Bosch IO-BOX32 User manual

Drive and control technology
IO-BOX32
Module Description
B~IO
Version 101

B~IO
IO-BOX32
Module Description
1070 072 302-101 (01.06) GB
E2001
by Robert Bosch GmbH, Erbach / Germany
All rights reserved, including applications for protective rights.
Reproduction or distribution by any means subject to our prior written permission.
Discretionary charge 10.00 DM

I
1070 072 302-101 (01.06) GB
Table of contents
Page
1 Safety instructions 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Use in accordance with intended purpose 1–1. . . . . . . . . . . . . . . . . .
1.2 Qualified personnel 1–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Safety signs on the products 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Safety instructions in this manual 1–4. . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Safety instructions for the product described 1–5. . . . . . . . . . . . . . .
1.6 Documentation and registered trade marks 1–6. . . . . . . . . . . . . . . . .
2 System introduction 2–1. . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Designation 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 System description 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Structure 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 GSD and EDS files 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Installation of the IO–BOX32 3–1. . . . . . . . . . . . . . . . . . .
3.1 Installation positions and distances 3–1. . . . . . . . . . . . . . . . . . . . . . . .
4 Connection 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Overview of connections 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Voltage supply 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Inputs/outputs 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Arrangement of inputs/outputs 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Connection 4–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Field bus 4–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Connection 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Interface to field bus 4–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Operation with PROFIBUS-DP 5–1. . . . . . . . . . . . . . . . .
5.1 Rotary switch for bus address 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 Baud rate 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.2 Displays 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.3 Configuring and setting parameters 5–4. . . . . . . . . . . . . . . . . . . . . . .
6 Operation with CANopen 6–1. . . . . . . . . . . . . . . . . . . . . .
6.1 Rotary switch for node ID 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 Rotary switch for baud rate 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.2 Displays 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.3 Operating characteristics CANopen 6–4. . . . . . . . . . . . . . . . . . . . . . .
6.1.4 Setting parameters via DIP switches 6–6. . . . . . . . . . . . . . . . . . . . . .
6.1.5 Setting parameters via the CAN master 6–8. . . . . . . . . . . . . . . . . . . .
6.1.6 CAN identifiers 6–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.7 Range of functions 6–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II
1070 072 302-101 (01.06) GB
7 Technical data 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 IO-BOX32 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 PROFIBUS-DP 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 CANopen 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Inputs 7–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Outputs 7–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Installation guidelines 8–1. . . . . . . . . . . . . . . . . . . . . . . .
8.1 Power connection 8–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Circuit diagrams 8–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.1 Reference lead connected to the protective earth 8–3. . . . . . . . . . .
8.2.2 Reference lead not connected to the protective earth 8–4. . . . . . . .
8.2.3 Capacitive load of the power supply 8–4. . . . . . . . . . . . . . . . . . . . . . .
8.2.4 Dimensioning of the power supply 8–5. . . . . . . . . . . . . . . . . . . . . . . .
8.2.5 Master switch 8–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.6 Fuses 8–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.7 Earthing 8–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 I/O connections 8–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.1 Outputs 8–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2 Inputs 8–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Electromagnetic compatibility 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1 General 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.2 Interference 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.3 Signal-to-interference ratio 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.4 EMC law and CE identification 8–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.5 EMC characteristics of IO-BOX32 8–10. . . . . . . . . . . . . . . . . . . . . . . .
8.4.6 Installation measures to ensure interference immunity 8–12. . . . . . .
9 Ordering data and accessories 9–1. . . . . . . . . . . . . . . .
9.1 IO–BOX32 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Accessories 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Appendix 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Abbreviations 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 Index 9–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–1
1070 072 302-101 (01.06) GB
1 Safety Instructions
Before you start working with the IO-BOX32, 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 Intended use
This instruction manual presents a comprehensive set of instructions and
information required for the standard operation of the described products.
The described products serve as decentralised input/output assemblies on
the CANopen bus and PROFIBUS-DP.
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
Dthe EMC Directives (89/336/EEC, 93/68/EEC and 93/44/EEC)
Dthe Low-Voltage Directive (73/23/EEC)
Dthe harmonized standards EN 50081-2 and EN 50082-2
Dare designed for operation in an industrial environment (Class A
emissions). The following restrictions apply:
DNo direct connection to the public low-voltage power supply is
permitted.
DConnection to the medium and/or high-voltage system must be
provided via transformer.
The following applies for application within a personal residence, in
business areas, on retail premises or in a small-industry setting:
DInstallation in a control cabinet or housing with high shield
attenuation.
DCables that exit the screened area must be provided with filtering or
screening measures.
DThe user will be required to obtain a single operating license issued by
the appropriate national authority or approval body.
.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.
Proper transport, handling and storage, placement and installation of the
product are indispensable prerequisites for its subsequent flawless service
and safe operation.

1–2
1070 072 302-101 (01.06) GB
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 manual is aimed at construction engineers and project engineers who
equip the machines and units with PLC as well as at skilled electrical
technicians who install and put the machines into operation. They require
special knowledge of PLC, the CANopen bus and the PROFIBUS-DP.
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 is 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
technical standards, of assessing the work to be carried out, and of
recognizing possible dangers.
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
comprehensive training program. The professional staff at our training
centre will be pleased to provide detailed information. You may contact the
centre by telephone at ([phone].

1–3
1070 072 302-101 (01.06) GB
1.3 Safety markings on components
DANGER! High voltage!
CAUTION! Electrostatically sensitive devices (ESD)!
Lug for connecting PE conductor only!
Functional earthing or low-noise earth only!
Screened conductor only!

1–4
1070 072 302-101 (01.06) GB
1.4 Safety instructions in this manual
DANGEROUS ELECTRICAL VOLTAGE
This symbol warns of the presence of a dangerous electrical voltage.
Insufficient of lacking compliance with this warning can result in personal
injury.
DANGER
This symbol is used wherever 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.
LThis asterisk symbol indicates that the manual is describing an activity which
the user will be required to perform.

1–5
1070 072 302-101 (01.06) GB
1.5 Safety instructions for the described product
DANGER
Danger to persons and equipment!
Test every new program before operating the system!
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 carried out on the active
system, these must be carried out by trained electricians.
CAUTION
Only Bosch-approved spare parts may be used!
CAUTION
Danger to the module!
All ESD protection measures must be observed when using the
module! Prevent electrostatic discharges!
Observe the following protective measures for electrostatically sensitive
devices (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 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
susceptible 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.

1–6
1070 072 302-101 (01.06) GB
1.6 Documentation, software release and trademarks
Relevant documentation The present manual provides the user with comprehensive information
about operation and installation of the IO-BOX32.
However, generally applicable processes for project engineering and
installation of the CANopen bus systems and the PROFIBUS-DP have been
excluded from this manual.
Trademarks All trademarks referring to software that is installed on Bosch products when
shipped from the factory represent the property of their respective owners.
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.
PROFIBUSris a registered trademark of the PROFIBUS
Nutzerorganisation e.V. (user organization).

2–1
1070 072 302-101 (01.06) GB
2 System introduction
The IO-BOX32 is a decentralised input / output device for the field buses
PROFIBUS-DP and CANopen and it provides 32 inputs/outputs per 0.5 A.
The device has IP65 protection.
In conjunction with a corresponding bus master circuit, the assembly can be
used as a decentralised peripheral.

2–2
1070 072 302-101 (01.06) GB
2.1 Designation
The designation of the devices consists of the following:
IO-BOX 32
Bus Input Output
Number of digital inputs / outputs
2.2 System description
A number of IO-BOX32s can be connected as slaves to PROFIBUS-DP
and/or CANopen. The sensors and actuators are connected directly to the
relevant connections on the IO-BOX32.
The IO-BOX32 offers the following advantages:
DIt can be connected to a wide variety of control systems and
Dis in permanent contact with the higher level control system via the
PROFIBUS-DP or CANopen, as the case may be.
DThe spatial separation of the control system and machine and/or its
assemblies enables a clearly laid out system structure.
DThe wiring overhead between control system and machine is reduced.
DSimple connection of sensors and actuators with 2-/3-/4-wire connec-
tions without intermediate terminals.
DThe IO-BOX32 provides 24 V for sensors.
DThe IO-BOX32 processes the input signals, e.g. from switches, light
barriers, sensors.
DIt controls the connected small consumers, e.g. valves, lamps and
contactors.
DExtensions can be retrofitted with low overhead.
DSpace savings in the switching cabinet due to direct installation at the
machine.
DSavings of input and output assemblies in the control system.
DFault diagnosis is simplified.
DSeparate switching of loads is possible.

2–3
1070 072 302-101 (01.06) GB
2.3 Structure
The IO-BOX32 has a die-cast housing. The housing cover has two windows
through which the bus address as well as the status LEDs can be read.
All bus and supply cables are led in via metric screw cable fastenings and
connected to spring terminals.
The distribution of the 32 IO terminals as inputs and outputs can be chosen in
steps:
D0 digital inputs and 32 digital outputs
D8 digital inputs and 24 digital outputs
D16 digital inputs and 16 digital outputs
D24 digital inputs and 8 digital outputs
D32 digital inputs and 0 digital outputs
2.4 GSD and EDS files
To map the slave connections, the master uses description files:
DIn the case of PROFIBUS-DP : device master data,
GSD file (German)
ESD file (English)
DIn the case of CANopen : Electronic Data Sheet,
EDS file
The relevant file can be taken from CD-ROM ”PLC-Tools”(Order number
1070 084 000) or downloaded from the Internet: http://www.bosch.de/at.
Alternatively, a floppy disk with all Bosch device master data can be ordered
(Order number, see section 9.2).

2–4
1070 072 302-101 (01.06) GB
Notes:

3–1
1070 072 302-101 (01.06) GB
3 Installation of the IO-BOX32
3.1 Installation positions and distances
Installation position In general, any desired installation position is possible. The IO-BOX32 is
attached directly to the machine using 2 to 4 M6 screws.
.The earth contact must be a screwed connection to the housing.
4 securing holes
Diameter 7
Depth 72 mm

3–2
1070 072 302-101 (01.06) GB
Minimum spacing The following minimum spacing must be adhered to due to heat:
DHorizontal installation
minimum
cable bending
radius plus
20 mm
DVertical installation

4–1
1070 072 302-101 (01.06) GB
4 Connection
4.1 Overview of connections
All connections of the IO-BOX32 can be plugged in socket terminal strips
(grid 3.5 mm). The cover must be opened to enable connection.
Metric
EMC screw
cable fastening
Field bus connections
Supply voltage
Inputs/outputs
PE

4–2
1070 072 302-101 (01.06) GB
Connector Connection allocation
X51 Bootstrap connector for loading firmware
X1 to X8 Spring terminals each for 4 digital inputs/outputs
with 6-pin terminal for supply
X10 Spring terminal (8-pin) for 24-V voltage supply
X71 Spring terminal (4-pin) for field bus (incoming)
X72 Spring terminal (4-pin) for field bus (outgoing)
Screw cable fastening All cables are fed through a removeable inlet plate on the underside of the
housing. This makes it relatively simple to replace the IO-BOX32. Tight
sealing is ensured by metric screw cable fastenings.
Power supply
Field bus
connections
Inputs and/or outputs
Function Size Number
Field bus connections 16 mm (resistant
to EM interference) 2
Power supply 16 mm 1
I/O 16 mm 8
132
LStrip cables.
LPush cables through all three parts until the cladding on part 3 protrudes by
around 3 mm.
LConnect cables to spring terminals of the socket terminal strips.
LClose screw fastenings that are not required with dummy plugs.
.During installation, ensure there is strain relief at the socket terminal
strips.

4–3
1070 072 302-101 (01.06) GB
4.2 Voltage supply
The IO-BOX32 requires a 24 V power supply. A 3-phase power connection
with simple full-bridge rectification is adequate. The superimposed
AC voltage proportion must not exceed 5 %. All voltages in the device are
electrically coupled, reverse-connect protected and can be drawn from
a power connection.
The voltage supply is separate for logic and sensors (US), outputs before
EMERGENCY STOP (U1) and outputs after EMERGENCY STOP (U2)
X10
8 7 6 5 4 32 1
Pin Allocation Current consumption
1US 24 V logic and sensor supply approx. 0.1 A (logic only)
approx. 0.5 A (for sensor
supply per input byte)
2U1 24 V load supply 1 for outputs, e.g.
before EMERGENCY STOP 8 A, no short circuit
3U2 24 V load supply 2 for outputs,
e.g. after EMERGENCY STOP 8 A, no short circuit
40 V 0 V for logic, inputs and outputs
50 V 0 V for logic, inputs and outputs
60 V 0 V for logic, inputs and outputs
7PE Protective earth
8not used
CAUTION
On devices with an index less than 103, even though the load supply
is switched off, there is a flow of current at activated outputs of max.
5 mA if the logic supply remains active.
Possible countermeasures:
DOn switching off the load supply at U1 or U2, make the relevant
connection with 0 V.
DConnect the relevant connection U1 or U2 permanently via 1 kW
with 0 V.
.Information on electrical installation, see chapter 8.

Device index greater than 103
(standard)
Device index less than 103
4–4
1070 072 302-101 (01.06) GB
4.3 Inputs/Outputs
4.3.1 Arrangement of inputs/outputs
Power jumpers determine the arrangement in inputs/outputs per terminal
block:
D0 inputs, 32 outputs
D8 inputs, 24 outputs
D16 inputs, 16 outputs
D24 inputs, 8 outputs
D32 inputs, 0 outputs
CAUTION
It is not permitted to mix inputs and outputs within one byte.
This can lead to undefinable states on the system!
Power jumpers S1 to S4
4 terminal blocks
Terminal block Power jumper Input byte Output byte
X1/2 S1 E0 A0
X3/4 S2 E1 A1
X5/6 S3 E2 A2
X7/8 S4 E3 A3
Jumper setting S1 to S4 Operating mode Load supply
Left Output U2
Right Output U1
Centre - top
(factory setting) Input –
Open Input –