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.

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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

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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

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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.

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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>

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•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.

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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.

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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.

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Improper use of the product includes, for example:
•Applications for which ATEX certification is necessary,
•Applications for which approval by classification societies is required,
or
•Applications in countries for which a national certificate not yet issued for the product is
required.
2.4 Qualification of personnel
The activities described in this documentation require basic knowledge of mechanical and
electrical systems, as well as knowledge of the associated technical terms. In order to
ensure safe use, these activities may therefore only be carried out by an appropriate
specialist or a trained person under the direction of a specialist.
Specialists are persons who, based on their professional training, their knowledge and
experience, as well as their knowledge of the relevant regulations, can assess the work
assigned to them, identify potential risks and take appropriate safety measures. Specialists
must always comply with the relevant technical rules.
2.5 General safety instructions
WARNING
Non-observance of the general safety instructions
Damage to the product and the environment
Observe the applicable regulations for accident prevention and environmental protection.
Observe the safety regulations and the regulations of the country in which the product is
used/applied.
Use Rexroth products only in technically perfect condition.
Observe all instructions on the product.
Persons who install, operate, dismantle or maintain Rexroth products must not be under
the influence of alcohol, other drugs or medications that affect their reaction capacity.
Only use accessories and spare parts approved by the manufacturer in order to
eliminate risks to personnel due to unsuitable spare parts.
Comply with the technical data and ambient conditions specified in the product
documentation.
If unsuitable products are installed or used in safety-related applications, unintended
operating conditions can occur in the application, which can cause personal injury
and/or property damage. Therefore, only use products in safety-related applications if
such use is expressly specified and permitted in the product documentation.
It is only allowed to commission the product after it is established that the final product
(e.g. a machine or a system) in which Rexroth products are installed complies with the
country-specific regulations, safety rules and application standards.

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2.6 Product- and technology-dependent safety instructions
The use of the devices must be restricted to their intended use in accordance with the list
above. Furthermore, the data values specified in Sections “9.1 and 10.1Device
characteristics" must be observed.
The content of this manual is limited to describing the basic functionality of the devices and
their installation. The programming and reparameterization of the devices are described in
more detail in the “Programming manual for ctrlX SAFETY SAFEX-C.1* devices with ctrlX
SAFETY Engineering DOK-XSAFE*-SAFEX-C.1XC-PRxx-DE-P. Knowing and
understanding that manual is a mandatory prerequisite for new installations or modifications
of the device function or device parameters.
WARNING
Any use of the devices contrary to the rules and conditions listed here can:
result in injury or death of persons, as well as damage to connected devices and machines
The guidelines and standards of the respective application must be observed. The
configured monitoring functions as well as their parameters and connections must be
verified via a validation report.
Never open the housing and/or make alterations on your own accord
Never install or commission damaged products. Please complain any damage to the
transport company immediately.
Inputs and outputs for standard functions and the digital and analog data transmitted via
communication devices cannot be used for safety-related applications.
CAUTION
Working with electrical components
Destruction of electrical components and risk of injury due to electrical voltage.
Perform wiring work only with appropriate qualifications and taking into account the
safety instructions. For storage and transport, the conditions according to EN 60068-2-6
with regard to the values specified in Sections 9.1.2 and 10.1.2 must be observed.
The wiring and connection instructions from the “Installation / Assembly” section must be
observed.
Commissioning (i.e. the start of the intended operation) is only permitted if the EMC
directive is complied with. The EMC test specifications EN 55011:2009 + A2:2010 and
EN 61000-6-2:2005 were used as a basis.

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2.7 Obligations of the operator
Observe the following points to ensure the intended use of the safety controller:
•The manufacturer and operator of the machine on which a safety controller is used must
coordinate and comply with all applicable safety regulations and rules under their own
responsibility.
•The instructions, in particular the test instructions of the operating, projecting and
installation manuals (e.g. for use, assembly, installation or integration into the machine
control system), must always be observed.
•The tests (see Installation manual ctrlX SAFETY SAFEX-C.1* devices DOK-XSAFE*-
SAFEX-C.1XC-COxx-DE-P section 17Fehler! Verweisquelle konnte nicht gefunden
werden.) must be carried out by qualified persons or by persons specifically authorized
and commissioned for this purpose and documented by third parties in a comprehensible
manner at all times.
•Safety controllers may only be installed, commissioned and maintained by qualified
persons.
Qualified persons are persons who ...
•have a suitable technical education
and
•were instructed by the machine operator on the operation and the valid
safety guidelines
and
•have access to the operating, projecting and installation instructions for
the safety controller and have read and taken note of the operating,
projecting and installation instructions for the safety controller
and
•have access to the operating instructions for the protective devices
connected to the safety controller (e.g. light curtains) have read and taken
note of these operating instructions.
NOTE
The safe condition of the device is:
All outputs of the device are safely switched off and the device is in the error state, which
is maintained until the cause has been eliminated and the error state has been
acknowledged or the device has been restarted.

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3General information about property
damage and product damage
CAUTION
Removal and installation of the devices.
Destruction of electrical components and risk of injury due to electrical voltage.
Before installing and removing the device or disconnecting signal lines, the device
must be de-energized. For this purpose, all live supply lines to the device must be
switched off and checked for the absence of voltage.
During the installation and removal of the device, electrostatic discharges on the
terminal and plug connections going outwards must be avoided by appropriate
measures. For this purpose, contact with these terminals should be kept to a
minimum and grounding should be carried out beforehand and during work, for
example by means of a grounding bracelet.

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4Scope of delivery
The scope of delivery includes
•the SAFEX-C.1* compact safety controller
•the terminal blocks (RTB) for voltage supply and inputs/outputs
•3 square stickers with the device serial number for optional and individual marking
on the front of the housing by the user
The components listed under section 11.3 “Accessories and spare parts can be used as
optional additional components.
The programming software “ctrlX SAFETY Engineering” necessary for the generation and
verification of a PLC-based monitoring program is licensed with the acquisition of the ctrlX
SAFETY SAFEX-C.1* device. It can be installed according to the “Application description for
the integration of the ctrlX SAFETY SAFEX-C.1* devices in ctrlX AUTOMATION DOK-
XSAFE*-SAFEX-C.1XC-APxx-DE-P.

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5Delivery condition, identification, transport
and storage
5.1 Delivery condition
5.1.1 Factory inspection
In the delivery condition, the device is loaded with an empty configuration file, so that the
device is in a safe state.
5.1.2 Customer-side inspection
CAUTION
Inspection of the machine or system
Risk of damage to the installed Rexroth components due to customer testing of the
machine or system!
Before you perform a voltage test or an insulation resistance test on a system or a
machine in which these components are used:
Disconnect all connections of the Rexroth components or disconnect the plug-in
connections to protect the electronic components.
5.2 Identification
5.2.1 Signs
5.2.1.1 Location of the signs
Tabelle 6:
Device Index Sign
1
2
Additional and
warning information
(optional, if required,
e.g. test sample
marking)
Name plate

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5.2.1.2 Name plate
Tabelle 7:
Sign No. Meaning
1 Wordmark / Logo
2 Material number
3 Type designation
4 Serial number
5 Factory
6 Date of manufacture
10 Designation of origin
11 Company address
14 CE conformity mark
29 Rated voltage
Input voltage
30 Rated current,
Input current
31 Product type
33 UL marking
47 Change index
84 MAC address
97 CCC marking 1)
177 Performance level
222 Security integrity level
223 SIL claim limit
227 KCs marking 1)
228 MAC code
230 QR code
236 Service hotline number
250 China RoHS 2 marking
252 S-Mark marking 1)
281 EtherCAT conformity mark
412 Interface to the MAC address
1) as soon as available
Sample devices also include the “Sample” designation on the nameplate.
238
230
31
3
4
2
33
29
249250
14
97
1
11
23610
5
6
19
47
227 252
177
222
223
280 281
30
84
228
412

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5.3 Transport of components
5.3.1 Ambient and operating conditions - Transport
Term Symbol Unit Value
Temperature range Ta_tran °C -25 … +70
relative humidity ϕ % 5 ... 95 (at max. 40°C)
absolute humidity f g/m31 … 60
Climate class (IEC721 resp.
DIN EN 60721-3-3)
2K3
Condensation not allowed
Icing not allowed
5.4 Storage of components
5.4.1 Ambient and operating conditions - Storage
Term Symbol Unit Value
Temperature range Ta_tran °C -40 … +70
relative humidity ϕ% 8 … 95
absolute humidity f g/m31 … 29
Climate class (IEC721 resp.
DIN EN 60721-3-3)
2K3
Condensation not allowed
Icing not allowed

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6Installation, removal, replacement and
electrical installation
6.1 Installation instructions
Installation location
The ctrlX SAFETY has protection class IP20 and is therefore intended for use in a closed
control cabinet or control box (terminal box) with protection class IP54 or higher.
DIN rail
Mount the ctrlX SAFETY controller on a 35 mm standard DIN rail. The required height of the
DIN rail is 7.5 mm (corresponding to TH 35-7.5 according to EN 60715).
The distance between the support rails must not be greater than 200 mm. This distance is
necessary for stability during installation and removal of the controller.
Only install the controller horizontally on a DIN rail that is attached to a wall!
Installation position
In order to ensure the natural convection cooling in the device, the controller must only be
installed vertically, according to the figure below:
In the illustrated installation position, the natural convection supports the forced flow of cooling
air. This prevents the formation of heat pockets in the device.
Fig. 2: Approved installation position
Fig. 1: Mounting of the DIN rail (information in mm)

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End holders
Attach the ctrlX SAFETY on the end holders on both sides. The end holders ensure the
correct fixation of a ctrlX SAFETY controller on the DIN rail and serve as lateral termination
elements.
Always fix the left end holder of the station in place at the beginning of the controller’s
installation. This way you ensure the following:
•You prevent the controller from inadvertent movement.
•The installation space for the end holder is secured.
Cable laying
Do not run the cables in parallel to motor cables or other strong sources of interference to
avoid the occurrence of interference. The Ethernet cable lines must not leave the building.
Bending radii
When laying the connecting cables, observe the bending radii of the cables used!
Short cable routing
Use the shortest possible cable routing. Cable loops can lead to mechanical stress or
coupling points (e.g. on control cabinet doors).
Strain reliefs
Use strain reliefs for all lines!
Interference sources
Keep as much distance as possible from sources of interference!
Minimum distances
To ensure adequate ventilation, provide the following minimum distances:
Fig. 3: Minimum distances for the circulation of ambient air