Bosch Rexroth IndraDrive Series Instructions for use

Levante Sistemas de
Automatización y Control S.L.
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The Drive & Control Company
Rexroth IndraDrive
Integrated Safety Technology
„Safe Torque Off“ (as of MPx-16)
Edition 06
Application Manual
R911332634
LSA Control S.L. www.lsa-control.com [email protected] ([phone]

Rexroth IndraDrive
Integrated Safety Technology
"Safe Torque Off" (as of MPx-16)
Application Manual
DOK-INDRV*-SI3-**VRS**-AP06-EN-P
RS-5756338bd252bea00a6846a001ea1d28-5-en-US-4
This documentation
● is used to make oneself familiar with the subject of "Integrated Safety
Technology "Safe Torque Off"",
● contains information on mounting and maintenance, on proper and safe
operation and on the decommissioning of the integrated safety
technology "Safe Torque Off" of IndraDrive Cs, IndraDrive Mi,
IndraDrive M / IndraDrive ML / IndraDrive C with control sections of the
Cxx02 type,
● is addressed to persons who mount, operate and maintain IndraDrive
Cs, IndraDrive Mi, IndraDrive M / IndraDrive ML / IndraDrive C with
control sections of the Cxx02 type with integrated safety technology
"Safe Torque Off".
Edition Release Date Notes
DOK‑INDRV*‑SI3‑OP‑MAN*‑OP01‑EN‑P
to DOK‑INDRV*‑SI3‑**VRS**‑AP06‑EN‑P
2010-10 to
2014-07
See chapter "About this
documentation", margin‐
al note "Editions of this
documentation"
Copyright © Bosch Rexroth AG 2014
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.
Liability The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated
in the contract. All rights are reserved with respect to the content of this
documentation and the availability of the product.
Editorial Department Dept. DC-IA/EDY
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revision
Bosch Rexroth AG DOK-INDRV*-SI3-**VRS**-AP06-EN-P
Rexroth IndraDrive Integrated Safety Technology "Safe Torque Off" (as of MPx-16)
LSA Control S.L. www.lsa-control.com [email protected] ([phone]

Table of Contents
Page
1 Introduction.................................................................................................................... 5
1.1 About this documentation....................................................................................................................... 5
1.2 Documentations...................................................................................................................................... 7
1.2.1 Drive systems, system components.................................................................................................... 7
1.2.2 Motors.................................................................................................................................................. 7
1.2.3 Gearboxes........................................................................................................................................... 8
1.2.4 Cables................................................................................................................................................. 8
1.2.5 Firmware.............................................................................................................................................. 8
2 Important Directions for Use ....................................................................................... 11
2.1 Appropriate Use ................................................................................................................................... 11
2.1.1 Introduction........................................................................................................................................ 11
2.1.2 Areas of Use and Application............................................................................................................ 11
2.2 Inappropriate Use................................................................................................................................. 12
3 Safety instructions for electric drives and controls....................................................... 13
3.1 Definitions of terms............................................................................................................................... 13
3.2 General information.............................................................................................................................. 14
3.2.1 Using the Safety instructions and passing them on to others............................................................ 14
3.2.2 Requirements for safe use................................................................................................................ 14
3.2.3 Hazards by improper use.................................................................................................................. 15
3.3 Instructions with regard to specific dangers.......................................................................................... 16
3.3.1 Protection against contact with electrical parts and housings........................................................... 16
3.3.2 Protective extra-low voltage as protection against electric shock .................................................... 17
3.3.3 Protection against dangerous movements........................................................................................ 18
3.3.4 Protection against electromagnetic and magnetic fields during operation and mounting.................. 19
3.3.5 Protection against contact with hot parts........................................................................................... 20
3.3.6 Protection during handling and mounting.......................................................................................... 20
3.3.7 Battery safety..................................................................................................................................... 20
3.3.8 Protection against pressurized systems............................................................................................ 21
3.4 Explanation of signal words and the Safety alert symbol..................................................................... 22
4 System overview.......................................................................................................... 23
4.1 Introduction........................................................................................................................................... 23
4.1.1 Motivation and objectives.................................................................................................................. 23
4.1.2 Conceptual overview......................................................................................................................... 24
4.1.3 Risk assessment............................................................................................................................... 24
4.2 Product presentation............................................................................................................................. 26
4.2.1 What is "Integrated Safety Technology"?.......................................................................................... 26
4.2.2 Integrated safety technology as IndraDrive platform solution............................................................ 27
4.3 Safety-relevant standards and regulations........................................................................................... 37
4.3.1 General information........................................................................................................................... 37
4.3.2 Standards relevant to components.................................................................................................... 37
DOK-INDRV*-SI3-**VRS**-AP06-EN-P
Rexroth IndraDrive Integrated Safety Technology "Safe Torque Off" (as of MPx-16)
Bosch Rexroth AG I/149
Table of Contents
LSA Control S.L. www.lsa-control.com [email protected] ([phone]

Page
4.3.3 Standards relevant to machinery....................................................................................................... 37
4.3.4 EC Directives..................................................................................................................................... 38
4.4 Overview of functions and characteristics............................................................................................ 38
4.4.1 Characteristics of integrated safety technology................................................................................. 38
4.4.2 Supported safety technology functions.............................................................................................. 39
4.4.3 Performance...................................................................................................................................... 39
4.5 Safety characteristics of the safety system........................................................................................... 40
4.5.1 Introduction........................................................................................................................................ 40
4.5.2 Optional safety technology modules "L3" / "L4"................................................................................. 41
4.5.3 Calculating the total PFH value of a safety zone............................................................................... 42
5 Functional principle of integrated safety technology.................................................... 43
5.1 Basic functions...................................................................................................................................... 43
5.1.1 Overview............................................................................................................................................ 43
5.1.2 Dynamization..................................................................................................................................... 44
6 Integrated safety functions........................................................................................... 49
6.1 Overview of safety functions................................................................................................................. 49
6.1.1 General information........................................................................................................................... 49
6.1.2 Classification of safety functions....................................................................................................... 49
6.2 Safety functions in special mode "Safe standstill"................................................................................ 50
6.2.1 Safe Torque Off (STO)...................................................................................................................... 50
6.2.2 Safe Brake Control (SBC)................................................................................................................. 54
7 Examples of application............................................................................................... 59
7.1 Examples of application for IndraDrive Cs, IndraDrive C and IndraDrive M......................................... 59
7.1.1 STO and SBC functions ("L4" only) when selected by means of passive safety units ..................... 59
7.1.2 STO and SBC functions ("L4" only) when selected by means of active safety units......................... 61
7.1.3 "Safe stop 1 (emergency stop)" function with "L3"/"L4" option.......................................................... 64
7.1.4 Zone setup......................................................................................................................................... 65
7.2 Examples of application for IndraDrive Mi............................................................................................ 65
7.2.1 Single-channel selection.................................................................................................................... 65
7.2.2 Central selection at KCU................................................................................................................... 68
7.2.3 Distributed selection at KSM02 / KMS02........................................................................................... 72
7.2.4 Zone setup......................................................................................................................................... 75
7.3 Mixed Operation of Optional Safety Technology Modules "L2" and "L3"/"L4"...................................... 78
7.3.1 Mixed Operation of Optional Safety Technology Modules "L2" and "L3"/"L4" at an Active Safe‐
ty Unit................................................................................................................................................ 78
7.3.2 Mixed Operation of Optional Safety Technology Modules "L2" and "L3"/"L4" at a Passive
Safety Unit......................................................................................................................................... 80
8 Commissioning the safety technology......................................................................... 83
8.1 Safety instruction.................................................................................................................................. 83
8.2 Prerequisites for using integrated safety technology............................................................................ 83
8.2.1 General information........................................................................................................................... 83
Bosch Rexroth AG DOK-INDRV*-SI3-**VRS**-AP06-EN-P
Rexroth IndraDrive Integrated Safety Technology "Safe Torque Off" (as of MPx-16)
II/149
Table of Contents
LSA Control S.L. www.lsa-control.com [email protected] ([phone]