Bosch Rexroth Automax 100 Series User manual

Operating instructions
DOK-SUPPL*-TS-AC B1-M2-ITRS-EN-P | 04.2021 | Bosch Rexroth AG
Automax 100
Basic module TS-AC B1-M2-1X

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.
Model series
Automax 100
Title
Basic module TS-AC B1-M2-1X
Type of documentation
Operating instructions
Documentation type
DOK-SUPPL*-TS-AC B1-M2-ITRS-EN-P
Materialnummer
R901540429
Purpose of the documentation
Primäre Information zur Nutzung
Sicherheitshinweise
Inbetriebnahme
Bedienung
Handhabung
Technischer Aufbau
Change history
Edition
Version
Comment
DOK-SUPPL*-TS-AC B1-M2-ITRS-EN-P
04.2021
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
Telefon [phone]
http://www.boschrexroth.com
Dept.: DC/SSD3 (EG), (AS)

Contents | Automax 100 | Basic module TS-AC B1-M2-1X I/II
Bosch Rexroth AG | 04.2021 | DOK-SUPPL*-TS-AC B1-M2-ITRS-EN-P
Contents
About this documentation 3
1.1 Validity of the documentation 3
1.2 Supplementary documentation 3
1.3 Illustration of information 3
1.3.1 Safety instructions 3
1.3.2 Symbols 4
1.3.3 Designations 5
1.3.4 Abbreviations 5
Safety instructions 7
2.1 About this chapter 7
2.2 Intended use 7
2.3 Improper use 8
2.4 Qualification of personnel 8
2.4.1 General informations 8
2.4.2 Teaching 8
2.4.3 Trained personnel 8
2.5 General safety instructions 8
2.6 Product and technology-dependent safety instructions 9
2.6.1 Introduction 9
2.6.2 Hazards by improper use 9
2.6.3 General information 9
2.6.4 Protection by means of protective extra low voltage (PELV) against electric
shock 9
2.6.5 Protection against contact with hot parts 10
2.6.6 Protection during handling and assembly 10
2.7 Personal protective equipment 10
2.8 Obligations of the operator 10
2.8.1 General information 10
2.8.2 Safety signs 11
2.9 Safety equipment 12
2.10 Operator workstations 12
2.10.1 General information 12
2.10.2 Teaching stations 14
General instructions concerning property damage and product damage 15
Scope of delivery 17
4.1 Delivery condition 17
About this product 19
5.1 Performance description 19
5.1.1 Information on IT security 19
5.2 Product description 19
5.2.1 Voltage supply, general information 20
5.2.2 Voltage supply for extension modules 21
5.2.3 NETGEAR Ethernet-switch 21
5.2.4 Dimensional sheet 22
5.3 Product identification 22
5.3.1 Type code 22
5.3.2 Type plate 23
Transport and storage 25
6.1 Transporting the product 25

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6.2 Storing the product 25
6.2.1 Storage times 26
Cable and connector 26
Assembly 27
7.1 Unboxing the product 27
7.2 Installation conditions 28
7.2.1 Installation position 28
7.3 Required accessories 28
7.4 Assembling the product 29
7.4.1 Connecting the power supply –UAinternally supplied 30
7.4.2 Connecting the power supply –UAexternally supplied 31
Commissioning 33
8.1 First commissioning 33
Operating 35
9.1 Configuration of the NETGEAR Ethernet-switch 35
Maintenance and repair 39
10.1 Cleaning and care 39
10.2 Maintenance 39
10.3 Spare parts 40
Diassembly and replacement 41
Disposal 43
12.1 Environmental protection 43
Extension and modification 45
13.1 Extension by 1 level 45
13.2 Extension by 2 levels 46
13.3 Product rebuild 46
Troubleshooting 47
Technical data 49
Appendix 51
16.1 Electrical circuit diagram 51
16.2 Spare part list 52
16.3 Contact addresses 53
16.3.1 Service and support 53
16.3.2 Contact for repair and spare parts 53
16.4 Declaration of confirmity 54
Alphabetical index 55

About this documentation | Automax 100 | Basic module TS-AC B1-M2-1X 1/54
Bosch Rexroth AG | 04.2021 | DOK-SUPPL*-TS-AC B1-M2-ITRS-EN-P
About this documentation
1.1 Validity of the documentation
This documentation applies to the following products:
Material number of product: R901540131
Basic module TS-AC B1-M2-1X
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 basic module TS-AC B1-M2-1X
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 Supplementary documentation
The following table provides links to the manufacturer site of NETGEAR Ethernet switches.
On these sites, you will find additional information on the integrated Ethernet switch.
These operating instructions and the titles with document numbers in the following table can
be found online in the Bosch Rexroth media directory: https://brmv2.kittelberger.net.
Supplementary documentation
Title
Dokument number
Dokument type
NETGEAR GS308E
https://www.downloads.netgear.com/files/GDC/
GS305E/GS305E_GS308E_IG_GR.pdf
---
Data sheet
NETGEAR GS308E
https://www.downloads.netgear.com/files/GDC/
GS305E/GS305E_GS308E_IG_GR.pdf
---
Installation
instructions
NETGEAR GS308E
https://www.downloads.netgear.com/files/GDC/
GS105EV2/WebManagedSwitches_UM_EN.pdf
---
User manual
Security guidelines
Electric drives and controls
R911342561
Project description
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.
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:

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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
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
SIGNAL WORD
Type and source of danger
Consequences of non-compliance
Hazard avoidance measures
<List>

About this documentation | Automax 100 | Basic module TS-AC B1-M2-1X 3/54
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
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
Basic module
Basic module TS-AC B1-M2-1X
Extension modules
Various extension modules are available
1.3.4 Abbreviations
The following abbreviations are used in this documentation:
Abbreviations
Abbreviation
Meaning
BR
Bosch Rexroth
RD
Rexroth document
DC
Direct current
AC
Alternating current
General abbreviations
Abbreviation
Unit
Meaning
U
V
Electrical voltage
I
A
Electric current intensity
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
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

4/54 About this documentation | Automax 100 | Basic module TS-AC B1-M2-1X
Bosch Rexroth AG | 04.2021 | DOK-SUPPL*-TS-AC B1-M2-ITRS-EN-P
Abbreviation
Unit
Meaning
T
mm
Depth
M
kg
Weight

Safety instructions | Automax 100 | Basic module TS-AC B1-M2-1X 5/54
Bosch Rexroth AG | 04.2021 | DOK-SUPPL*-TS-AC B1-M2-ITRS-EN-P
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 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
The product may be used as follows:
To impart knowledge and skills in the field of drive and control engineering as well as
control technology
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“as of page [7] and the chapter „General
instructions concerning property damage and product damage“as of page [15].

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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
2.4 Qualification of personnel
2.4.1 General informations
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

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2.6 Product and technology-dependent 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 customer service
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.
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 information
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
operating instructions and must always be observed
2.6.4 Protection by means of protective extra low voltage (PELV) against
electric shock
All connections and terminals on this Bosch Rexroth product are for protective extra low
voltage, designed to be safe to touch in accordance with product standards.

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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
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:

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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
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, it may be necessary to attach warnings at the
place of installation. The operator is responsible for attaching the safety signs.
For a recommendation regarding warnings, please refer to the following table.
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
Mandatory signs according to DIN EN ISO 7010 (2019)
Symbol
Description
Observe operating instructions
Registration number: M002
Wear safety footwear
Registration number: M008

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Symbol
Description
Disconnect mains plug (before opening)
Registration number: M006
2.9 Safety equipment
To protect people, the product is equipped with the following safety equipment:
Contact-protected safety sockets
Main switch
Internal fuse protection of the supply voltage for extension modules
The main switch button disconnects the product on all poles from the connected supply
voltage.
Fuse protection of voltage ULS is ensured via micro-fuse. If the connector is used, this fuse
also provides protection of voltage UA.
If the available current of the supply voltage is lower (< 6.3 A) than the trigger current of the
micro-fuse, it is not triggered in case of error.
This is the case if an external power supply unit with low power is used.
Information on correct selection of the external power supply unit and replacement of the
micro-fuse can be found in the technical data.
2.10 Operator workstations
2.10.1 General information
This chapter describes the space requirement for operation of the basic module to be
ensured by the operator. Operation of the basic module 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
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.
Main switch
Fuse protection of
the supply voltages
ULS and UAfor
extension modules

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Basic module with extension module
Worktable
Operator workplaces (dimensions in cm)
Table rows can also be arranged inside a training room. If the table width is sufficient, the
tables can also be directly placed next to each other. If several rows of tables are in place, a
passage width of 100-200 cm must be ensured between the table rows. Escape routes must
be generally kept free and may not be obstructed. 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. If cable ducts are installed on the floor within the passage areas, a
„Tripping hazard“warning sign must be attached. Please refer to the table „Warning signs
according to DIN EN ISO 7010 (2019)“as of page [11].
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.

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Basic module with extension module
(worktable 1)
Worktable 1
Basic module with extension module
(worktable 2)
Worktable 2
Operator workplaces (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
1
Operating
1

General instructions concerning property damage and product damage | Automax 100 | Basic module TS-AC B1-M2-1X 13/54
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General instructions concerning property
damage and product damage
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 basic module TS-AC B1-M2-1X 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.
Make sure that suitable external voltage supply (power supply unit) is available.
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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Scope of delivery | Automax 100 | Basic module TS-AC B1-M2-1X 15/54
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Scope of delivery
The following table lists all components that are included in the scope of delivery of the
basic module TS-AC B1-M2-1X.
The term „not included in the scope of delivery“refers exclusively to this table.
Regardless of this, additional components may be included in a device set in which this
basic module is included.
Scope of delivery
Quantity
Mat.-No.:
Designation
1
R901540131
Basic module TS-AC B1-M2-1X
Basic module with network switch
1
1827003218
Measuring line TS-EC-1000 MM-RD
Contact-protected measuring line, 4 mm, red, according to IEC EN
61010-031 (measurement category CAT II)
1
1827003219
Measuring line TS-EC-1000 MM-BU
Contact-protected measuring line, 4 mm, blue, according to IEC
EN 61010-031 (measurement category CAT II)
1
R911405746
Connector XVB-4/19
nsulated connector, Ø 4 mm, according to IEC EN 61010-031 of
measurement category CAT II, connector width 19 mm
1
---
Master sheet / Scope of delivery
1
R901540429
DOK-SUPPL*-TS-AC B1-M2-ITRS-EN-P
Operating instructions (English)
1
R901540428
DOK-SUPPL*-TS-AC B1-M2-ITRS-DE-P
Operating Instruction (German)
4.1 Delivery condition
On delivery, the product is ready for operation. For operation, a suitable voltage source is
required. For further specifications and details on connection, refer to the following chapters.

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