Bosch Rexroth IPC User manual

Antriebs- und Steuerungstechnik
IPC / IPC300
Connectivity Manual
Industrial PC
104
Edition

Industrial PC
IPC / IPC300
Connectivity Manual
1070 073 822-104 (02.06) GB
E1999 – 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 V
1070 073 822-104 (02.06) GB
Contents
Page
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
VI
1070 073 822-104 (02.06) GB
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions 1–1
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 ex-
haustive details regarding all available combinations of functional options.
Similarly, it is not feasible to consider every conceivable integration or oper-
ating 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 sys-
tems or application software on the industrial PCs, the occurrence of unex-
pected 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.
The products described hereunder
Dwere 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.
Dare certified to be in full compliance with the requirements of the
DCOUNCIL 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)
DCOUNCIL DIRECTIVE 73/23/EEC (electrical equipment designed for
use within certain voltage limits)
DHarmonized standards EN 50081-2 and EN 50082-2
Dare designed for operation in an industrial environment (Class A
emissions). The following restrictions apply:
DDirect connection to the public low-voltage power supply is prohibited.
DConnection 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 pro-
duce undue interference with other devices.
.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.

Safety Instructions
1–2
1070 073 822-104 (02.06) GB
1.2 Qualified personnel
This instruction manual is designed for specially trained personnel. The rel-
evant 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:
DThey are capable, due to their professional training, skills and expertise,
and based upon their knowledge of and familiarity with applicable techni-
cal standards, of assessing the work to be carried out, and of recognizing
possible hazards.
DThey 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 com-
prehensive 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 ([phone].

Safety Instructions 1–3
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!
Lug for connecting PE conductor only!
Screened conductor only!

Safety Instructions
1–4
1070 073 822-104 (02.06) GB
1.4 Safety instructions in this manual
DANGEROUS ELECTRICAL VOLTAGE
This symbol 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 is used wherever insufficient or lacking observance of this in-
struction can result in personal injury.
CAUTION
This symbol is used wherever insufficient or lacking observance of instruc-
tions can result in damage to equipment or data files.
.This symbol is used to alert the user to an item of special interest.
LThis asterisk symbol indicates that the manual is describing an activity which
the user will be required to perform.

Safety Instructions 1–5
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 access-
ible during all operating modes of the system. The release of func-
tional locks imposed by Emergency-STOP devices must never be al-
lowed to cause an uncontrolled system restart!
Before restoring power to the system, test the Emergency-STOP se-
quence!
DANGER
Retrofits or modifications may interfere with the safety of the prod-
ucts described hereunder!
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 manufac-
turers 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 sup-
ply. 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 sys-
tems, these must be carried out by trained electricians.
CAUTION
Only Bosch Rexroth-approved spare parts may be used!
CAUTION
Danger to the module!
All ESD protection measures must be observed when using the mo-
dule! Prevent electrostatic discharges!

Safety Instructions
1–6
1070 073 822-104 (02.06) GB
Observe the following protective measures for electrostatically sensitive de-
vices (ESD)!
DThe personnel responsible for storage, transport and handling must be
trained in ESD protection.
DESDs must be stored and transported in dedicated protective packaging.
DOut of principle, ESDs may be handled only at special ESD work stations
equipped for this particular purpose.
DPersonnel, work surfaces and all devices and tools that could might come
into contact with ESDs must be on the same potential (e.g., earthed).
DAn approved earthing wrist strap must be worn. It must be connected to
the work surface via a cable with integrated 1 MWresistor.
DESDs 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.
DWhen installing ESDs in or removing them from an electronic device, the
power supply of the device must be switched OFF.