Bosch rexroth Automax 100 User manual

Operating instructions
DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P | 05.2021 | Bosch Rexroth AG
Automax 100
Extension module TS-AC E2-M3-1X

Impressum
The data specified above only serve to describe the product. No statements concerning a
certain condition or suitability for a certain application can be derived from our information.
The information given does not release the user from the obligation of own judgment and
verification. It must be remembered that our products are subject to a natural process of
wear and aging.
This document, as well as the data, specifications 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. The cover shows an example application. The product delivered
may differ from the image on the cover.
The original operating instructions were created in the German language.
Series
Automax 100
Title
Extension module TS-AC E2-M3-1X
Type of documentation
Operating instructions
Documentation type
DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P
Material number
R901540463
Purpose of the documentation
Primary information for use
Safety instructions
Commissioning
Operation
Handling
Technical setup
Change history
Edition
Version
Comment
DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P
05.2021
Repla. for ---
Proprietary note
© Bosch Rexroth AG 2021
All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well
as in the event of applications for industrial property rights.
Liability
The data specified only serves to describe the product and are not to be understood as warranted
properties in the legal sense. Changes in the content of the documentation and delivery options of the
products remain reserved.
Publisher
Bosch Rexroth AG
Bahnhofplatz 2 ■D-97070 Würzburg
Phone [phone]
http://www.boschrexroth.com
Dept.: DC/SSD3 (EG), (AS)

Contents | Automax 100 | Extension module TS-AC E2-M3-1X I/IV
Bosch Rexroth AG | 05.2021 | DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P
Contents
About this documentation 1
1.1 Validity of the documentation 1
1.2 Required and supplementary documentation 1
1.3 Illustration of information 1
1.3.1 Safety instructions 2
1.3.2 Symbols 3
1.3.3 Designations 3
1.3.4 Abbreviations 3
Safety instructions 5
2.1 About this chapter 5
2.2 Intended use 5
2.3 Improper use 5
2.4 Qualification of personnel 6
2.4.1 General information 6
2.4.2 Teaching 6
2.4.3 Trained personnel 6
2.5 General safety instructions 6
2.6 Product- and technology dependend safety instructions 6
2.6.1 Introduction 6
2.6.2 Hazards by improper use 7
2.6.3 General informations 7
2.6.4 Protection by means of protective extra low voltage (PELV) against electric shock
7
2.6.5 Protection against contact with hot parts 7
2.6.6 Protection during handling and assembly 8
2.7 Personal protective equipment 8
2.8 Obligations of the operator 8
2.8.1 General information 8
2.8.2 Safety signs 9
2.9 Safety equipment 9
2.10 Operator workstations 9
2.10.1 General information 9
2.10.2 Teaching stations 11
General information on damage to property and damage to the product 13
Scope of delivery 15
4.1 Delivery conditions 15
About this product 17
5.1 Performance description 17
5.1.1 Information on IT security 17
5.2 Product description 17
5.2.1 Front with operating equipment 18
5.2.2 Rear 19
5.2.3 Voltage supply 19
5.2.4 IndraControl PR21 (-7KE1) 21
Technical data 22
Local diagnostics and status indicator 23
Reset- and power push button 23
Ethernet interfaces 23
5.2.5 Bus coupler (-7KE2) 23

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Technical data 23
Ethernet-interface (XF6, XF7) 24
Rotary coding switch 25
Reset-push button 25
Local diagnostics and status indicators 27
5.2.6 Digital input module (-3KE1) 29
Terminal point assignment 29
Schematic diagram of digital inputs 30
Technical data of digital inputs 30
Local diagnostics and status indicators 31
5.2.7 Analog input module (-5KE1) 31
Terminal point assignment 32
Schematic diagram of analog inputs 32
Technical data of analog inputs 33
Local diagnostics and status indicators 33
5.2.8 System connectors for digital and analog inputs 34
M12 system connectors (-3XG1, -4XG1) 35
M12 system connectors (-5XG1, -5XG2, -6XG1, -6XG2) 39
5.2.9 Dimensional sheet 43
5.3 Product identification 44
5.3.1 Type code 44
5.3.2 Type plate 44
Transport and storage 45
6.1 Transporting the product 45
6.2 Storing the product 45
6.2.1 Storage time 46
Cables and plug 46
Assembly 47
7.1 Unboxing the product 47
7.2 Installation conditions 48
7.2.1 Installation position 48
7.3 Required accessories 48
7.4 Assembling the product 49
7.4.1 Assembly of extension module at the basic module 50
Commissioning 53
8.1 First commissioning 53
8.1.1 Network cable connection 53
8.1.2 Setting the IP addresses 54
IndraControl PR21 55
Bus coupler ETH-BK 56
PC 57
Operation 61
9.1 Software description 61
9.1.1 Web based management of bus coupler ETH-BK 61
9.1.2 Overview of the WBM interface of the bus coupler ETH-BK 63
Bus coupler navigation „Quick Setup“ 64
Bus coupler navigation „Information“ 65
Bus coupler navigation „Diagnostics“ 66
Bus coupler navigation „Modbus/TCP (UDP)“ 66
Bus coupler navigation „Configuration“ 67
Bus coupler navigation „Administration“ 67
9.1.3 IoT Gateway / First steps WBM 68

Contents | Automax 100 | Extension module TS-AC E2-M3-1X III/IV
Bosch Rexroth AG | 05.2021 | DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P
9.1.4 IoT Gateway / Licensing software 71
9.1.5 IoT Gateway / Overview of the WBM interface 73
Maintenance and repair 77
10.1 Cleaning and care 77
10.2 Maintenance 78
10.3 Spare parts 78
Disassembly and replacement 79
Disposal 81
12.1 Environmental protection 81
Extension and modification 83
13.1 Extending the product 83
13.2 Modifying the product 84
Troubleshooting 85
Technical data 87
Appendix 89
16.1 Electrical circuit diagram 89
16.2 Spare part list according to positions 90
16.3 Contact addresses 91
16.3.1 Service and support 91
16.3.2 Contact for product support and repair 91
16.4 Declaration of conformity 92
Alphabetical index 93

IV/IV Contents |Automax 100 | Extension module TS-AC E2-M3-1X
Bosch Rexroth AG | 05.2021 | DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P

About this documentation | Automax 100 | Extension module TS-AC E2-M3-1X 1/94
Bosch Rexroth AG | 05.2021 | DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P
About this documentation
1.1 Validity of the documentation
This documentation applies to the following products:
Material number of product: R901540133
Extension module TS-AC E2-M3-1X
This documentation is intended for trainers, training participants, operators and the system
end-user.
This documentation contains important information on how to assemble, transport,
commission, operate, use, maintain and disassemble the extension module TS-AC E2-M3-
1X safely and properly and to resolve simple faults independently.
You should read this documentation thoroughly, and in particular the chapter „Safety
instructions“before working with the product.
1.2 Required and supplementary documentation
The documents marked with a book symbol are documentations of the Bosch
Rexroth components integrated in this extension module.
The documentations can be ordered under the material number (document number) from
your Bosch Rexroth sales representative. Alternatively, the documentations are available on
the Bosch Rexroth website under the following link.
https://brmv2.kittelberger.net
Required and supplementary documentation
Title
Document number
Document type
IndraControl PR21 Embedded Automation
Computer
R911389662
Operating
instructions
IndraControl S20 bus coupler for Ethernet
R911372205
Data sheet
Rexroth IndraControl S20 digital input module
16 inputs
R911339275
Data sheet
Rexroth IndraControl S20 analog input module 4
inputs
R911342764
Data sheet
Rexroth IndraControl S20
Error messages
R911344826
Application
description
IoT Gateway
Quick start guide
R911378848
Commissioning
description
IoT Gateway
Software application
R911403022
Application
description
IndraControl PR, VR, DR and DE Devices,
Software Applications
R911384733 *
Application
description
Security Manual Electric Drives and Controls
R911342562
Project description
* In this documentation, „Linux Ubuntu Core“, the operating system of IndraControl PR21 is described in chapter 6. This also
includes information for use of the USB stick for recovery.
1.3 Illustration of information
Uniform safety instructions, symbols, terms and abbreviations are used so that you can
quickly and safely work with your product using this documentation. For better
understanding, they are explained in the following sections.

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1.3.1 Safety instructions
In this documentation, safety instructions are included whenever sequences of actions are
explained which bear the danger of personal injury or damage to property. The measures
described for the hazard avoidance must be observed.
Safety instructions are set out as follows:
Warning sign: Draws attention to the danger
Signal word: Indicates the seriousness of the danger
Type and source of danger: Designates the type and source of danger
Consequences: Describes the consequences of non-compliance
Precautions: Specifies how the danger can be prevented
Risk classes according to ANSI Z535.6-2006
Warning sign, Signal word
Meaning
DANGER
Indicates a dangerous situation which may cause death or
severe personal injuries if not avoided
WARNING
Indicates a dangerous situation which may cause death or
severe personal injuries if not avoided
CAUTION
Indicates a dangerous situation which may cause minor to
medium personal injuries if not avoided
NOTICE
Indicates damage to property: The product or the environment
could be damaged
SIGNAL WORD
Type and source of danger
Consequences of non-compliance
Hazard avoidance measures
<List>

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1.3.2 Symbols
The following symbols indicate notes which are not safety-relevant but increase the
comprehensibility of the documentation.
Meaning of Symbols
Symbol
Meaning
If this information is not observed, the product cannot be optimally used and/or operated.
Tip, general note, useful additional information
Observe instructions on disposal and environmental protection

Enumeration

Individual, independent action
Numbered instruction:
The numbers indicate that the actions must be carried out one after the other.
[**]
Indicates the page of a cross reference
Text
Indicates a cross reference in this document
http://
Indicates a hyperlink in this document
1.3.3 Designations
The following designations are used in this documentation:
Designations
Designation
Meaning
TS
Training system
Extension modul
Extension module TS-AC E2-M3-1X
1.3.4 Abbreviations
The following abbreviations are used in this documentation:
Abbrevations
Designation
Meaning
BR
Bosch Rexroth
RD
Rexroth-document
WBM
Web based management
DC
Direct current
AC
Alternating current
Generelly valid abbreviations
Abrevation
Unit
Meaning
U
V
Electrical voltage
I
A
Electric current intensity

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Abrevation
Unit
Meaning
ULS
V
Supply voltage for logic and sensor (DC voltage)
UA
V
Supply voltage for actuators (DC voltage)
R
Ω
Electrical resistance
P
W
Electric power
F
Hz
Frequency
PE
---
Protective earthing
H
%
Air humidity
T
℃
Temperature
LP
dB
Sound pressure level (according to ISO 11205)
NN
m
Height above sea level
B
mm
Width
H
mm
Height
T
mm
Depth
M
kg
Weight

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Safety instructions
2.1 About this chapter
The product has been manufactured according to the generally accepted rules of
technology. However, there is still the danger of personal injury and damage to property if
you do not observe this chapter and the safety instructions in this documentation.
Read this documentation completely and thoroughly before working with the product. If
you have not clearly understood the documentation in the available language, please
contact your responsible Bosch Rexroth sales representative
Keep this documentation in a location where it is accessible to all users at all times
Always include the required documentation when you pass the product on to third parties
The unobjectionable and safe operation of this device requires appropriate and proper
transport, storage, assembly and installation as well as careful operation and
maintenance
2.2 Intended use
Bosch Rexroth products are developed and produced according to the relevant state of the
art. Before their delivery, they are checked for their operationally safe condition.
Before using the Bosch Rexroth products, the following prerequisites must be complied with
in order to guarantee intended use of the products:
Everyone who in any way deals with our products must read and understand the
corresponding safety regulations and notes regarding the intended use
Software products must not be decompiled; their source codes must not be modified
Damaged or defective products must not be installed or commissioned
For control and monitoring of this product, it may be necessary to connect additional
sensors and/or actuators.
The product may be used as follows:
To impart knowledge and skills in the field of drive and control engineering as well as
automation technology and industry 4.0
For educational and commercial applications
As training system
The product is not intended for private use.
Intended use also includes having read and understood this documentation completely,
especially the chapter „Safety instructions“and the chapter „General information on damage
to property and damage to the product“.
2.3 Improper use
Any use deviating from the intended use is improper and thus not admissible.
Bosch Rexroth AG does not assume any liability for damage caused by improper use. The
user assumes all risks involved with improper use.
Improper use of the product is defined as in particular:
Exposure to operating conditions which do not satisfy the prescribed environmental
conditions. Examples of prohibited operation include operation under water, under
extreme temperature variations or extreme maximum temperatures

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2.4 Qualification of personnel
2.4.1 General information
Basic mechanical and electric knowledge as well as knowledge of corresponding technical
terms is required for assembly, commissioning, maintenance (incl. service, inspection,
repair) and disassembly. To ensure operational reliability, these activities may therefore only
be performed by a qualified expert or an instructed person under the supervision of an
expert. Experts are those who are able to recognize potential dangers and apply the
appropriate safety measures due to their professional training, knowledge and experience,
as well as their understanding of the relevant conditions pertaining to the work to be
undertaken. An expert must observe the relevant specific professional rules.
2.4.2 Teaching
At this product, trainees may only work:
Under direct supervision
After being given appropriate instructions
By an instructor or trained member of staff
2.4.3 Trained personnel
For the supervision during the exercises, trained personnel may also be used.
These are qualified people who were instructed and briefed in relation to:
Tasks ordered
Possible dangers in the event of improper use
Safeguards and protective measures
2.5 General safety instructions
Observe the valid regulations on accident prevention and environmental protection
Observe the safety regulations and provisions of the country where the product is
implemented/used
Exclusively use Rexroth products in technically perfect condition
Observe all notes on the product
Persons permitted to assemble, operate, disassemble or maintain Rexroth products must
not be under the influence of alcohol, other drugs or medication which can impair
responsiveness when doing so
Only use spare parts approved by the manufacturer in order to exclude hazards to
persons due to unsuitable spare parts
Comply with the technical data and environmental conditions specified in the product
documentation
2.6 Product- and technology dependend safety instructions
2.6.1 Introduction
The following notes must be read before the first commissioning of the system to avoid
physical injury and/or damage to property. These safety instructions must be observed at all
times.
Do not attempt to install or commission this device without first reading all documentation
provided with the system. Please contact your responsible Bosch Rexroth sales
representative in case you are not provided with any user information.
If the device is resold, rented and/or passed on to others in any other form, these operating
instructions must be handed over, as well.

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2.6.2 Hazards by improper use
CAUTION
Hot surfaces possible on device housings!
Risk of injury! Risk of burning!
CAUTION
Risk of injury by improper handling!
Injury due to crushing, shearing, hitting or incorrect handling!
2.6.3 General informations
In case of damage due to non-compliance with the warnings in these operating
instructions, Bosch Rexroth AG will not accept any liability
Before the commissioning, the operating, maintenance and safety instructions are to be
read. If you have not understood the documentation in the available language, please
contact your responsible Bosch Rexroth customer service
The unobjectionable and safe operation of this device requires appropriate and proper
transport, storage, assembly and installation as well as careful operation and
maintenance
You must observe the safety regulations and provisions of the country where the device
is used
The environmental conditions specified in the product documentation must be observed
Technical data as well as connection and installation conditions are available in the
product documentation and must imperatively be observed
2.6.4 Protection by means of protective extra low voltage (PELV) against
electric shock
All connections and terminals with voltages of UDC = 0 to 24 V at Rexroth products are
protective extra low voltages which are designed in a contact-protected form according to
the product standards.
WARNING
High electric voltage by incorrect connection!
Danger to life, risk of injury by electric shock!
At all connections and terminals of this product, only devices, electric components and
lines with protective extra low voltage (PELV) may be connected
All power sources for protective extra low voltage must ensure secure separation from
dangerous voltages. These include:
–Accumulators
–Safety transformers according to VDE 0551
–Power sources with protection properties like functional low voltage with secure
separation (PELV)
2.6.5 Protection against contact with hot parts

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CAUTION
Hot surfaces possible on device housings!
Risk of injury! Risk of burning!
Do not touch housing surfaces near sources of heat! Risk of burning!
Before touching, first allow devices to cool down for 10 minutes after switching off
Touching hot equipment parts such as device housings in which cooling elements and
resistors are located can lead to burns!
2.6.6 Protection during handling and assembly
CAUTION
Risk of injury by improper handling!
Bodily injury by bruising, shearing, cutting, hitting!
Observe the general construction and safety regulations on handling and assembly
Use suitable assembly and transport equipment
Avoid jamming and bruising by appropriate measures
If necessary, use suitable protective equipment (for example safety goggles, safety
shoes, protective gloves)
2.7 Personal protective equipment
The personal protective equipment for users of the product consists of:
Safety shoes during teaching
All parts of the personal protective equipment must be in full working order.
2.8 Obligations of the operator
2.8.1 General information
The operator of the product is to provide for personnel training on the following subjects on a
regular basis:
Observation and use of the operating instructions as well as the legal provisions
Intended operation of the Bosch Rexroth product
Observation of the instructions from the factory security offices as well as the operator’s
operating instructions
Behavior in case of emergency
The operator has to guarantee the required prerequisites for the set-up and the installation
of the product and provides for:
Safe set-up by their personnel and/or the persons authorized by them
Compliance with the accident prevention regulations (UVV)
Compliance with the safety regulations of the professional unions as well as further
internal and local requirements
He shall in particular make sure that the underground
Is stable
Is level and horizontal

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The operator will instruct their employees and/or those of third-party companies on possible
dangers at the place of installation.
The operator must provide adequate illumination around the area of installation of the
product.
2.8.2 Safety signs
Depending on the installation conditions, warning notices may have to be attached at the
installation place. The operator is responsible for affixing the safety signs.
Refer to the table below for a recommendation of the warning labels to be used.
Prohibitory signs according to DIN EN ISO 7010 (2019)
Symbol
Description
Open flames, fire, open ignition sources and smoking prohibited
Registration number: P003
Do not extinguish with water
Registration number: P011
Warning signs according to DIN EN ISO 7010 (2019)
Symbol
Description
Warning! Hot surface
Registration number: W017
Warning! Obstacles on the floor
Registration number: W007
Electrostatic sensitive components
Mandatory signs according to DIN EN ISO 7010 (2019)
Symbol
Description
Observe operating instructions
Registration number: M002
Wear safety footwear
Registration number: M008
2.9 Safety equipment
For protection of the product, the following safety equipment is used
Safety socket
Safety plugs
2.10 Operator workstations
2.10.1 General information
This chapter describes the space requirement for operation of the extension module with a
basic module. Operation in an office as well as in a training room are considered.
In general, sufficient lighting of the workstations in compliance with „Lighting of work places
–DIN EN 12464-1“must be ensured. According to DIN EN 12464-1, a light intensity of 500

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Lux is recommended in the classification for „training institutions“for training workshops,
exercise rooms and laboratories.
The criteria of the following list must also be taken into consideration.
Prevention of blinding
Sufficient evenness of indoor lighting
Low shading
Suitable light color
–Color temperature of 4000 Kelvin is regarded to be suitable. This is neutral white. To
generate artificial daylight, a light color of approx. 6000 Kelvin can also be used. This
light, however, has a light shade of blue and is not considered as pleasant by
everyone
The height of the worktable must be selected in such a way that ergonomic working is
possible. To ensure stability of the basic module, a minimum distance of 10 cm should be
ensured to the worktable edge in all sides. The spatial arrangement of the worktable may
vary depending on the task.
For example, the rear and sides of the working table may also end at the wall in an office. In
this case, the distance must only be ensured behind the operator. In general, an open
escape path to an emergency exit must be ensured.
Basic module with extension module
Workstation (Worktable)
Space requirement of one workstation (dimensions in cm)
Furthermore, rows of tables can also be formed in a training room. If the table width is
sufficient, the tables may then also be lined up directly at the sides. If several rows of tables
are in place, a passage width of 100-200 cm must be ensured between the table rows.
Escape routes to emergency exits must be reached from all workstations. No cables should
be routed on the ground in the passages. If this is not possible, the cables must be covered
with suitable cable ducts or similar. This hazard area is marked by the „Tripping hazard“
warning sign. Please refer to table „Warning signs according to DIN EN ISO 7010 (2019)“as
of page [9].

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The tables can also be arranged opposite of each other. Table rows can also be arranged
opposite of each other. This worktable arrangement must also comply with the above
criteria.
See the following figure.
Basic module with extension module
Workstation 1 (Worktable 1)
Basic module with extension module
Workstation 2 (Worktable 2)
Space requirement of two workstations (dimensions in cm)
2.10.2 Teaching stations
The following teaching stations are provided depending on how the product is used:
Teaching stations per training system
Work step
Recommended max. number of people
Set-up
2
Operating
2

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General information on damage to property and damage to the product | Automax 100 | Extension module TS-AC E2-M3-1X 13/94
Bosch Rexroth AG | 05.2021 | DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P
General information on damage to
property and damage to the product
DANGER
Risk of fire due to overheating!
Risk of fire
Ventilation of the device must not be obstructed by covering the ventilation openings
with objects like documents, notes, etc.
You should ensure extensively dimensioned air circulation around the device. You can
thus prevent possible damage at the device as well as risk of fire due to overheating
Open fires must be kept away from the device at all times
NOTICE
Danger due to improper handling!
Damage to property
The product may only be operated according to the intended use
NOTICE
Contamination by foreign bodies!
Premature wear and malfunctions
During assembly, provide for cleanliness in order to prevent foreign bodies from
getting into the extension module TS-AC E2-M3-1X and causing malfunctions
Before commissioning, ensure that all electric and mechanical connections have been
made
NOTICE
Energized system!
Damage to property
Do not remove any electric connections as long as the training system and the
exercise setup are connected to the power supply
For operation, a basic module of this range of training systems must be used. The
basic module provides the voltage supply. Further information can be found in the
operating instructions of the basic module
The warranty only applies to the supplied configuration.
The claim to warranty expires if the product is assembled, commissioned and operated
incorrectly, as well as used and/or handled improperly.

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