

IDE, A–1 impact resistance, 2–4 installation, 4–4

dimensions, 4–3

installed positions, clearances, 4–2 interfaces

battery connector, 8–9

COM1, 6–3

COM2, 6–4

COM3, 6–6

COM4, 6–6

Ethernet, 6–10

Gigabit (IPC300), 6–13

LCD (IPC300), 6–13

LPT1, 6–9

LVDS (IPC), 6–11

PS/2 keyboard, 6–19

PS/2 mouse port, 6–21

USB, 6–7

VGA port, 6–16

X57, 6–5 interference suppression, 5–3 ISA, A–1 ISA slot, 8–12

KBD, A–1

LCD, A–1 LCD interface, 6–13 LED displays, 7–1 LPT, A–1 LPT1 parallel port, 6–9 LVSD interface, 6–11

maintenance schedule, 8–1

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Appendix

A–3

MB, A–1 mouse port, 6–21 MTB, A–1

operating conditions, 2–4 operating power, 230/115 VAC, 5–8 operating status, LED display, 7–1 OS software, 9–1

PCI, A–1 PCI slot, 8–12 PE conductor system, 5–2 PE connections, 5–2 pin assignment

COM1 through COM4, 6–3

LPT1, 6–9 ports / connectors, overview, 6–1 ports and connectors, battery terminal, 8–10 power supplies, 5–5 power supply connection, X11, 6–18 Protection Category, 2–4 PS/2 keyboard port, 6–19 PS/2 mini DIN to MF2 keyboard adapter , 6–19 PS/2 mouse port, 6–21

qualified personnel, 1–2

RAM, A–1 rechargeable battery pack, 2–3 relative humidity, 2–4 release information, 1–7 replacing

battery pack, 8–9

CD–ROM drive, 8–6

floppy disk, 8–7

hard disk, 8–4 RESET button, 7–1 RS–232 interface, COM1, 6–3 RS–422/485 interface, COM1, 6–3

safety instructions, 1–4 safety instructions, specific, 1–5

approved spare parts, 1–5

Emergency–OFF safety devices, 1–5

maintenance procedures, 1–5

measuring / testing procedures, 1–5

retrofits / modifications, 1–5 safety markings, 1–3 safety transformer, 5–5 screening information, 5–2

Shutdown Delay Time, 3–11 software, 9–1 spare parts, 1–5 specifications, 2–2 SPP, A–1 standard operation, 1–1 standards compatibility, 2–5 storage temperature, 2–4 system overview, 2–1

temperature, 2–4 temperature monitoring, 3–1 TFT, A–1 TFT display, resolution, 6–11 trademarks, 1–7

uninterruptible power supply, 3–2

UPS program, 3–4 UPS, A–1 UPS functionality, 3–2 UPS program

configuration, UPSnt for IPC300 (Windows NT), 3–13

default settings, 3–8

Functionality, 3–4

UPSnt for IPC (Windows NT), configuration, 3–10

UPSnt for IPC, default settings, 3–12

UPSnt for IPC300, default settings, 3–16

UPSnt, operating, 3–9

UPSplus Mode, command, 3–8

UPSplus, operating, 3–5 UPSnt for IPC300, program, 3–15

COM port, 3–13

Command, dialog, 3–15

configuration, 3–13

Default, button, 3–16

Enable Fan Control, 3–14

Enable Temp Control, option, 3–14

Enable Voltage Control, option, 3–15

Health Monitor, dialog section, 3–16

No Powerdown on Shortbreak, option, 3–15

Shutdown Count, option, 3–16

Shutdown Delay Time, 3–14

Startup Battery Test, 3–14 UPSnt, program, 3–9

COM port, 3–10

configuration, 3–10

Default, button, 3–12

Disable Auto Power Off, option, 3–12

Enable Accu Test, option, 3–11

Enable Temp Control, option, 3–11

operation, 3–9

Shutdown Count, option, 3–12

Shutdown Delay Time, 3–11

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A–4

UPSplus, program

USB, 6–7 utilities, 9–1

Appendix

Brute shutdown, command, 3–6 COM port, 3–6 configuration, 3–6 Default, button, 3–8 Delay Time, parameter, 3–7 Disable Auto Power Off, option, 3–8 Enable Accu Test, option, 3–7 Enable Temp Control, option, 3–7 Exit, command, 3–5 Hide, command, 3–5 Run as Service, option, 3–8 Run as User Task, 3–8 Shutdown Count, option, 3–8 Smart Shutdown, command, 3–6 Start, command, 3–5 Stop, command, 3–5 UPSplus Mode, command, 3–8

Versions, 2–1 VGA, A–1 VGA port, 6–16 vibration resistance, 2–4 video adapter

CRT, 6–16 setting resolution on IPC, 6–11 setting resolution on IPC300, 6–14

X11, power supply connection, 6–18 X57, 6–5

1070 073 822-104 (02.06) GB

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Bosch Automation Technology

A–1

Australia

Robert Bosch (Australia) Pty. Ltd. Head Office Cnr. Centre - McNaughton Roads P.O. Box 66 AUS-3168 Clayton, Victoria Fax (03) 95 41 77 03

Great Britain

Robert Bosch Limited Automation Technology Division

Meridian South Meridian Business Park

GB-LE3 2WY Braunstone Leicestershire Fax (01 16) 28-9 28 78

Canada

Robert Bosch Corporation Automation Technology Division 6811 Century Avenue CAN-Mississauga, Ontario L5N 1R1 Fax (905) 5 42-42 81

USA

Robert Bosch Corporation Automation Technology Division Fluid Power Products 7505 Durand Avenue USA-Racine, Wisconsin 53406 Fax (414) 5 54-81 03

Robert Bosch Corporation Automation Technology Division Factory Automation Products 816 East Third Street USA-Buchanan, MI 49107 Fax (616) 6 95-53 63

Robert Bosch Corporation Automation Technology Division Industrial Electronic Products 40 Darling Drive USA-Avon, CT 0 60 01-42 17 Fax (860) 4 09-70 80

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1070 073 822-104 (02.06) GB

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