Bosch Rexroth CS351 User manual

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IL RUN/STOP ERROR
CS351/ CC-CS351 3 609 929 B45
AD/09.2014
DE/EN
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ENGLISH
Contents
1 About This Document .............................................................................................................. 57
2 General safety instructions ................................................................................................... 58
3 Scope of delivery ........................................................................................................................ 62
4 Product description ................................................................................................................... 63
5 Transport and storage ............................................................................................................. 84
6 Assembly ........................................................................................................................................ 85
7 Commissioning ............................................................................................................................ 87
8 Operation ........................................................................................................................................ 91
9 Maintenance and repair ........................................................................................................... 93
10 Decommissioning .................................................................................................................... 100
11 Disassembly and replacement .......................................................................................... 101
12 Disposal ......................................................................................................................................... 102
13 Extension and conversion .................................................................................................... 102
14 Troubleshooting ........................................................................................................................ 102
15 Technical data ........................................................................................................................... 103
16 Service and sales ..................................................................................................................... 106
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56/108 Bosch Rexroth AG CS351 | 3609929B45/2014-09
The data specified above only serves to de-
scribe the product. No statements concern-
ing a certain condition or suitability for a cer-
tain application can be derived from our
information. The information given does not
release the user from the obligation of own
judgment and verification. Please note that
our products are subject to a natural pro-
cess of wear and aging.
© This document, as well as the data, spec-
ifications, and other information set forth in
it, are the exclusive property of Bosch
Rexroth AG. It may not be reproduced or
given to third parties without its consent.
This document was written in German.
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About This Document
ENGLISH
1 About This Document
This manual contains important information
on the safe and appropriate assembly,
transport, commissioning, operation, main-
tenance, disassembly and simple trouble-
shooting of the CS351/CC-CS351 Com-
pact System.
The description of the software used in the
Compact System is not a part of these in-
structions. For any information on software
and operation which you may require,
please see the online help of the operating
program for BS350 as well as the system
documentation on the enclosed USB sys-
tem stick.
Read these instructions completely, espe-
cially chapter “General safety instructions”
on page 58 before working with the Com-
pact System.
Scope of the documentation
This documentation is applicable for the
CS351 and CC-CS351 Compact Sys-
tems. Tightening operations requiring docu-
mentation according to VDI/VDE 2862 Cat-
egory A can be performed using tightening
systems which consist of the ErgoSpin
hand-held nutrunner and the CS351E...
Compact System. Tightening operations re-
quiring documentation according to VDI/
VDE 2862 Category B can be performed
using CC tightening systems which consist
of the CC-ErgoSpin hand-held nutrunner
and the CS351E... or CC-CS351E-D Com-
pact System.
The CS351... Compact System allows con-
necting the system to field buses.
Related documents
Please also observe the generally applica-
ble, legal or otherwise binding regulations
of European or national legislation and the
rules for the prevention of accidents and for
environmental protection applicable in your
country.
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General safety instructions
2 General safety instruc-
tions
The Compact System has been manufac-
tured according to the accepted rules of cur-
rent technology. There is, however, still a
danger of personal injury or damage to equip-
ment if the following general safety instruc-
tions and the warnings before the steps con-
tained in these instructions are not complied
with.
• Read these instructions completely and
thoroughly before working with the Com-
pact System.
• Keep these instructions in a location
where they are accessible to all users at
all times.
• Always include the operating instructions
when you pass the Compact System on to
third parties.
Intended use
The product described in this documentation
is part of the control and power electronics
for Rexroth tightening systems and is in-
tended for the industrial application of tight-
ening processes exclusively in conjunction
with other products. Only use the product
with the corresponding connecting cables.
The product is intended for industrial use,
and not for domestic applications.
Observe the operating conditions and perfor-
mance limits specified in the technical data.
Proper use includes having read and under-
stood these instructions, particularly chapter
2 “General safety instructions”.
Only use the Compact System CS351 in
conjunction with a Rexroth ErgoSpin/CC-Er-
goSpin hand-held nutrunner or tightening
spindles to tighten and loosen bolts and nuts.
Only use the Compact System CC-CS351 in
conjunction with a Rexroth CC-ErgoSpin
hand-held nutrunner or tightening spindles to
tighten and loosen bolts and nuts.
The integrated logic is not permitted for
safety-critical applications. Safety-critical ap-
plications are all applications that may result
in personal injury or property damage.
Improper use
Any use of the Compact System other than
that described in the section “Intended use”
is considered improper.
NOTE
The Compact System CS351/CC-
CS351 is not designed to be directly
connected to the public low-voltage po-
wer supply, it is only intended for use in
industrial environments (emission
class A).
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General safety instructions
ENGLISH
Personnel qualification
Assembly, commissioning and operation,
disassembly, service (including mainte-
nance and care) require basic electrical and
mechanical skills and familiarity with the as-
sociated technical concepts. In order to en-
sure operating safety, these activities must
therefore only be carried out by appropri-
ately qualified technical personnel or an in-
structed person under the direction and su-
pervision of qualified personnel.
Qualified personnel are those who are able
to assess the tasks they are commissioned
to perform, identify possible risks and take
the appropriate safety measures due to
their professional training, knowledge, and
experience as well as their knowledge of the
applicable regulations. Qualified personnel
must observe the rules relevant to the sub-
ject area.
Safety instructions in this document
In this manual, all activities entailing a dan-
ger of personal injury or damage to the
equipment are preceded by a warning. The
hazard avoidance measures described
must be observed.
Warnings are structured as follows:
•Warning symbol (warning triangle):
alerts the user to the hazard
•Signal word: identifies the severity of the
hazard
•Type of hazard: identifies the type or
source of the hazard
•Consequences: describes the conse-
quences of failing to comply with the
safety instructions
•Precautions: indicates how the hazard
can be avoided
The signal words have the following me-
anings:
SIGNAL WORD
Type of HAZARD!
Consequences
Precautions
This warning symbol cautions
against dangers to your health.
Observe all safety instructions
that follow this symbol to avoid
possible injuries or death.
This warning symbol cautions
against dangers to your health
caused by electric voltages or
currents. Observe all safety in-
structions that follow this symbol
to avoid possible injuries or
death.
DANGER
DANGER indicates an imminently hazar-
dous situation which, if not avoided, will
certainly result in death or serious injury.
WARNING
WARNING indicates a potentially hazar-
dous situation which, if not avoided, can
result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazar-
dous situation which, if not avoided, can
result in minor or moderate injury or da-
mage to equipment.
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General safety instructions
Adhere to the following instructions
General instructions
Observe the valid regulations for occupa-
tional safety and environmental protection
for the country where the product is used
and at the workplace.
Only use Rexroth products that are in per-
fect technical condition.
• Check the product for visible defects
such as cracks in the housing or missing
screws or seals.
Do not change or modify the Compact Sys-
tem under any circumstances.
Only use the product within the perfor-
mance range indicated in the technical
data.
Persons who assemble, operate, disassem-
ble or maintain Rexroth products must not
do so while under the influence of alcohol,
other drugs or pharmaceuticals that may af-
fect their ability to respond.
Do not expose the Compact System to un-
acceptable mechanical loads under any cir-
cumstances. Never use the product as a
handle or step. Do not place any objects on
it.
Observe the local, system-specific regula-
tions and requirements; proper use of tools,
lifting, and transport equipment; as well as
the relevant standards, provisions, and oc-
cupational safety regulations.
During assembly
Make sure the system component in ques-
tion is depressurized and de-energized be-
fore assembling the product or connecting
or disconnecting plugs. Protect the system
from being switched on.
Lay cables and lines in accordance with the
permissible bending radiuses so that they
cannot be damaged and no one can trip
over them.
Before commissioning, make sure that all
the connection gaskets and plugs are in-
stalled correctly to ensure that they are leak-
proof and fluids and foreign bodies are pre-
vented from penetrating the product.
During commissioning
Let the product acclimate itself for several
hours before commissioning, otherwise
condensation may form in the housing.
Condensation can damage the compact
system when it is switched on.
Make sure that all electrical connections are
either assigned or covered. Commission
the product only if it is installed completely.
During operation
Only allow persons who are authorized by
the operator to access the system's direct
operating area. This also applies when the
system is not in operation.
In case of an emergency, fault or any other
anomalies, switch the system off and pro-
tect it from being switched on again.
NOTE
NOTE indicates a situation which, if not
avoided, can result in minor or moderate
damage to equipment.
If this information is not obser-
ved, operation may be impaired.
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General safety instructions
ENGLISH
Only operate the Compact System in
grounded networks. Operation in non-
grounded networks (IT network) is not per-
mitted, as clearance and creepage dis-
tances in the system may be overloaded.
Here, protective grounding is the permissi-
ble protective measure in accordance with
EN 50178. The input cable to the Compact
System must have a PE wire.
Ensure that there is potential equalization
between the workpiece and the tightening
spindle, as well as the carrier plate therefor,
so that potential equalization is ensured for
all system components.
Protect the system from short circuits in the
connector cables with a fuse provided by
the customer.
After switching the device off, wait 10 sec-
onds before turning it back on.
Observe the discharging time (at least 90
seconds after disconnecting the system
from the network) before working on the
power supply connections.
During cleaning
Cover all openings with appropriate protec-
tive devices to prevent detergent from get-
ting into the system.
Never use solvents or aggressive deter-
gents. Only clean the product using a
slightly damp, lint-free cloth. Only use water
to do this and, if necessary, a mild deter-
gent.
Do not use a high-pressure cleaner for
cleaning.
During maintenance and repair
Perform the prescribed maintenance work
at the intervals specified in the instruction
manual.
Make sure that no lines, connectors or com-
ponents are disconnected while the system
is under pressure and energized. Protect
the system from being switched on again.
DANGER
Inadequate emergency OFF equip-
ment!
Danger to life through electrical or me-
chanical forces
The user is responsible for determin-
ing the need for an emergency OFF
system, its implementation, and the
risk analysis therefor! Make sure the
emergency OFF equipment is acces-
sible and effective. Releasing the
emergency OFF equipment must not
result in an uncontrolled system re-
start!
Check the function of the emergency
OFF equipment before switching the
system on.
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62/108 Bosch Rexroth AG CS351 | 3609929B45/2014-09
Scope of delivery
Disposal
Dispose of the product in accordance with
the currently applicable national regulations
in your country.
Batteries must not be disposed in the gen-
eral waste; the end user is obliged by law to
return used batteries. Used batteries may
contain contaminants which might be harm-
ful for the environment or for your personal
health if not correctly stored or disposed of.
However, batteries also contain various
valuable materials and must be collected
and recycled separately.
Our batteries can be returned after use ei-
ther
• to commercial waste management com-
panies for used batteries
• to treatment facilities for used devices ac-
cording to the electric and electronic de-
vices act
• or free of charge at our distribution agen-
cies or the Murrhardt site
The symbol with the crossed out waste con-
tainer means that batteries must not be dis-
posed of in the general waste but collected
and recycled separately.
3 Scope of delivery
The delivery contents include:
• 1 CS351 or CC-CS351 Compact Sys-
tem
• 1 power supply connection cable (in acc.
with the EU regulations), length 2 m
• 1 hardware operating instructions for the
Compact System
• 1 suspension strip
• Preassembled dummy panels on all slots
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Product description
ENGLISH
4 Product description
Performance description
The Compact System combines a servo
amplifier, power supply, display, controller,
and slots for optional interface cards.
The system is a comprehensive solution for
use with ErgoSpin or CC-ErgoSpin hand-
held nutrunners or tightening spindles.
Compact System variants for hand-held nu-
trunners include:
• CS351E-D with LC display.
• CS351E-D IL with LC display and inte-
grated logic compliant with IEC 61131-3.
• CS351E-G with large color TFT display
(VGA 640x480) with integrated touch-
screen.
• CS351E-G IL with large color TFT dis-
play (VGA 640x480) with integrated
touchscreen and integrated logic compli-
ant with IEC 61131-3.
• CS351E-G+ with large color TFT display
(VGA 640x480) with integrated touch-
screen, integrated logic compliant with
IEC 61131-3., and integrated computer
unit
• CS351E-D NK with LC display for con-
nection to the modular system 350
(SB356, BT356).
A Compact System variant for hand-held
nutrunners is:
• CC-CS351E-D with LC display.
Compact System variants for tightening
spindles include:
• CS351S-D with LC display.
• CS351S-D IL with LC display and inte-
grated logic compliant with IEC 61131-3.
• CS351S-G with large color TFT display
(VGA 640x480) with integrated touch-
screen.
• CS351S-G IL with large color TFT dis-
play (VGA 640x480) with integrated
touchscreen and integrated logic compli-
ant with IEC 61131-3.
• CS351S-G+ with large color TFT display
(VGA 640x480) with integrated touch-
screen, integrated logic compliant with
IEC 61131-3., and integrated computer
unit
• CS351S-D NK with LC display for con-
nection to the modular system 350
(SB356, BT356)
In normal operating state, the front panel is
covered.
The front cover can be opened or removed
to connect external devices.
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Product description
Device description
Fig. 1: Compact System view
Legend relating to Fig. 1:
1 Name plate
2Front cover lock
3 Cable duct strip
4 Side cable ducts
5 Affixed pressure compensation memb-
rane
(do not remove)
6Safety warning (only visible when front
cover is open)
7Type label
Warning
This warns about the high electrical volta-
ges in the Compact System during opera-
tion and provides maintenance information
(see “Disassembly and replacement” on
page 101).
3
4
4
2
1
5
6
7
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Product description
ENGLISH
Interface overview
Controller and servo amplifier of the Com-
pact System feature the following available
electrical interfaces (see Fig. 2; the inter-
face components depend on the particular
CS variant):
Outside the front cover:
• 1 USB device interface for CS351 cont-
roller (X3U3),
specification compatible with 2.0
(with screwed-on cover)
• 1 power supply connection interface
(X1N)
• CS351E: interface for hand-held nutrun-
ner (XDS1)
• CS351S: interface for tightening spindle
(XDS2)
• 1 power switch (Q0)
Inside the front cover:
• 1 motor OFF interface (XDN1)
• 2 USB host interfaces for CS351 cont-
roller (X3U1, X3U2), specification 2.0
• 1 slot (A) for the use of standard type A
modules
Slot A is without function in CC-CS351;
inserted modules will not be detected
• 2 slots (B1, B2) for the use of standard
type B modules
Slot B2 is not applicable in CS351E-G+
and CS351S-G+ due to the integrated
computer unit.
• 1 restart/reset button (reset)
• 1 RS232 interface for CS351 controller
(X3C1),
• 1 Ethernet interface (X7E1) for CS351
controller
• 1 mass storage slot (X6C1)
• Only in CS351E-D (IL) / CS351S-D (IL):
– DVI interface to connect an external
monitor (DVI-D single link,
XDVI)
– USB host interface (X3U4)
• Only in CS351E-D NK/ CS351S-D NK:
– Interfaces for connection to the system
bus 350 (XDAC1, XDAC2)
The external interfaces of the integrated
computer unit (variants) CS351E-G+,
CS351S-G+) are arranged inside the front
cover below slots B1/B2 (see Fig. 3):
• Slot for a Micro-SD memory card
(X6MSD2)
• Status bar (St1, St2), St2 is orange in
normal operation mode
• Reset button of the integrated computer
unit (reboot)
• RS232 interface of the computer unit
(X3C2)
• 1 DVI interface to connect an external
monitor (DVI digital, XDVI2)
• 3 USB interfaces (X3U6, X3U7, X3U8)
to connect a mouse, keyboard, USB stick
• 1 Ethernet interface (X7E4) to the built-in
Ethernet switch (connected to computer
unit and CS351 controller)
• 1 Ethernet interface (X7E5) for integrated
computer unit
NOTE
Damage due to use of non-original
parts!
Damage to the Compact System
Only use interface modules from Rex-
roth (manufacturer ID “Rexroth”).
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Product description
Fig. 2: Available interfaces of the Compact System (interface components depending on CS va-
riant)
Fig. 3: Interfaces of the integrated computer unit (below slots B1/B2)
X3U3
XDS1
QO
X1N
XDAC1 XDAC2
XDS2
St2
St1
X6MSD2 X3U6 X3U7 X3U8
X3C2 XDVI2 X7E4 X7E5
Reboot
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Product description
ENGLISH
Tab.1: Interface combinations
CS351S-
D
CS351S-
D IL
CS351S-
G
CS351S-
G IL
CS351S-
G+
CS351S-
D NK –
CS351E-
D
CS351E-
D IL
CS351E-
G
CS351E-
G IL
CS351E-
G+
CS351E-
D NK
CC-
CS351E-
D
Inside the front cover
XDN1 XXXXXXX
X3U1,
X3U2
XXXXXXX
Slot A XXXXX––
Slot B1 XXXXXXX
Slot B2 XXXX–XX
X3C1 XXXXXXX
X7E1 XXXXXXX
X6C1 XXXXXXX
XDVI XX––––X
X3U4 XX––––X
XDAC1,
XDAC2
–––––X–
X6MSD2 ––––X––
X3C2 ––––X––
XDVI2 ––––X––
X3U6 –
X3U8
––––X––
X7E4,
X7E5
––––X––
Outside the front cover
X1N XXXXXXX
X3U3 XXXXXXX
XDS1 CS351E-
D
CS351E-
D IL
CS351E-
G
CS351E-
G IL
CS351E-
G+
CS351E-
D NK
CC-
CS351E-
D
XDS2 CS351S-
D
CS351S-
D IL
CS351S-
G
CS351S-
G IL
CS351S-
G+
CS351S-
D NK
–
X: Interface present
–: Interface not present or without function
Variant
Inter-
face
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68/108 Bosch Rexroth AG CS351 | 3609929B45/2014-09
Product description
4.1 External interfaces
X1N power supply connection
interface
The compact system is delivered with an
EU power supply connection and power
plug with screw terminals. The power sup-
ply connection cable can be unscrewed at
the connection plug and assembled as
desired.
A connection cable for the American market
is available, but must be ordered separately.
Fig. 4: Connection assignment of the power
supply connection plug
NOTE
Damage due to use of non-original
parts!
Damage to the Compact System
Only use power supply connection
cables from Rexroth.
The Rexroth product range includes
suitable cables. Observe local regula-
tions in this regard.
12
PE 3
Tab.2: X1N pin assignment
Pin Signal Description/
function
Voltage/
current
1 L1 L1 power supply
connection
230 VAC/5 A,
120VAC/10A
2 N Power supply
connection
neutral
230 VAC/5 A,
120VAC/10A
3n.c. -
PE PE Leading PE wire PE potential
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Product description
ENGLISH
XDS1 interface for hand-held
nutrunner
The ErgoSpin/CC-ErgoSpin hand-held nut-
runner is connected to the Compact Sys-
tem via a spindle connection cable that is
connected to the 11-pin connection socket.
The power supply for the motor, logic sup-
ply, and transmission of interface signals is
provided via this cable.
Fig. 5: Socket, 11-pin, female (view from
front side)
XDS2 interface for tightening spindle
The tightening spindle is connected to the
Compact System via a spindle connecting
cable that is connected to the 14-pin so-
cket.
The power supply for the motor and the
transmission of the interface signals is pro-
vided via this cable.
Fig. 6: 14-pin socket, female
(front view)
Tab.3: XDS1 assignment
Pin Signal Description/function
1 CANL Serial spindle data CAN low
2 CANH Serial spindle data CAN high
3 VEE 24 V spindle power supply
4 GND Reference potential logic
5 HS Start switch for motor contac-
tor
(motor breaker)
6 B Serial interface B
7 A Serial interface A
UU MotorphaseU
VV MotorphaseV
WW MotorphaseW
PE Protective conductor (project-
ing)
V1
2
3
4
5
6
7
PE
UW
Tab.4: XDS2
Pin Signal Description/function
PE Protective conductor (project-
ing)
AU MotorphaseU
BV MotorphaseV
CW MotorphaseW
1 VTR Driver power supply
2 CANL Serial spindle data CAN low
3 CHB Incremental encoder channel 2
4 GND Reference potential logic
5INDXIndeximpulse
6 VEE 24 V spindle power supply
7 MKTF Motor ID and motor
temperature error
8 HS Start switch for motor contactor
(motor breaker)
9 CANH Serial spindle data CAN high
10 CHA Incremental encoder channel 1
89
10
7
6
543
2
1
C
B
A
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Product description
1 motor OFF interface XDN1
Two independent motor stop circuits are
available:
• motor off circuit 1 (NH1) is implemented
via a contactor installed in the Compact
System. This separates the motor from
the servo amplifier (motor is braked).
• motor off circuit 2 (NH2) prevents the de-
velopment of a motor rotating field (motor
is not braked).
Both connections are bridged in the deli-
very state.
Fig. 7: Delivery state with bridged motor off
circuits (NH1 and NH2)
Fig. 8: XDN1
Boundary conditions:
• The maximum cable length for the motor
OFF circuit is 30 m.
• Always design the motor OFF circuits se-
parately and with potential-free contacts.
Do not mix up the motor OFF circuits un-
der any circumstances.
• Both motor OFF interfaces must be led
back. If only one is used, the other one
must be provided with a wire jumper.
• If you are only using one motor OFF con-
nection option, we recommend imple-
menting the motor OFF function via motor
OFF circuit NH1 (see Fig. 9, page 72).
CAUTION
Risk of damage to persons and pro-
perty!
Make sure the emergency OFF equip-
ment is accessible and effective. Re-
leasing the emergency OFF equip-
ment must not result in an
uncontrolled system restart!!
The motor off interface is used to
integrate the tightening control-
ler into an emergency stop me-
chanism. For information about
the category and performance
level of the motor off interface,
refer to the technical information
TIe_197 or the project planning
manual.
NH1
NH2
Tab.5: XDN1 assignment
Pin Signal as-
signment
Descrip-tion/
function
Voltage/
current
1 VEE NH1 motor off 2
supply voltage
24 V/0.3 A
2NH1 motoroff1re-
turn (motor con-
tactor)
24 V/0.1A
3 VEE NH2 motor off 2
supply voltage
24 V/0.3 A
4NH2 motoroff2re-
turn (end step)
24 V/0.1A
XDN1
1234
CS351_zweispaltig - D.book Seite 70 Donnerstag, 2. Oktober 2014 8:36 08

CS351 | 3609929B45/2014-09 Bosch Rexroth AG 71/108
Product description
ENGLISH
The maximum torque at the bol-
ted connections of the terminals
at XDN1 must not exceed 0.3
Nm.
CAUTION
Risk of damage to persons and pro-
perty!
The user is obliged to maintain the
system-specific requirements for an
emergency OFF system.
When using external power supply
contactors in higher-level emergency
OFF circuits, observe the restarting
time of 10 seconds for single swit-
ching and 30 seconds for repeated
switching.
Check that the emergency OFF cir-
cuits are functioning properly before
commissioning the tightening system.
Observe the local, system-specific re-
gulations and requirements; proper
use of tools, lifting, and transport
equipment; as well as the pertinent
standards, provisions, and occupatio-
nal safety regulations.
CAUTION
Risk of damage to persons and pro-
perty!
Dangerous shock currents due to inade-
quate PE wire connections!
Protective conductor connections
must not be affected by mechanical,
chemical, or electrochemical influen-
ces. The connection must be perma-
nent.
NOTE
The voltage circuits at terminal XDN1
are safely isolated from the power
supply circuits (safe isolation in ac-
cordance with EN50178). The requi-
rements for safe isolation of electric
circuits must be observed when using
the connection options on this termi-
nal.
CS351_zweispaltig - D.book Seite 71 Donnerstag, 2. Oktober 2014 8:36 08

72/108 Bosch Rexroth AG CS351 | 3609929B45/2014-09
Product description
Motor OFF protective circuit
1. Cut-out via the internal motor contactors
After a cut-out via the motor contactor, the
motor phases are electromechanically isola-
ted from the power supply.
Fig. 9: Motor OFF circuit 1 (NH1) connection to the Compact System
Motor Off switch directly connected to
the contacts for motor OFF
If the S1 motor breaker switch is actuated,
the motor of the hand-held nutrunner/tighte-
ning spindle will be decelerated by the
servo amplifier and the internal contactor in
the compact system will be opened. This
tightening job abort leads to an error mes-
sage in the controller. The error message is
automatically acknowledges once switch
S1 is closed again. Now you can restart the
system.
XDN1
1234
S1
Einsatz
Motor-Stopp-Schalter
1 mm
2
VEE NH1
NH1
NH1
CS351_zweispaltig - D.book Seite 72 Donnerstag, 2. Oktober 2014 8:36 08