Bosch Rexroth Inline Series Instruction Manual

Application Description
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics
Configuring and Installing the
Rexroth Inline Product Range
for INTERBUS
R911317023
Edition 01

Bosch Rexroth AG | Electric Drives Inline |Application Description
and Controls
Title Configuring and Installing the
Rexroth Inline Product Range
for INTERBUS
Type of Documentation Application Description
Document Typecode DOK-CONTRL-ILSYSPRO***-AW01-EN-P
Internal Reference 7427_en_00, 120-0401-B330/EN -01
Purpose of Documentation This documentation describes configuration and installation of the Rexroth Inline
product range for INTERBUS
Record of Revisions
Copyright © Bosch Rexroth AG, 2010
Copying this document, giving it to others and the use or communication of the
contents thereof without express authority, are forbidden. Offenders are liable for
the payment of damages. All rights reserved in the case of patent award or listing
of a registered design (DIN 34-1).
Validity The specified data is for product description purposes only and may not be
deemed to guarantee unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation and the
availability of the product.
Published by Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 • 97816 Lohr a. Main, Germany
Telephone [phone] / 40-0 • Fax [phone] / 40-48 85
www.boschrexroth.com
Dept. DCC/EAH1 (TL)
Information This document is printed on non-chlorine bleached paper.
Document designation of
previous editions
Release
date
Notes
120-0401-B330/EN -01 08/2010 First edition

Table of Contents
Page
Application Description |Inline Electric Drives | Bosch Rexroth AG 3/6
and Controls
1 Important Directions for Use ..................................................................................... 1
1.1 Appropriate Use .......................................................................................................................................1
1.1.1 Introduction ..........................................................................................................................................1
1.1.2 Areas of Use and Application ...............................................................................................................2
1.2 Inappropriate Use.....................................................................................................................................2
2 Safety Instructions for Electric Drives and Controls ............................................... 3
2.1 Safety Instructions - General Information .................................................................................................3
2.1.1 Using the Safety Instructions and Passing them on to Others ..............................................................3
2.1.2 How to Employ the Safety Instructions .................................................................................................3
2.1.3 Warning Symbols and Degrees of Hazard Seriousness .......................................................................5
2.1.4 Hazards by Improper Use ....................................................................................................................5
2.2 Instructions with Regard to Specific Dangers...........................................................................................6
2.2.1 Protection Against Contact with Electrical Parts and Housings ............................................................6
2.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage .....................................................8
2.2.3 Protection Against Dangerous Movements ..........................................................................................8
2.2.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting ................10
2.2.5 Protection Against Contact with Hot Parts ..........................................................................................10
2.2.6 Protection During Handling and Mounting ..........................................................................................11
2.2.7 Battery Safety .....................................................................................................................................11
2.2.8 Protection Against Pressurized Systems ...........................................................................................12
3 Integration of Inline Into the INTERBUS System ................................................... 13
3.1 The INTERBUS System .........................................................................................................................13
3.2 Example Topology of an INTERBUS System.........................................................................................14
3.3 Inline, an INTERBUS Product Group......................................................................................................16
3.3.1 Features .............................................................................................................................................16
3.3.2 Example of an Inline System ..............................................................................................................17
3.3.3 System Requirements ........................................................................................................................18
3.3.4 Product Description ............................................................................................................................18
4 Inline Terminals Specifically for INTERBUS ........................................................... 19
4.1 Bus Coupler ...........................................................................................................................................19
4.1.1 Terminal with Remote Bus Branch .....................................................................................................24
4.1.2 Interface Detection .............................................................................................................................25
4.2 Other Terminals .....................................................................................................................................25
4.3 Typical Structure of an Inline Station ......................................................................................................26
5 Electrical Potential and Data Routing ..................................................................... 27
5.1 Circuits and Provision of Supply Voltages..............................................................................................27
5.1.1 Bus Coupler Supply ...........................................................................................................................27
5.1.2 Example of a Circuit Diagram .............................................................................................................28
5.2 Electrical Potential and Data Routing .....................................................................................................30
Table of Contents

Table of Contents
4/6 Bosch Rexroth AG | Electric Drives Inline |Application Description
and Controls
6 Mounting/Removing InlineTerminals and Connecting Cables .............................31
6.1 Connecting the Voltage Supplies .......................................................................................................... 31
6.1.1 Bus Interface Module Supply ............................................................................................................ 31
6.1.2 Notes on Supply Voltages ................................................................................................................. 32
6.2 Connecting the Bus............................................................................................................................... 32
6.3 Connecting I/O Devices......................................................................................................................... 32
7 Diagnostic and Status Indicators ............................................................................33
7.1 Diagnostic Indicators on Bus Couplers.................................................................................................. 34
7.2 Indicators on Terminals with Remote Bus Branch ................................................................................. 35
7.3 Indicators on Other Terminals ............................................................................................................... 36
7.4 Error Localization .................................................................................................................................. 36
8 Configuration, Installation, and Startup of an Inline System (Example) .............39
8.1 Task ...................................................................................................................................................... 39
8.2 Selecting the Required I/O Terminals.................................................................................................... 40
8.2.1 Inline Station Devices ........................................................................................................................ 40
8.2.2 System Restrictions .......................................................................................................................... 41
8.3 Selecting Accessories........................................................................................................................... 43
8.3.1 Power Supplies ................................................................................................................................. 43
8.3.2 End Clamps and Labeling Fields ....................................................................................................... 43
8.3.3 Minimizing Interference ..................................................................................................................... 43
8.4 Installing an Inline Station...................................................................................................................... 44
8.5 Connecting the Bus Coupler ................................................................................................................. 45
8.6 Checking the Installation ....................................................................................................................... 45
8.7 Software Configuration for INTERBUS.................................................................................................. 46
8.8 Addressing ............................................................................................................................................ 46
8.9 Startup .................................................................................................................................................. 46
9 Technical Data and Ordering Data ...........................................................................47
9.1 INTERBUS System Data....................................................................................................................... 47
9.2 Technical Data for Inline Modular IO on INTERBUS ............................................................................. 48
9.3 Ordering Data........................................................................................................................................ 48
10 Examples and Tips ....................................................................................................49
10.1 Tips for Working with Inline ................................................................................................................... 49
10.1.1 Configuring a Station ......................................................................................................................... 49
10.1.2 Voltage Failure Diagnostics ............................................................................................................... 49
10.2 Voltage Concept Using the Example of a Station with an R-IBS IL 24 BK-T/U-PAC.............................. 50
10.3 Temperature Response of the Terminals .............................................................................................. 51
10.4 Explanation of Abbreviations and Symbols ........................................................................................... 51

Table of Contents
Application Description |Inline Electric Drives | Bosch Rexroth AG 5/6
and Controls
11 Disposal and Environmental Protection ................................................................. 53
11.1 Disposal .................................................................................................................................................53
11.1.1 Products .............................................................................................................................................53
11.1.2 Packaging Materials ...........................................................................................................................53
11.2 Environmental Protection .......................................................................................................................53
11.2.1 No Release of Hazardous Substances ...............................................................................................53
11.2.2 Materials Contained in the Products ...................................................................................................53
11.2.3 Recycling ...........................................................................................................................................54
12 Service & Support ..................................................................................................... 55
12.1 Helpdesk................................................................................................................................................55
12.2 Service Hotline.......................................................................................................................................55
12.3 Internet...................................................................................................................................................55
12.4 Helpful Information .................................................................................................................................55

Table of Contents
6/6 Bosch Rexroth AG | Electric Drives Inline |Application Description
and Controls

Important Directions for Use
Application Description |R-IB IL INC-PAC Electric Drives | Bosch Rexroth AG 1/58
and Controls
1 Important Directions for Use
1.1 Appropriate Use
1.1.1 Introduction
Rexroth products represent state-of-the-art developments and manufacturing.
They are tested prior to delivery to ensure operating safety and reliability.
The products may only be used in the manner that is defined as appropriate. If they
are used in an inappropriate manner, then situations can develop that may lead to
property damage or injury to personnel.
Bosch Rexroth, as manufacturer, is not liable for any damages
resulting from inappropriate use. In such cases, the guarantee and the
right to payment of damages resulting from inappropriate use are for-
feited. The user alone carries all responsibility of the risks.
Before using Rexroth products, make sure that all the pre-requisites for
appropriate use of the products are satisfied:
• Personnel that in any way, shape or form uses our products must first read
and understand the relevant safety instructions and be familiar with
appropriate use.
• If the product takes the form of hardware, then they must remain in their
original state, in other words, no structural changes are permitted. It is not
permitted to decompile software products or alter source codes.
• Do not mount damaged or faulty products or use them in operation.
• Make sure that the products have been installed in the manner described in
the relevant documentation.

Important Directions for Use
2/58 Bosch Rexroth AG | Electric Drives R-IB IL INC-PAC |Application Description
and Controls
1.1.2 Areas of Use and Application
The Inline system of Rexroth is a modular and flexibly scalable input/output system
in the degree of protection IP 20. It can be operated locally at the IndraControl L or
peripherally via a field bus coupler.
The Rexroth Inline system may only be used with the accessories and
parts specified in this document. If a component has not been
specifically named, then it may not be either mounted or connected.
The same applies to cables and lines.
Operation is only permitted in the specified configurations and
combinations of components using the software and firmware as
specified in the relevant function descriptions.
Typical applications of the Rexroth Inline system are:
• Handling and assembly systems,
• Packaging and foodstuff machines,
• Printing and paper processing machines and
• Machine tools.
The Rexroth Inline system may only be operated under the assembly, installation
and ambient conditions as described here (temperature, system of protection,
humidity, EMC requirements, etc.) and in the position specified.
In residential areas as well as in business and commercial areas Class A devices
may be used with the following note:
This is a Class A device. In a residential area, this device may cause
radio interferences. In such a case, the user may be required to
introduce suitable countermeasures at his own cost.
1.2 Inappropriate Use
Using the Rexroth Inline system outside of the above-referenced areas of
application or under operating conditions other than described in the document
and the technical data specified is defined as "inappropriate use".
The Rexroth Inline system may not be used if
• they are subject to operating conditions that do not meet the above specified
ambient conditions. This includes, for example, operation under water, in the
case of extreme temperature fluctuations or extremely high maximum
temperatures or if
• Bosch Rexroth has not specifically released them for that intended purpose.
Please note the specifications outlined in the general Safety Guidelines!

Safety Instructions for Electric Drives and Controls
Application Description |R-IB IL INC-PAC Electric Drives | Bosch Rexroth AG 3/58
and Controls
2 Safety Instructions for Electric Drives and Controls
2.1 Safety Instructions - General Information
2.1.1 Using the Safety Instructions and Passing them on to Others
Do not attempt to install or commission this device without first reading all docu-
mentation provided with the product. Read and understand these safety instruc-
tions and all user documentation prior to working with the device. If you do not have
the user documentation for the device, contact your responsible Bosch Rexroth
sales representative. Ask for these documents to be sent immediately to the per-
son or persons responsible for the safe operation of the device.
If the device is resold, rented and/or passed on to others in any other form, these
safety instructions must be delivered with the device in the official language of the
user's country.
2.1.2 How to Employ the Safety Instructions
Read these instructions before initial commissioning of the equipment in order to
eliminate the risk of bodily harm and/or material damage. Follow these safety in-
structions at all times.
• Bosch Rexroth AG is not liable for damages resulting from failure to observe
the warnings provided in this documentation.
• Read the operating, maintenance and safety instructions in your language
before commissioning the machine. If you find that you cannot completely un-
derstand the documentation for your product, please ask your supplier to
clarify.
• Proper and correct transport, storage, assembly and installation, as well as
care in operation and maintenance, are prerequisites for optimal and safe op-
eration of this device.
• Only assign trained and qualified persons to work with electrical installations:
– Only persons who are trained and qualified for the use and operation of
the device may work on this device or within its proximity. The persons
are qualified if they have sufficient knowledge of the assembly, installa-
tion and operation of the product, as well as an understanding of all
warnings and precautionary measures noted in these instructions.
– Furthermore, they must be trained, instructed and qualified to switch
electrical circuits and devices on and off in accordance with technical
safety regulations, to ground them and to mark them according to the re-
quirements of safe work practices. They must have adequate safety
equipment and be trained in first aid.
• Only use spare parts and accessories approved by the manufacturer.
Improper use of these devices, failure to follow the safety instruc-
tions in this document or tampering with the product, including dis-
abling of safety devices, may result in material damage, bodily
harm, electric shock or even death!
Observe the safety instructions!
WARNING

Safety Instructions for Electric Drives and Controls
4/58 Bosch Rexroth AG | Electric Drives R-IB IL INC-PAC |Application Description
and Controls
• Follow all safety regulations and requirements for the specific application as
practiced in the country of use.
• The devices have been designed for installation in industrial machinery.
• The ambient conditions given in the product documentation must be ob-
served.
• Only use safety-relevant applications that are clearly and explicitly approved
in the Project Planning Manual. If this is not the case, they are excluded. Safe-
ty-relevant are all such applications which can cause danger to persons and
material damage.
• The information given in the documentation of the product with regard to the
use of the delivered components contains only examples of applications and
suggestions.
• The machine and installation manufacturer must
– make sure that the delivered components are suited for his individual
application and check the information given in this documentation with
regard to the use of the components,
– make sure that his application complies with the applicable safety regu-
lations and standards and carry out the required measures, modifica-
tions and complements.
• Commissioning of the delivered components is only permitted once it is sure
that the machine or installation in which they are installed complies with the
national regulations, safety specifications and standards of the application.
• Operation is only permitted if the national EMC regulations for the application
are met.
• The instructions for installation in accordance with EMC requirements can be
found in the section on EMC in the respective documentation (Project Plan-
ning Manuals of components and system).
The machine or installation manufacturer is responsible for compliance with
the limiting values as prescribed in the national regulations.
• Technical data, connection and installation conditions are specified in the
product documentation and must be followed at all times.
National regulations which the user must take into account
• European countries: according to European EN standards
• United States of America (USA):
– National Electrical Code (NEC)
– National Electrical Manufacturers Association (NEMA), as well as local
engineering regulations
– regulations of the National Fire Protection Association (NFPA)
• Canada: Canadian Standards Association (CSA)
• Other countries:
– International Organization for Standardization (ISO)
– International Electrotechnical Commission (IEC)

Safety Instructions for Electric Drives and Controls
Application Description |R-IB IL INC-PAC Electric Drives | Bosch Rexroth AG 5/58
and Controls
2.1.3 Warning Symbols and Degrees of Hazard Seriousness
The safety instructions describe the following degrees of hazard seriousness. The
degree of hazard seriousness informs about the consequences resulting from
non-compliance with the safety instructions:
2.1.4 Hazards by Improper Use
Warning sym-
bol
Signal word Degree of hazard seriousness acc. to
ANSI Z 535.4-2002
Danger Death or severe bodily harm will occur.
Warning Death or severe bodily harm may occur.
Caution Minor or moderate bodily harm or material damage
may occur.
Fig. 2-1 Hazard classification (according to ANSI Z 535)
High electric voltage and high working current! Risk of death or se-
vere bodily injury by electric shock!
Observe the safety instructions!
Dangerous movements! Danger to life, severe bodily harm or mate-
rial damage by unintentional motor movements!
Observe the safety instructions!
High electric voltage because of incorrect connection! Risk of
death or bodily injury by electric shock!
Observe the safety instructions!
Health hazard for persons with heart pacemakers, metal implants
and hearing aids in proximity to electrical equipment!
Observe the safety instructions!
Hot surfaces on device housing! Danger of injury! Danger of burns!
Observe the safety instructions!
DANGER
DANGER
WARNING
WARNING
CAUTION

Safety Instructions for Electric Drives and Controls
6/58 Bosch Rexroth AG | Electric Drives R-IB IL INC-PAC |Application Description
and Controls
2.2 Instructions with Regard to Specific Dangers
2.2.1 Protection Against Contact with Electrical Parts and Housings
This section concerns devices and drive components with voltages of
more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal danger
and electric shock. When operating electrical equipment, it is unavoidable that
some parts of the units conduct dangerous voltage.
Risk of injury by improper handling! Risk of bodily injury by bruis-
ing, shearing, cutting, hitting or improper handling of pressurized
lines!
Observe the safety instructions!
Risk of injury by improper handling of batteries!
Observe the safety instructions!
CAUTION
CAUTION

Safety Instructions for Electric Drives and Controls
Application Description |R-IB IL INC-PAC Electric Drives | Bosch Rexroth AG 7/58
and Controls
For electrical drive and filter components with voltages of more than
50 volts, observe the following additional safety instructions.
High electrical voltage! Danger to life, electric shock and severe
bodily injury!
• Only those trained and qualified to work with or on electrical equipment are
permitted to operate, maintain and repair this equipment.
• Follow general construction and safety regulations when working on electri-
cal power installations.
• Before switching on the device, the equipment grounding conductor must
have been permanently connected to all electrical equipment in accordance
with the connection diagram.
• Do not operate electrical equipment at any time, even for brief measure-
ments or tests, if the equipment grounding conductor is not permanently
connected to the mounting points of the components provided for this pur-
pose.
• Before working with electrical parts with voltage potentials higher than 50 V,
the device must be disconnected from the mains voltage or power supply
unit. Provide a safeguard to prevent reconnection.
• For electrical drive and filter components, observe the following:
Wait 30 minutes after switching off power to allow capacitors to dis-
charge before beginning to work. Measure the electrical voltage on the ca-
pacitors before beginning to work to make sure that the equipment is safe to
touch.
• Never touch the electrical connection points of a component while power is
turned on.
• Install the covers and guards provided with the equipment properly before
switching the device on. Before switching the equipment on, cover and safe-
guard live parts safely to prevent contact with those parts.
• A residual-current-operated circuit-breaker or r.c.d. cannot be used for elec-
tric drives! Indirect contact must be prevented by other means, for example,
by an overcurrent protective device according to the relevant standards.
• Secure built-in devices from direct touching of electrical parts by providing
an external housing, for example a control cabinet.
DANGER
High housing voltage and high leakage current! Risk of death or
bodily injury by electric shock!
• Before switching on, the housings of all electrical equipment and motors
must be connected or grounded with the equipment grounding conductor to
the grounding points. This is also applicable before short tests.
• The equipment grounding conductor of the electrical equipment and the de-
vices must be non-detachably and permanently connected to the power
supply unit at all times. The leakage current is greater than 3.5 mA.
• Over the total length, use copper wire of a cross section of a minimum of 10
mm² for this equipment grounding connection!
• Before commissioning, also in trial runs, always attach the equipment
grounding conductor or connect to the ground wire. Otherwise, high voltag-
es may occur at the housing causing electric
DANGER

Safety Instructions for Electric Drives and Controls
8/58 Bosch Rexroth AG | Electric Drives R-IB IL INC-PAC |Application Description
and Controls
2.2.2 Protection Against Electric Shock by Protective Extra-Low
Voltage
Protective extra-low voltage is used to allow connecting devices with basic insula-
tion to extra-low voltage circuits.
All connections and terminals with voltages between 5 and 50 volts at Rexroth
products are PELV systems1. It is therefore allowed to connect devices equipped
with basic insulation (such as programming devices, PCs, notebooks, display
units) to these connections and terminals.
2.2.3 Protection Against Dangerous Movements
Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:
• improper or wrong wiring of cable connections
• incorrect operation of the equipment components
• wrong input of parameters before operation
• malfunction of sensors, encoders and monitoring devices
• defective components
• software or firmware errors
These errors can occur immediately after equipment is switched on or even after
an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be sufficient to avoid faulty
operation in the connected drives. Regarding personal safety, especially the dan-
ger of bodily harm and/or material damage, this alone cannot be relied upon to en-
sure complete safety. Until the integrated monitoring functions become effective,
it must be assumed in any case that faulty drive movements will occur. The extent
of faulty drive movements depends upon the type of control and the state of oper-
ation.
1) "Protective Extra-Low Voltage"
High electric voltage by incorrect connection! Risk of death or bodi-
ly injury by electric shock!
If extra-low voltage circuits of devices containing voltages and circuits of more
than 50 volts (e.g. the mains connection) are connected to Rexroth products, the
connected extra-low voltage circuits must comply with the requirements for
PELV1.
WARNING

Safety Instructions for Electric Drives and Controls
Application Description |R-IB IL INC-PAC Electric Drives | Bosch Rexroth AG 9/58
and Controls
Dangerous movements! Danger to life, risk of injury, severe bodily
harm or material damage!
• For the above reasons, ensure personal safety by means of qualified and
tested higher-level monitoring devices or measures integrated in the instal-
lation.
They have to be provided for by the user according to the specific conditions
within the installation and a hazard and fault analysis. The safety regulations
applicable for the installation have to be taken into consideration. Unintend-
ed machine motion or other malfunction is possible if safety devices are dis-
abled, bypassed or not activated.
To avoid accidents, bodily harm and/or material damage
• Keep free and clear of the machine’s range of motion and moving parts. Pos-
sible measures to prevent people from accidentally entering the machine’s
range of motion:
– use safety fences
–usesafetyguards
– use protective coverings
– install light curtains or light barriers
• Fences and coverings must be strong enough to resist maximum possible
momentum.
• Mount the emergency stop switch in the immediate reach of the operator.
Verify that the emergency stop works before commissioning. Do not operate
the device if the emergency stop switch is not working.
• Isolate the drive power connection by means of an emergency stop circuit or
use a safety related starting lockout to prevent unintentional start.
• Make sure that the drives are brought to a safe standstill before accessing
or entering the danger zone.
• Additionally secure vertical axes against falling or dropping after switching
off the motor power by, for example:
– mechanically securing the vertical axes,
– adding an external braking/arrester/clamping mechanism or
– ensuring sufficient equilibration of the vertical axes.
• The standard equipment motor brake or an external brake controlled by the
drive controller are not sufficient to guarantee personal safety!
• Disconnect electrical power to the equipment using a master switch and se-
cure the switch against reconnection for:
– maintenance and repair work
– cleaning of equipment
– long periods of discontinued equipment use
• Prevent the operation of high-frequency, remote control and radio equip-
ment near electronics circuits and supply leads. If the use of such devices
cannot be avoided, verify the system and the installation for possible mal-
functions in all possible positions of normal use before initial commissioning.
If necessary, perform a special electromagnetic compatibility (EMC) test on
the installation.
DANGER

Safety Instructions for Electric Drives and Controls
10/58 Bosch Rexroth AG | Electric Drives R-IB IL INC-PAC |Application Description
and Controls
2.2.4 Protection Against Magnetic and Electromagnetic Fields During
Operation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors
and permanent magnets in motors represent a serious personal danger to those
with heart pacemakers, metal implants and hearing aids.
2.2.5 Protection Against Contact with Hot Parts
Health hazard for persons with heart pacemakers, metal implants
and hearing aids in proximity to electrical equipment!
• Persons with heart pacemakers and metal implants are not permitted to en-
ter following areas:
– Areas in which electrical equipment and parts are mounted, being op-
erated or commissioned.
– Areas in which parts of motors with permanent magnets are being
stored, repaired or mounted.
• If it is necessary for somebody with a pacemaker to enter such an area, a
doctor must be consulted prior to doing so. The noise immunity of present or
future implanted heart pacemakers differs greatly so that no general rules
can be given.
• Those with metal implants or metal pieces, as well as with hearing aids, must
consult a doctor before they enter the areas described above. Otherwise
health hazards may occur.
Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury!
Danger of burns!
• Do not touch surfaces of device housings and chokes in the proximity of heat
sources! Danger of burns!
• Do not touch housing surfaces of motors! Danger of burns!
• According to the operating conditions, temperatures can be higher than
60 °C, 140 °F during or after operation.
• Before accessing motors after having switched them off, let them cool down
for a sufficiently long time. Cooling down can require up to 140 minutes!
Roughly estimated, the time required for cooling down is five times the ther-
mal time constant specified in the Technical Data.
• After switching drive controllers or chokes off, wait 15 minutes to allow them
to cool down before touching them.
• Wear safety gloves or do not work at hot surfaces.
• For certain applications, the manufacturer of the end product, machine or in-
stallation, according to the respective safety regulations, has to take mea-
sures to avoid injuries caused by burns in the end application. These
measures can be, for example: warnings, guards (shielding or barrier), tech-
nical documentation.
WARNING
CAUTION

Safety Instructions for Electric Drives and Controls
Application Description |R-IB IL INC-PAC Electric Drives | Bosch Rexroth AG 11/58
and Controls
2.2.6 Protection During Handling and Mounting
In unfavorable conditions, handling and mounting certain parts and components in
an improper way can cause injuries.
2.2.7 Battery Safety
Batteries consist of active chemicals enclosed in a solid housing. Therefore, im-
proper handling can cause injury or material damage.
Environmental protection and disposal! The batteries contained in the
product are considered dangerous goods during land, air, and sea
transport (risk of explosion) in the sense of the legal regulations. Dis-
pose of used batteries separate from other waste. Observe the local
regulations in the country of assembly.
Risk of injury by improper handling! Bodily injury by bruising,
shearing, cutting, hitting!
• Observe the general construction and safety regulations on handling and
mounting.
• Use suitable devices for mounting and transport.
• Avoid jamming and bruising by appropriate measures.
• Always use suitable tools. Use special tools if specified.
• Use lifting equipment and tools in the correct manner.
• If necessary, use suitable protective equipment (for example safety goggles,
safety shoes, safety gloves).
• Do not stand under hanging loads.
• Immediately clean up any spilled liquids because of the danger of skidding.
CAUTION
Risk of injury by improper handling!
• Do not attempt to reactivate low batteries by heating or other methods (risk
of explosion and cauterization).
• Do not recharge the batteries as this may cause leakage or explosion.
• Do not throw batteries into open flames.
• Do not dismantle batteries.
• When replacing the battery/batteries do not damage electrical parts in-
stalled in the devices.
• Only use the battery types specified by the manufacturer.
CAUTION

Safety Instructions for Electric Drives and Controls
12/58 Bosch Rexroth AG | Electric Drives R-IB IL INC-PAC |Application Description
and Controls
2.2.8 Protection Against Pressurized Systems
According to the information given in the Project Planning Manuals, motors cooled
with liquid and compressed air, as well as drive controllers, can be partially sup-
plied with externally fed, pressurized media, such as compressed air, hydraulics
oil, cooling liquids and cooling lubricating agents. Improper handling of the con-
nected supply systems, supply lines or connections can cause injuries or material
damage.
Environmental protection and disposal! The agents used to operate
the product might not be economically friendly. Dispose of ecologically
harmful agents separately from other waste. Observe the local regula-
tions in the country of assembly.
Risk of injury by improper handling of pressurized lines!
• Do not attempt to disconnect, open or cut pressurized lines (risk of explo-
sion).
• Observe the respective manufacturer's operating instructions.
• Before dismounting lines, relieve pressure and empty medium.
• Use suitable protective equipment (for example safety goggles, safety
shoes, safety gloves).
• Immediately clean up any spilled liquids from the floor.
CAUTION

Integration of Inline Into the INTERBUS System
Application Description |Inline Electric Drives | Bosch Rexroth AG 13/58
and Controls
3 Integration of Inline Into the INTERBUS System
3.1 The INTERBUS System
INTERBUS is a serial bus system that transmits data between control systems
(e.g., PLCs, PCs, VMEbus computers, robot controllers, etc.) and spatially
distributed I/O modules that are connected to sensors and actuators (operating
and display units, drives, etc.).
INTERBUS has a ring structure. The ring structure enables data to be sent and
received simultaneously.
INTERBUS is a single master system, i.e., a master (e.g., controller board, control
terminal) controls all devices of an INTERBUS ring.
From the master, all devices are connected to the bus system. Each device has
two separate lines for data transmission: one for forward data transfer and one for
return data transfer. This eliminates the need for a return line from the last device
to the first device, which is necessary in a simple ring system. The forward and
return lines run in one bus cable. From the installation point of view, INTERBUS
has a tree structure, as only one cable is led from one device to the next.
This application description is only valid in association with the DOK-
CONTRL-ILSYSINS***-AW..-EN-P application description.
This application description only describes the special features of a
Rexroth Inline system on INTERBUS. For bus-neutral properties,
please refer to the DOK-CONTRL-ILSYSINS***-AW..-EN-P
application description.

Integration of Inline Into the INTERBUS System
14/58 Bosch Rexroth AG | Electric Drives Inline |Application Description
and Controls
3.2 Example Topology of an INTERBUS System
Fig. 3-1 Example topology of an INTERBUS system
7427A004
Bus segment (400 m, maximum)
Remote bus (12.8 km, maximum)
INTERBUS control system
Remote bus branch
Inline station
Inline station
12
D
DO2
12
D
DO2
12
D
DI8
121212
BA
RC
UL
RD
TR
US
UM
12
D
DO8
121212
RC
RC
RD
D
RB-T
LD
BA
RC
UL
RD
TR
US
UM
12
D
DO8
121212
12
D
DI2
12
D
DI2
12
D
DI2
FLM DI 8
FLM DI 8
IN
LB LB
OUT
U
LS
U
LS
FLM DI 8
FLM DI 8
IN
LB LB
OUT
U
LS
U
LS
BK IB
BK IB
U
LS
OUT
BUS
BUS
LB
OUT
U
LS
FLM AI
IN
LB LB
OUT
U
LS
U
LS
FLM DIO 8
FLM DIO 8
IN
LB LB
OUT
U
LS
U
LS
Fieldline Modular M12 station
D
E
DIO8/4 DIO8/4
UL
Fieldline Modular M8 devices
1
RUN
FAIL
RUN/ PROG
MRESET
STP
RDY/ RUN
BSA
FAIL
PF
PRG
LNK
ACT
100
10/100
RESET
INLINECONTROL
ILC370 PN 2TX-IB
Ord.No.: 2876915
xxxxxxx (Seriennr.)
PLC
IL
ETH
LNK
ACT
100
RC
BA
RD
TR
RBIN RBOUT
IB
12
1
2
3
4
1
2
3
4
12
12
1
2
3
4
1
2
3
4
5
6
5
6
12
12
1
2
3
4
1
2
3
4
5
6
5
6
12
12
1
2
3
4
1
2
3
4
5
6
5
6
12
12
1
2
3
4
1
2
3
4
5
6
5
6
12
12
D
DO2
12
D
DO2
12
D
DI8
121212
BA
RC
UL
RD
TR
US
UM
12
D
DO8
121212
RC
RD
D
RB-T
LD
Inline station
Remote bus branch