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

II/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
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.

2/94 About this documentation |Automax 100 | Extension module TS-AC E2-M3-1X
Bosch Rexroth AG | 05.2021 | DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P
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>

About this documentation | Automax 100 | Extension module TS-AC E2-M3-1X 3/94
Bosch Rexroth AG | 05.2021 | DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P
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

4/94 About this documentation |Automax 100 | Extension module TS-AC E2-M3-1X
Bosch Rexroth AG | 05.2021 | DOK-SUPPL*-TS-AC E2-M3-ITRS-EN-P
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