Bosch Rexroth Nexo Technical manual

Nexo cordless Wi-Fi nutrunner
by Rexroth
Version AE
EN
Project planning
3 608 870 A47/05.2017
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The data specified serve to describe the product.
Instructions on use, if any, only constitute application
examples and suggestions. Catalog specifications are
no warranted properties. The information given does
not release the user from the obligation of own
judgment and verification. 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 title page shows an exemplary configuration. The
supplied product may therefore vary from the
illustration.
The original instructions were written in German.

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Title Nexo cordless Wi-Fi nutrunner by Rexroth
Type of Documentation Project planning
Document typecode DOK-NEXO-DOKU_V1.300-EN
Internal file reference 3 608 870 A47_EN
Purpose of documentation This documentation describes the Nexo cordless Wi-Fi nutrunner by Rexroth.
Copyright ©Bosch Rexroth AG, 2017
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
are reserved in the event of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
Validity The specified data is for product description purposes only and may not be deemed to be guaran-
teed properties unless expressly confirmed in the contract. All rights are reserved with respect to
the content of this documentation and the availability of the products.
Published by Bosch Rexroth AG
Electric Drives and Controls
Postfach 1161
D-71534 Murrhardt, Germany
Fornsbacher Str. 92
D-71540 Murrhardt, Germany
Phone: [phone]
Fax: [phone]
[email protected]
www.boschrexroth.com
Note Original documentation. This documentation is available as a PDF file.
Record of revision Version Status Comments
3 608 870 A47_AA/EN 07/2013 Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1000
3 608 870 A47_AB/EN 10/2013 Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1000
Editorial revision
3 608 870 A47_AC/EN 02/2015 Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1100
3 608 870 A47_AD/EN 11/2015 Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1200
3 608 870 A47_AE/EN 05/2017 Edition for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1300

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Contents
1 About this documentation 9
1.1 Overview of this documentation . . . . . . . . . 10
1.2 Scope of the documentation . . . . . . . . . . . . 10
1.3 Additional documentation . . . . . . . . . . . . . . . 10
1.4 Representation of information . . . . . . . . . . . 11
1.4.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.4.2 Symbols and representations. . . . . . . . . . . . . . . . . . .12
1.4.3 Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.4.4 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2 Safety instructions 17
2.1 About this chapter . . . . . . . . . . . . . . . . . . . . . . 18
2.1.1 Using and communicating the safety instructions . .18
2.1.2 Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.1.3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . .20
2.1.4 Cleaning instructions . . . . . . . . . . . . . . . . . . . . . . . . .20
2.1.5 Maintenance and repair instructions . . . . . . . . . . . . .21
2.1.6 Disposal instructions. . . . . . . . . . . . . . . . . . . . . . . . . .21
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2.2.2 Application areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.3 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Personnel qualifications . . . . . . . . . . . . . . . . 23
2.5 General safety instructions . . . . . . . . . . . . . . 24
2.6 Product-related safety instructions for the
Nexo cordless Wi-Fi nutrunner by Rexroth 25
2.6.1 General product-dependent instructions . . . . . . . . .25
2.6.2 Safety warning sticker. . . . . . . . . . . . . . . . . . . . . . . . .28
2.7 Product- and technology-dependent
safety instructions for the Rexroth
tightening system 350 . . . . . . . . . . . . . . . . . . 28
2.7.1 Protection against accidental contact with electrical
parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.7.2 Protective extra-low voltage for protection against
electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.7.3 Protection against dangerous movements . . . . . . . .31
2.7.4 Protection against magnetic and electromagnetic
fields during operation and assembly . . . . . . . . . . . .33
2.7.5 Protection against accidental contact with hot parts33
2.7.6 Protection during handling and assembly. . . . . . . . .34
2.7.7 Protection when handling batteries. . . . . . . . . . . . . .34
2.7.8 Protection against pressurized lines . . . . . . . . . . . . .35
3 Introduction 37
3.1 Nexo cordless Wi-Fi nutrunner . . . . . . . . . . 38
3.1.1 NX-SD Micro SD card . . . . . . . . . . . . . . . . . . . . . . . .38
3.1.2 NEXO-OS operating system . . . . . . . . . . . . . . . . . . .39
3.1.3 Tool display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
3.1.4 Nexo battery system . . . . . . . . . . . . . . . . . . . . . . . . . .44
3.1.5 Technical data of the nutrunner . . . . . . . . . . . . . . . . .46
3.1.6 Technical WLAN data . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1.7 Technical data of the barcode scanner . . . . . . . . . . 47
3.2 WLAN (Wireless Local Area Network) . . . . .48
3.2.1 Access point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2.2 Infrastructure mode using WLAN controller . . . . . . 49
3.2.3 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3 Connection options of the Nexo cordless
Wi-Fi nutrunner . . . . . . . . . . . . . . . . . . . . . . . . .50
3.3.1 Result storage without radio connection. . . . . . . . . 50
3.3.2 Result storage via WLAN: . . . . . . . . . . . . . . . . . . . . 51
3.3.3 Control and result storage via WLAN . . . . . . . . . . . 52
3.3.4 PLC control and result storage via WLAN . . . . . . . 54
3.3.5 Fieldbus control and result storage via WLAN . . . . 55
3.3.6 Process Quality Manager (PQM). . . . . . . . . . . . . . . 56
4 Assembly 57
4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
4.2 Initial commissioning, re-commissioning . .58
4.3 Adjusting the angle head . . . . . . . . . . . . . . . .59
4.4 Attaching the torque support . . . . . . . . . . . . .61
4.5 Attaching the accessories . . . . . . . . . . . . . . .64
5 Construction Guidelines 65
5.1 Designing a bolted connection . . . . . . . . . . .66
5.1.1 Clamp force and distortion of connected parts,
operating forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.1.2 Determination of the required torque to create a
bolted connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.1.3 Tightening case (soft – hard) . . . . . . . . . . . . . . . . . . 70
5.1.4 Tightening processes . . . . . . . . . . . . . . . . . . . . . . . . 70
5.2 Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
5.2.1 Total duration for all tightening steps. . . . . . . . . . . . 71
5.3 Compatibility with foreign substances . . . .71
5.4 Planning assistance . . . . . . . . . . . . . . . . . . . . .71
5.4.1 3-D/CAD data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6 Control signals 73
6.1 PLC signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
6.2 Description of all PLC signals . . . . . . . . . . . .74
6.2.1 Input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.2.2 Output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7 Data services 85
7.1 Overview of tightening results communication
86
7.1.1 Identification code (ID code) . . . . . . . . . . . . . . . . . . 86
7.2 Data output via FTP . . . . . . . . . . . . . . . . . . . . .87

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7.2.1 Opening and closing the FTP connections for
results output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.2.2 Data volume and expected transfer time for
tightening results files . . . . . . . . . . . . . . . . . . . . . . . . 88
7.3 Data output via HTTP . . . . . . . . . . . . . . . . . . . .89
7.4 Data output via File Share . . . . . . . . . . . . . . .90
7.5 Rexroth Open Protocol . . . . . . . . . . . . . . . . . .91
7.5.1 Sequence diagrams - examples . . . . . . . . . . . . . . . . 92
7.5.2 Message structure . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
7.5.3 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.6 Rexroth IPM Protocol . . . . . . . . . . . . . . . . . . .162
7.6.1 Message structure . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.7 VW-XML protocol . . . . . . . . . . . . . . . . . . . . . . .165
7.7.1 Assignment of PLC signals. . . . . . . . . . . . . . . . . . . 165
7.7.2 Particularities with VW-XML results output. . . . . . 166
7.7.3 Tightening process . . . . . . . . . . . . . . . . . . . . . . . . . 166
8 Commissioning 169
8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
8.1.1 Overview of commissioning steps . . . . . . . . . . . . . 170
8.2 NEXO-OS operating system . . . . . . . . . . . .171
8.2.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.2.2 Assigning IP addresses for the Nexo cordless
Wi-Fi nutrunner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .172
9 Operating system
NEXO-OS 173
9.1 General information about the NEXO-OS
operating system . . . . . . . . . . . . . . . . . . . . . .174
9.1.1 Full versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
9.1.2 Updating the firmware version . . . . . . . . . . . . . . . . 175
9.2 Starting the program . . . . . . . . . . . . . . . . . . .175
9.2.1 Main window of the NEXO-OS operating
system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
9.2.2 Exiting the program . . . . . . . . . . . . . . . . . . . . . . . . . 179
9.3 Function overview . . . . . . . . . . . . . . . . . . . . . .180
9.4 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
9.4.1 Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
9.4.2 Stored values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
9.4.3 Actual graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.4.4 Stored graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
9.5 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
9.5.1 Structure of the Mode tab. . . . . . . . . . . . . . . . . . . . 184
9.5.2 Mode steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
9.5.3 Change mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
9.6 Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
9.6.1 Structure of the Job tab. . . . . . . . . . . . . . . . . . . . . . 189
9.6.2 Job steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.6.3 Create new job/change job . . . . . . . . . . . . . . . . . . 190
9.7 Tightening programs . . . . . . . . . . . . . . . . . . .195
9.7.1 Definition: Target, monitoring, additional function. 195
9.7.2 Programs tab structure . . . . . . . . . . . . . . . . . . . . . . 196
9.7.3 Gradient average value of the step. . . . . . . . . . . . . 197
9.7.4 Creating a new tightening program/editing an
existing tightening program . . . . . . . . . . . . . . . . . . . 197
9.8 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
9.8.1 Time & date. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9.8.2 User accounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
9.8.3 Tool display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
9.8.4 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
9.8.5 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
9.8.6 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
9.8.7 PLC signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
9.8.8 OK/NOK counter . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
9.8.9 Quality code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
9.8.10 WLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
9.8.11 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
9.8.12 LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
9.8.13 ID assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
9.8.14 Scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
9.8.15 Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9.8.16 Backup/Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9.9 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
9.9.1 System information. . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.9.2 Event viewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
9.9.3 Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
9.9.4 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
9.9.5 System errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
9.9.6 Web server log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
9.9.7 Screenshot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
9.9.8 Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
9.9.9 Export logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
9.10 Help menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
10 Tightening processes 247
10.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
10.2 Torque-controlled tightening process . . . 249
10.3 Angle-of-turn-controlled tightening
process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
11 Troubleshooting 251
11.1 Error codes and classes . . . . . . . . . . . . . . . .252
11.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
11.1.2 Error code assignment table . . . . . . . . . . . . . . . . . . 252
11.1.3 Error classes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
11.2 Detecting and acknowledging errors
with the NEXO-OS operating system . . . . 253
11.2.1 Error lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
11.2.2 WLAN errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
11.3 Complete error list . . . . . . . . . . . . . . . . . . . . .254
11.4 Replacing defective components . . . . . . . . 257
11.5 Shortening of power supply on battery
change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
12 License agreement 259

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13 Service and sales 261
13.1 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
13.2 Sales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
13.3 Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

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1About this
documentation
This chapter contains general information on the present documentation.
•Overview of this documentation (page 10)
•Scope of the documentation (page 10)
•Additional documentation (page 10)
•Representation of information (page 11)

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1.1 Overview of this documentation
This documentation describes the tightening system in the following chapters:
1.2 Scope of the documentation
All of the information provided in this document refers to the Nexo cordless Wi-Fi nutrunner by Rexroth.
The Nexo cordless Wi-Fi nutrunner by Rexroth can be connected to and operated with the Rexroth Tight-
ening System 350 with software version V2.300 and higher.
1.3 Additional documentation
Please also observe the current instructions for all tightening system components, as well as the doc-
umentation of the machine or system manufacturer.
You can find current documentation for project planning, as well as related documents, in the media di-
rectory at:
www.boschrexroth.com/various/utilities/mediadirectory/index.jsp?publication=NET
Please also observe the generally applicable, legal or otherwise binding regulations of European or
national legislation and the rules for the prevention of accidents and for environmental protection ap-
plicable in your country.
Chapter Title Contents
1About this documentation Scope of this document, abbreviations, representations used, glossary.
2Safety instructions Safety precautions on how to avoid hazardous situations when using Rexroth tightening sys-
tems. Information on the intended use of Rexroth tightening systems.
3Introduction This chapter: Definitions, system structure, components, integration in an overall system.
4Assembly Assembly options for the Nexo cordless Wi-Fi nutrunner
5Construction Guidelines Planning as well as construction of a tightening system regarding the tightening cases to be
processed with the system.
6Control signals Signals of the tightening controller (PLC), control signals for the tightening cell, PLC tables.
7Data services Available data services, e. g. exchange of data regarding tightening results and ID codes be-
tween the Nexo cordless Wi-Fi nutrunner and partner controllers.
8Commissioning All steps required for commissioning the Nexo cordless Wi-Fi nutrunner.
9Operating system NEXO-OS Browser-based operating system NEXO-OS: configuring and controlling the Nexo cordless
Wi-Fi nutrunner from any computer.
10 Tightening processes Various tightening program step types.
11 Troubleshooting Troubleshooting by means of hardware and software, error hierarchy with error code tables.
12 License agreement License information
13 Service and sales Options for contacting Rexroth, sources for additional information on the tightening system.

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1.4 Representation of information
This section shows how the data, e.g. safety instructions, and symbols are represented in the present
documentation.
1.4.1 Safety instructions
In this documentation, safety instructions precede an instruction when there is the danger of personal in-
jury or damage to equipment. The hazard avoidance measures described must be observed.
Safety instructions have the following structure:
•Safety sign (warning triangle): draws attention to the danger
•Signal word: identifies the degree of the risk (type of risk)
•Type of danger: identifies the type or source of the danger
•Consequences: describes what occurs when the safety instructions are not complied with
•Precautions: states how the risk can be avoided
Warning symbols (e.g. dangerous electric voltage) warn of dangers and consequential damages or
denote prohibitions. This documentation uses the following warning symbols:
The safety instructions describe the following types of risk. The type of risk describes the risk if the cor-
responding safety instruction is not observed. The signal words have the following meanings:
SIGNAL WORD
Type of DANGER
Consequences
Precautions
Table 1–1: Warning symbols used
Symbol Meaning
This warning symbol cautions against dangers to your health. Observe all safety instructions
that follow this symbol to avoid possible injuries or death.
This warning symbol cautions against dangers to your health caused by electric voltages or cur-
rents. Observe all safety instructions that follow this symbol to avoid possible injuries or death.
DANGER
Death or serious bodily harm will result.
WARNING
Death or serious bodily harm may result.

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1.4.2 Symbols and representations
CAUTION
Bodily harm or damage to equipment may result.
NOTE
Damage to equipment may result.
If this information is not observed, the operating procedure may be impaired.
Table 1–2: Symbols and representations used in the documentation
Symbol Explanation
Prerequisite
Ensure that the stipulated prerequisite is met before proceeding to the next step.
Step
This symbol indicates an individual step.
1.
2.
3.
Sequence of steps
Take the steps specified while following the order specified.
Result
This symbol indicates the result of a step.
Example Examples are in a gray field and illustrate the previously stated information.
A tip provides additional information that is not decisive for working with the tightening system, but
is important and useful.
Blue text References to other sections are shown in blue. Click the reference in the PDF to jump directly to
the referenced target.
Bold text Special text is shown in bold. This includes operating elements, screen displays, or important text
passages.
<n> Angle brackets indicate a variable value that can be replaced with a specific value in the concrete
case.

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1.4.3 Terms
DMS Strain gauges. Measuring device that changes its electrical resistance in case of deformations even
if these are minor and is thus used as a strain gauge sensor.
Torque filter factor Additional parameter for determining the gradient.
NX-SD Micro SD card On delivery, the NX-SD Micro SD card inserted in the Nexo cordless Wi-Fi nutrunner contains docu-
mentations and license information.
Ring memory Limited storage is available in the ring memory. The oldest data will be overwritten with the latest data
if more storage space is required.
Tightening process The tightening process describes the entire tightening procedure including the various individually pa-
rameterized tightening program steps (such as "finding", "driving in" "tightening", etc.) until the target
function is reached (torque, angle, etc.).
Tightening application Within a tightening application (also called application), 1 to a maximum of 40 tightening channels are
coordinated.
Tightening channel Where the Nexo cordless Wi-Fi nutrunner is concerned, this refers to the nutrunner itself.
A tightening channel in the Tightening System 350 comprises the necessary components for tighten-
ing. This includes the complete tightening spindle, controller, servo amplifier, and connecting cable.
Tightening program The tightening program coordinates the tightening process/sequence. It is divided into various tight-
ening steps, where tightening parameters are set.
Tightening position The tightening position is the defined location where tightening is performed using a tightening chan-
nel and a tightening program.
Tightening system A tightening system is a complete system with all tightening channels that are needed to carry out the
defined tightening case.
Tightening cell The Nexo cordless Wi-Fi nutrunner is a separate tightening cell which features a data interface for
communication with an operating program or a partner controller.
Torque threshold The torque threshold is a parameter to help measure the angle of turn for a target or monitoring func-
tion. The monitoring function of the angle is started as soon as the measured torque for the bolt reach-
es the value for the torque threshold for the first time. Afterwards, the torque threshold has no more
influence on the tightening process, except for angle correction.
Chord angle The chord angle is an additional parameter for determining the gradient.
Controller Where the Nexo cordless Wi-Fi nutrunner is concerned, the controller is the tightening controller in-
tegrated in the nutrunner.

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1.4.4 Abbreviations
This documentation uses the following abbreviations:
Monitoring function The monitoring function keeps track that the upper and lower limits are complied with during the tight-
ening process by checking a monitoring parameter (e.g. gradient).
If the monitoring function has switching capabilities, the tightening step will be terminated immediately
if a limit is exceeded. If it is has no switching capabilities, the step result changes to NOK, even if the
target parameter has been reached.
Monitoring parameter The monitoring parameter is the measured quality (e.g. gradient) of a tightening step that must be kept
within specific limits in order for a tightening process to be performed safely. If the limits are violated,
the tightening step may be terminated.
Angle correction The angle correction is an additional parameter to measure the angle of turn. Since the angle of turn
is never measured directly on a bolt, but above the output drive, there is a small deviation between the
measured angle and the angle on the bolt as a result of the torsion of the output drive due to the
torque. This deviation can be avoided with an angle correction at the end of the tightening process
(never during tightening!). The angle value measured at the end of tightening after falling below the
torque threshold is then used as the target or last monitoring parameter (the torsion of the output drive
has then reset itself).
Target function The target function controls the process sequence of the tightening step by monitoring the target pa-
rameter (e.g. torque) and ends the step once the parameter has reached its target value.
Target parameter The target parameter is the measured variable (e.g. torque) of a tightening step, which must reach a
specific value (target value) for a tightening process to be performed successfully. The tightening step
is terminated once the target value has been reached.
Additional function The additional function defines further parameters for the tightening step. Although they have an effect
on the tightening process (e.g. start-up suppression, speed setting), additional functions cannot inter-
rupt it. They do not carry out an OK/NOK evaluation.
Additional parameters Additional parameters are parameters of a tightening step which cannot interrupt the tightening pro-
cess (e.g. target speed, torque threshold) although they have an effect on it.
Table 1–3: Abbreviations for the components of the Nexo cordless Wi-Fi nutrunner
Abbreviation Explanation
BT356 Subrack system 350 for max. 6 tightening channels
BS350 Operating System 350
CS Compact System
ES ErgoSpin hand-held nutrunner
HMI Human-machine interface
IL Integrated logic
KE350 System 350 communication unit without DVI interface
KE350G-IL System 350 communication unit with DVI interface and integrated logic
LT35x Size-dependent servo amplifiers for System 350 stationary tightening technology
LTS350D Servo amplifier for tightening spindle
LTU350/1 Servo amplifier for System 350 ErgoSpin
LTE350D Servo amplifier for System 350 ErgoSpin
MC/DMC Measurement transducer
NK350 System 350 network coupler
NK350S System 350 network coupler with external power supply
NXA Nexo right-angle nutrunner

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NXP Nexo pistol grip nutrunner
SB356 System 350 system box for max. 6 tightening channels
SE352 System 350 controller for two-channel operation
SE352M System 350 controller for two-channel operation with slot for B module
PLC Programmable logic controller
Table 1–3: Abbreviations for the components of the Nexo cordless Wi-Fi nutrunner
Abbreviation Explanation

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2Safety instructions
This chapter describes cardinal safety requirements to be met during operation of the
Rexroth Tightening System 350 and the Nexo cordless Wi-Fi nutrunner by Rexroth
(referred to as Rexroth tightening system below). It contains important information
that is necessary for the safe use of the Rexroth tightening system.
•About this chapter (page 18)
•Intended use (page 21)
•Improper use (page 22)
•Personnel qualifications (page 23)
•General safety instructions (page 24)
•Product-related safety instructions for the Nexo cordless Wi-Fi nutrunner by Rex-
roth (page 25)
•Product- and technology-dependent safety instructions for the Rexroth tightening
system 350 (page 28)

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2.1 About this chapter
2.1.1 Using and communicating the safety instructions
Read all supplied documents carefully before installing any components or commissioning the Rexroth
tightening system. Read these safety instructions and all other user information each time before working
with the Rexroth tightening system. If you do not have a copy of the user information for the Rexroth tight-
ening system and components, please contact your Bosch Rexroth sales representative. Request that
documents be immediately sent to the person responsible for safe operation of the Rexroth tightening sys-
tem.
If the Rexroth tightening system and components are sold, lent, or otherwise passed on within the Euro-
pean Union (EU), these safety instructions must also be included in the language of one country of the
European Union.
WARNING
Risk of injury!
Improper use of the Rexroth tightening system and components, non-compliance with the safety
warnings stated here, or improper interventions in the safety equipment can cause damage to equip-
ment, injury, electric shock, and even, in extreme cases, death.
Observe the safety instructions.

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2.1.2 Instructions for use
To prevent injury and/or damage to equipment, read the following instructions before commissioning the
Rexroth tightening system and components. These safety instructions must be observed at all times.
• Bosch Rexroth AG does not assume any liability for damages resulting from non-compliance with the
safety warnings in this documentation and in the documentation of all the Rexroth tightening system
components.
• Read the operating, maintenance, and safety instructions prior to commissioning. If the documenta-
tion in the available language is not clearly understood, please contact the supplier and inform him of
this.
• The prerequisites for correct, safe operation of the Rexroth tightening system are: proper transporta-
tion, storage, assembly, and installation, as well as careful operation and maintenance.
– Check the product for visible defects, for example cracks in the housing or missing screws and
seals.
– Before commissioning, make sure that all the connection gaskets and plugs are installed correctly
to ensure that they are leakproof and fluids and foreign bodies are prevented from penetrating the
product.
– Make sure that all electrical connections are either used or covered. Commission the product only
if it is installed completely.
– Only use Rexroth products within the performance range specified in the respective technical da-
ta.
– Do not expose Rexroth products to any mechanical loads under any circumstances. Never use
Rexroth products as a handle or step. Do not place any objects on Rexroth products.
• Only use accessories and spare parts that are approved by the manufacturer.
• Observe the safety regulations of the country in which the Rexroth tightening system and compo-
nents are used.
• Rexroth tightening system components are designed for installation in machines used in industrial
applications.
• Always observe the ambient conditions specified in the product documentation of the respective
component.
– Let new components acclimate for several hours before commissioning. Otherwise, water may
condense, e.g. in the control housings.
– Make sure that all electrical connections are either used or covered. Commission the component
only if it is installed completely.
• Safety-relevant applications are only permitted if they are clearly and explicitly stated in the planning
documents. If this is not the case, they are excluded.
Safety-relevant applications are all applications that may result in injury to personnel or damage to
equipment.
• In the respective product documentation, information is provided regarding use of the supplied com-
ponents. These are application examples and suggestions only.
The machine manufacturer and system installer must check that
– the supplied components and specifications made in the respective documentation are suitable
for the application on hand, and that they
– correspond to the safety regulations and standards valid for that application. The machine manu-
facturer and system installer must implement the required measures, modifications, and amend-
ments.
• Commissioning of the supplied components is prohibited until it has been determined that the ma-
chine or system in which they are installed corresponds to country-specific provisions, safety regula-
tions, and standards for the specific application.
• Operation is only permitted in accordance with the national EMC regulations for the respective ap-
plication.

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• For instructions on EMC installations, refer to the documentation for the respective component.
The manufacturer of the system or machine is responsible for maintaining the limit values required by
national regulations.
• The technical data, connection conditions, and installation conditions can be found in the corre-
sponding product documentation and must be complied with at all times.
• The Compact System CS351 is not designed to be directly connected to the public low-voltage
power supply, but is only intended for use in industrial environments (emission class A).
Country-specific regulations that the user must observe
• European countries:
– Corresponding EN European standards
• United States of America (USA):
– National Electrical Code (NEC),
– National Electrical Manufacturers Association (NEMA), as well as regional building codes
• Canada
– Canadian Standards Association (CSA)
• Other countries:
– International Organization for Standardization (ISO)
– International Electrotechnical Commission (IEC)
2.1.3 Operating instructions
Observe the regulations for accident prevention and environmental protection for the country where the
product is used and at the workplace.
Only allow persons who are authorized by the operator to access the system's direct operating area. This
is also valid when the system is standing still.
In case of an emergency, fault or any other anomalies, switch the system off and protect it against being
switched on again.
Only operate the control and power electronics for Rexroth tightening technology in a grounded network.
Operation in non-grounded networks (IT network) is not permitted, as clearance and creepage distances
in the system may be overloaded. Here, protective grounding is the permissible protective measure in ac-
cordance with EN 50178. The inlet cables to the control and power electronics must be equipped with
a protective conductor (PE).
Make sure that there is potential equalization between the workpiece and nutrunner, as well as its carrier
plate, so that potential equalization is ensured for all system components.
Protect the system from short circuits in the connector cables with a fuse provided by the customer.
2.1.4 Cleaning instructions
Observe the following notes in order to guarantee the IP protection classes of the components (IP54
when assembled):
Cover all openings in Rexroth tightening system components with the appropriate protective equip-
ment in order to prevent detergents from penetrating the system.
Never use solvents or aggressive detergents.
Do not use a high-pressure cleaner for cleaning.
Also observe the cleaning instructions in the operating instructions for the respective system component.