Bosch Rexroth ctrlX SAFETY SAFEX-C.12 User manual

Operating instructions
R911405651, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03, Bosch Rexroth AG
ctrlXSAFETY
Compact safety controller
Devices SAFEX-C.12 / SAFEX-C.15

R911405651, Bosch Rexroth AG, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03
The provided data is intended for product
description purposes. If any information on
product use is given, such information may
only be viewed as application examples and
suggestions. Catalog information does not
constitute guaranteed properties. The
information does not release users from the
responsibility to perform their own
assessments and tests. Our products are
subject to a natural wear and aging process.
© Bosch Rexroth AG 2022
All rights reserved, also with regard to any
disposal, utilization, reproduction,
processing, transfer, as well as in the event
of property rights applications.
An example configuration is depicted on the
title page. The delivered product may
therefore differ from the depicted image.
The original operating instruction was
created in German.

ctrlX SAFETY | Content 3/83
DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03, Bosch Rexroth AG
Content
1 About this documentation 6
1.1 Editions 6
1.2 Validity of the documentation 6
1.3 Required and supplementary documentation 7
1.4 Presentation of information 7
1.4.1 Safety instructions 7
1.4.2 Symbols 8
1.4.3 Terms 9
1.4.4 Abbreviations 9
2 Safety instructions 10
2.1 About this section 10
2.2 Intended use 10
2.3 Improper use 10
2.4 Qualification of personnel 11
2.5 General safety instructions 11
2.6 Product- and technology-dependent safety instructions 12
2.7 Obligations of the operator 13
3 General information about property damage and product damage 14
4 Scope of delivery 15
5 Delivery condition, identification, transport and storage 16
5.1 Delivery condition 16
5.1.1 Factory inspection 16
5.1.2 Customer-side inspection 16
5.2 Identification 16
5.2.1 Signs 16
5.2.1.1 Location of the signs 16
5.2.1.2 Name plate 17
5.3 Transport of components 18
5.3.1 Ambient and operating conditions - Transport 18
5.4 Storage of components 18
5.4.1 Ambient and operating conditions - Storage 18
6 Installation, removal, replacement and electrical installation 19
6.1 Installation instructions 19
6.2 Installation of the ctrlX SAFETY controller 21
6.3 Removal of the ctrlX SAFETY controller 21
6.3.1 Removal steps 22
6.3.2 Locking mechanism for mounting on standard DIN rail 23
6.4 Replacement of the ctrlX SAFETY controller 24
6.5 Electrical installation 25
6.5.1 External power supply 25
6.5.2 Voltage supply for the controller 26
6.5.3 Terminal blocks for voltage supply and inputs/outputs 27
6.5.4 Connection of the safe digital inputs and outputs 29
7 Commissioning 30
7.1 ctrlX SAFETY Engineering 30
7.2 μSD memory card 31

4/83 ctrlX SAFETY | Content
R911405651, Bosch Rexroth AG, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03
7.3 Switch-on sequence and device status 32
7.4 Reset behavior 34
7.4.1 Reset types and triggering events 34
7.4.2 Reset timing 34
7.4.3 Reset function 35
8Maintenance 37
8.1 Regular maintenance activities 37
9Device type SAFEX-C.12 38
9.1 Device characteristics 38
9.1.1 Safety-related characteristics 38
9.1.2 General technical characteristics 39
9.1.3 Electrical data 40
9.1.4 Ambient data 41
9.1.5 Mechanical data 42
9.2 Device interfaces 43
9.2.1 Interface for voltage supply and inputs/outputs 44
9.2.2 Ethernet interface 1 (XF28 / XF29) 45
9.2.2.1 EtherCAT 45
9.2.2.2 TCP/IP (in preparation) 46
9.2.3 Pin assignment of Ethernet interface 1 (RJ45 sockets) 47
9.2.4 ctrlX SAFETYlink master interface 47
9.2.5 USB-C interface 48
9.3 Device diagnostics 49
10 Device type SAFEX-C.15 53
10.1 Device characteristics 53
10.1.1 Safety-related characteristics 53
10.1.2 General technical characteristics 54
10.1.3 Electrical data 55
10.1.4 Ambient data 56
10.1.5 Mechanical data 57
10.2 Device interfaces 58
10.2.1 Interface for voltage supply and inputs/outputs 59
10.2.2 Ethernet interfaces 60
10.2.3 Ethernet 1 interface (XF28 / XF29) 60
10.2.3.1 EtherCAT 60
10.2.3.2 TCP/IP (in preparation) 61
10.2.4 Ethernet 2 interface (XF30 / XF31) 61
10.2.4.1 EtherCAT / FSoE slave (in preparation) 61
10.2.4.2 PROFINET / PROFIsafe slave (in preparation) 62
10.2.4.3 TCP/IP (in preparation) 62
10.2.5 Pin assignment of the Ethernet interfaces (RJ45 sockets) 63
10.2.6 CtrlX SAFETYlink interface 63
10.2.7 USB-C interface 64
10.3 Device diagnostics 65
10.3.1 Ethernet 1 interface: 68
10.3.2 Ethernet 2 interface: 69
11 Order information 70
11.1 Control device SAFEX-C.12 70
11.2 Control device SAFEX-C.15 70

ctrlX SAFETY | Content 5/83
DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03, Bosch Rexroth AG
11.3 Accessories and spare parts 70
11.4 Wearing parts 72
12 Additional information 73
12.1 Cable lengths 73
13 Standards 74
13.1 EU directives 74
13.2 CE marking 75
13.2.1 Declaration of conformity 75
13.3 UL/CSA - Certification 77
14 Causes and correction of errors 78
15 General ordering information 79
15.1 Type code 79
15.2 Controller devices 80
15.3 Accessories and spare parts 80
16 List of abbreviations 81

6/83 ctrlX SAFETY | About this documentation
R911405651, Bosch Rexroth AG, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03
1About this documentation
1.1 Editions
Tabelle 1: Index of editions
Edition No. Edition date Changes
01 2021-01 First edition
02 2021-11 Addition of notes on mechanics and response times
03 2022-01 Addition of accessories and spare parts
1.2 Validity of the documentation
This documentation applies to the following products:
•R911175242 SAFEX-C.12
•R911175243 SAFEX-C.15
This documentation is intended for designers, installers, commissioning engineers,
maintenance technicians, service technicians and waste disposal companies.
This documentation contains important information for the safe and proper installation,
commissioning, operation, use, maintenance, independent troubleshooting of minor faults,
disassembly and disposal of the product.
This manual contains instructions for technical staff of the machine manufacturer for safe
mechanical and electrical installation and commissioning of the controller.
Required qualifications: Person who is able to assess the work assigned to them and
identify potential risks on the basis of their professional training, knowledge and experience,
as well as their knowledge of the relevant standards and regulations.
Read this documentation in its entirety and pay particular attention to Section 2 "Safety
instructions" before working with the product.

ctrlX SAFETY | About this documentation 7/83
DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03, Bosch Rexroth AG
1.3 Required and supplementary documentation
Only commission the product after making sure that the documentation marked with the
book symbol ( ) is available and you have understood and observed it.
Tabelle 2: Required and supplementary documentation
Title Document number Document type
Installation manual ctrlX SAFETY
SAFEX-C.1* devices DOK-XSAFE*-
SAFEX-C.1XC-COxx-DE-P 1)
R911405649 Installation manual
Programming manual for ctrlX
SAFETY SAFEX-C.1* devices with
ctrlX SAFETY Engineering DOK-
XSAFE*-SAFEX-C.1XC-PRxx-DE-P2)
R911405647 Programming manual
Error list / Diagnostic messages for
ctrlX SAFETY SAFEX-C.1* devices
DOK-XSAFE*-SAFEX-C.1XC-RExx-
DE-P 3)
R911406843 Error and diagnostic
reference
Application description for the
integration of the ctrlX SAFETY
SAFEX-C.1* devices in ctrlX
AUTOMATION DOK-XSAFE*-
SAFEX-C.1XC-APxx-DE-P 4)
R911407750 Application description
1) COxx: latest edition of installation manual
2) PRxx: latest edition of programming manual
3) RExx: latest edition of error list / diagnostic messages
4) APxx: latest edition of application description in ctrlX AUTOMATION
1.4 Presentation of information
Uniform safety instructions, symbols, terms and abbreviations are used in this
documentation to make working with your product quick and safe. For better understanding
these are explained in the following sections.
1.4.1 Safety instructions
In this documentation, safety instructions precede action sequences in which there is a risk
of personal injury or property damage. The described safety measures must be adhered to.
Safety instructions are structured as follows:
SIGNAL WORD
Type and source of the danger
Consequences of non-compliance
Safety measure
<List>

8/83 ctrlX SAFETY | About this documentation
R911405651, Bosch Rexroth AG, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03
•Warning sign: draws attention to the danger
•Signal word: indicates the severity of the danger
•Type and source of danger: identifies the type and source of the danger
•Consequences: describes the consequences of non-compliance
•Protection: indicates how to avert the danger
Tabelle 3: Hazard classes according to ANSI Z535.6-2006
Warning sign, signal word Meaning
DANGER
indicates a hazardous situation which, if not avoided, will
result in death or serious injury
WARNING
indicates a hazardous situation which, if not avoided, could
result in death or serious injury
CAUTION
indicates a hazardous situation which, if not avoided, could
result in minor to moderate injury
NOTE
indicates property damage: Damage to the product or the
environment could occur.
1.4.2 Symbols
The following symbols indicate information that is not related to safety, but instead improves
your understanding of the documentation.
Tabelle 4: Meaning of the symbols
Symbol Meaning
If this information is not observed, the product cannot be used or operated
optimally.
This is a note.
individual, independent action step
1.
2.
3.
numbered instructions for action:
The digits indicate that the action steps are sequential.

ctrlX SAFETY | About this documentation 9/83
DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03, Bosch Rexroth AG
1.4.3 Terms
The following terms are used in this documentation:
The term “safe” is used in accordance with/within the meaning of the following standards:
DIN EN ISO 13849-1, DIN EN 61508-1:2011-02 (cf. the Relevant standards section). The
term “safe function for application up to PL e/SIL 3” specifies functions with appropriate
integrity (reliability) within the meaning of the standards mentioned above.
The ctrlX SAFETY controllers are devices for the implementation of safety-related functions
with safe communication via FSoE and non-safety-related data communication via
EtherCAT. These are internally structured as two channels: System A and System B.
The “ctrlX SAFETY Engineering” system software is used for the programming and
configuration of ctrlX SAFETY controllers, ctrlX DRIVE
plus
and 3rd party FSoE devices. It
implements safety-oriented functions.
Tabelle 5: Terms
Term Meaning
ctrlX SAFETY refers to the compact safety controllers SAFEX-C.12 / SAFEX-C.15
in the document
ctrlX SAFETY
link
master
interface
is a safe communication interface between a ctrlX SAFETY
(SAFEX-C.1*) controller and a ctrlX DRIVE
plus
drive
EtherCAT® is a registered trademark and patented technology,
licensed via Beckhoff Automation GmbH, Germany.
Safety over EtherCAT® is a registered trademark and patented
technology, licensed via Beckhoff Automation GmbH, Germany.
E /PE Programmable electronic controller/programmable electronic system
POR Power Off Reset, reset by switching the voltage supply off and on
SAFEX-C.1* Compact safety controller ctrlX SAFETY, safety master and slave
SMMC Safe master-to-master communication
SRP/CS Safety related parts of control systems
1.4.4 Abbreviations
The abbreviations used in this documentation can be found in the List of abbreviations
section at the end of this documentation.

10/83 ctrlX SAFETY | Safety instructions
R911405651, Bosch Rexroth AG, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03
2Safety instructions
2.1 About this section
The product has been developed, tested and manufactured in accordance with generally
accepted rules of technology. Nevertheless, there is a risk of personal injury and property
damage if the safety instructions in this documentation and this section are not observed.
Read the documentation listed in Section 1.2 thoroughly and completely before working
with the product.
Store the documentation in such a way that it is accessible to all users at all times.
Always pass the product on to third parties together with the necessary documentation.
2.2 Intended use
The product is a programmable safety controller.
You may use the product as follows:
•for provision safety shut-off systems and safety functions
•as a safety component within the meaning of the Machinery Directive 2006/42/EC,
•as an E/PE for risk reduction within the meaning of IEC 61508,
•in safety circuits according to EN 60204-1 and EN 60204-32,
•as an E/PE for functional safety within the meaning of 62061,
•as SRP/CS (see abbr.) within the meaning of EN 13849,
•as a device for the provision of safety functions according to EN 61800-5-2,
•as a logic unit for signal conversion and processing in two-hand controls according to EN
574.
The device is a safety component according to Annex IV of the EU Directive 2006/42/EC
(Machinery Directive). It was developed, designed and manufactured in accordance with the
above-mentioned directive, as well as EU Directive 2014/30/EU (EMC Directive)
The product is intended for professional use only and not for private use.
Intended use also includes and requires fully reading and understanding this documentation
and, in particular, the 2 “Safety instructions section.
2.3 Improper use
Any use other than the use described in the Intended use section is considered improper
use and is therefore not permitted.
If unsuitable products are installed or used in safety-related applications, this could lead to
the occurrence of unintended operating conditions in the application, which could cause
personal injury and/or property damage. Therefore, only use products in safety-related
applications if such use is explicitly specified and permitted in the product documentation.
For example, in EX-protected areas or in safety-related parts of a controller (functional
safety).
Bosch Rexroth AG disclaims liability for damage caused by improper use. All risks
associated with improper use are borne solely by the user.