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Industrial PC
IPC / IPC300
Connectivity Manual
Antriebs- und Steuerungstechnik
Edition
104
Industrial PC
IPC / IPC300
Connectivity Manual
1070 073 822-104 (02.06) GB
E 1999 – 2002
by Bosch Rexroth AG, Erbach / Germany
All rights reserved, including applications for protective rights.
Reproduction or distribution by any means subject to our prior written permission.
Discretionary charge 6.–
Contents
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1070 073 822-104 (02.06) GB
VI
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1070 073 822-104 (02.06) GB
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.
1070 073 822-104 (02.06) GB
. 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.
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.
1070 073 822-104 (02.06) GB
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!
1070 073 822-104 (02.06) GB
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.
1070 073 822-104 (02.06) GB
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!
1070 073 822-104 (02.06) GB
CAUTION
Danger to the module!
All ESD protection measures must be observed when using the module! Prevent electrostatic discharges!
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.
1070 073 822-104 (02.06) GB
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.
1070 073 822-104 (02.06) GB
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).
1–8
Notes:
Safety Instructions
1070 073 822-104 (02.06) GB
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
DC
. The 230/115 V
version
AC
version
version also has a 24 VDC input (X10_1) which is not
AC
functional, however.
230/115 V
24 V
version
AC
version CD-ROM drive
DC
Expansion slots
230/115 V
AC
3.5” Floppy disk
1070 073 822-104 (02.06) GB
24 V
+ –
DC
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.
1070 073 822-104 (02.06) GB
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.
1070 073 822-104 (02.06) GB
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.
1070 073 822-104 (02.06) GB
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)
(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.
1070 073 822-104 (02.06) GB
2–6
Notes:
IPC System Overview
1070 073 822-104 (02.06) GB
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
NT
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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
V
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.
t
t0 t1 < 800 ms
t
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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
V
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.
V
Mains voltage failure
Operating system
shutdown
Operating voltage interrupted
for 8 seconds
Operating
system startup
< 60 sec
t
2
t
= t2 + 8 sec
3
t
t
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).
NT
t
t
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
NT
for IPC300 with Windows NT
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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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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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.
1070 073 822-104 (02.06) GB
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.
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
1070 073 822-104 (02.06) GB
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.
NT
Control).
NT
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
NT
started: Started entry in Status column
NT
service is started and stopped via the Start
NT
and Stop buttons, respectively.
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3–10
Security Functions
Configuration – UPSNT for IPC
To configure the UPS
program, select UPS NT Control in the control
NT
panel (see illustration below).
. The UPS
program always runs as a Windows NT service. Changing
NT
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.
1070 073 822-104 (02.06) GB
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
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.
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 a temperature warning message.
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.
1070 073 822-104 (02.06) GB
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
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.
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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