Bosch Rexroth Nexo User manual

Nexo cordless Wi-Fi nutrunner
by Rexroth
Version AF
EN
Project planning
3 608 870 A47/10.2019
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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.

3/279 Bosch Rexroth AG | Tightening Technology
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Title Nexo cordless Wi-Fi nutrunner by Rexroth
Type of Documentation Project planning
Document Typecode DOK-NEXO-DOKU_V1.400-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, 2019
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
Postfach 1161
D-71534 Murrhardt, Germany
Fornsbacher Str. 92
D-71540 Murrhardt, Germany
Phone: [phone]
Fax: [phone]
www.boschrexroth.com
Note Translation of the 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
3 608 870 A47_AF/EN 09/2019 Version for the Nexo cordless Wi-Fi nutrunner by Rexroth
and firmware V1400

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Contents
1 About this documentation 7
1.1 Overview of this documentation . . . . . . . . . . .8
1.2 Validity of the documentation . . . . . . . . . . . . .8
1.3 Additional documentation . . . . . . . . . . . . . . . . .8
1.4 Representation of information . . . . . . . . . . . . .9
1.4.1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.2 Symbols and representations. . . . . . . . . . . . . . . . . . .10
1.4.3 Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.4.4 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2 Safety instructions 15
2.1 About this chapter . . . . . . . . . . . . . . . . . . . . . . 16
2.2 General power tools safety
warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Work area safety . .. . . . . . . . . . . . . . . . . . . . . . 16
2.4 Electrical safety . . .. . . . .. . . . .. . . . .. . . . .. . 17
2.5 Personal safety . . . . . . . . .. . . . .. . . . .. . . . .. . 17
2.6 Power tool use and care . . . . . . . . . . . . . . .. . 18
2.7 Battery tool use and care . . . . . . . . . . . . . . .. . 18
2.8 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Safety Instructions for nutrunners . . . . . . . 19
2.10 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.11 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.12 Personnel qualifications . . . . . . . . . . . . . . . . 21
2.13 Symbol on the product . . . . . . . . . . . . . . . . . . 22
3 Introduction 23
3.1 Nexo cordless Wi-Fi nutrunner . . . . . . . . . . 24
3.1.1 NX-SD Micro SD card . . . . . . . . . . . . . . . . . . . . . . . .25
3.1.2 MicroUSB interface. . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.1.3 Safety lock interface . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.1.4 NEXO-OS operating system . . . . . . . . . . . . . . . . . . .26
3.1.5 Tool display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3.1.6 Nexo battery system . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.1.7 Technical data of the nutrunner . . . . . . . . . . . . . . . . .31
3.1.8 Technical WLAN data. . . . . . . . . . . . . . . . . . . . . . . . .31
3.1.9 Technical data of the barcode scanner. . . . . . . . . . .31
3.2 WLAN (Wireless Local Area Network) . . . . 32
3.2.1 Access point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.2.2 Infrastructure mode using WLAN controller . . . . . . .32
3.2.3 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.3 Connection options of the Nexo cordless
Wi-Fi nutrunner . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3.1 Result storage without radio connection . . . . . . . . .34
3.3.2 Results storage via WLAN: . . . . . . . . . . . . . . . . . . . .35
3.3.3 Control and results storage via WLAN . . . . . . . . . . .36
3.3.4 PLC control and result storage via WLAN . . . . . . . .38
3.3.5 Fieldbus control and result storage via WLAN . . . . 39
3.3.6 Process Quality Manager (PQM). . . . . . . . . . . . . . . 40
4 Assembly 41
4.1 Assembly notes . . . . . . . . . . . . . . . . . . . . . . . . .42
4.2 Adjusting the angle head . . . . . . . . . . . . . . . .43
4.3 Attaching the torque support . . . . . . . . . . . . .45
4.4 Attaching the accessories . . . . . . . . . . . . . . .47
5 Construction guidelines 49
5.1 Design of a bolted connection . . . . . . . . . . . .50
5.1.1 Clamp force and distortion of connected parts,
operating forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.1.2 Determination of the required torque to create
a bolted connection. . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1.3 Tightening case (soft – hard) . . . . . . . . . . . . . . . . . . 54
5.1.4 Tightening processes . . . . . . . . . . . . . . . . . . . . . . . . 54
5.2 Cycle times . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.2.1 Total duration for all tightening steps. . . . . . . . . . . . 55
5.3 Compatibility with foreign substances . . . .55
5.4 Planning assistance . . . . . . . . . . . . . . . . . . . . .55
5.4.1 3-D/CAD data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6 Control signals 57
6.1 PLC signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
6.2 Description of all PLC signals . . . . . . . . . . . .58
6.2.1 Input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6.2.2 Output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7 Data services 69
7.1 Overview of tightening results
communication . . . . . . . . . . . . . . . . . . . . . . . . .70
7.1.1 Identification code (ID code) . . . . . . . . . . . . . . . . . . 70
7.2 Data output via FTP . . . . . . . . . . . . . . . . . . . . .71
7.2.1 Opening and closing the FTP connections for
results output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.2.2 Data volume and expected transfer time for
tightening results files . . . . . . . . . . . . . . . . . . . . . . . . 72
7.3 Data output via HTTP . . . . . . . . . . . . . . . . . . . .73
7.4 Data output via File Share . . . . . . . . . . . . . . .74
7.5 Rexroth Open Protocol . . . . . . . . . . . . . . . . . .75
7.5.1 Sequence diagrams - examples . . . . . . . . . . . . . . . . 76
7.5.2 Message structure. . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.5.3 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.6 Rexroth IPM Protocol . . . . . . . . . . . . . . . . . . .162
7.6.1 Message structure. . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.7 VW-XML protocol . . . . . . . . . . . . . . . . . . . . . . .165

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7.7.1 Assignment of PLC signals. . . . . . . . . . . . . . . . . . . 165
7.7.2 Particularities with VW-XML results output. . . . . . 166
7.7.3 Tightening process . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.8 BMW-TPC service . . . . . . . . . . . . . . . . . . . . . .168
7.8.1 Assignment of PLC signals. . . . . . . . . . . . . . . . . . . 168
8 Commissioning 169
8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
8.1.1 Overview of commissioning steps . . . . . . . . . . . . . 171
8.2 NEXO-OS operating system . . . . . . . . . . . .172
8.2.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
8.2.2 Assigning IP addresses for the Nexo cordless
Wi-Fi nutrunner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
8.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .173
8.4 Special features of nutrunners with angle
compensation . . . . . . . . . . . . . . . . . . . . . . . . .173
8.4.1 Function and accuracy check of the nutrunner. . . 174
8.4.2 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
9 Operating system
NEXO-OS 175
9.1 General information about the NEXO-OS
operating system . . . . . . . . . . . . . . . . . . . . . .176
9.1.1 Full versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
9.1.2 Updating the firmware version . . . . . . . . . . . . . . . . 177
9.2 Starting the program . . . . . . . . . . . . . . . . . . .177
9.2.1 Main window of the NEXO-OS operating system 179
9.2.2 Exiting the program . . . . . . . . . . . . . . . . . . . . . . . . . 181
9.3 Function overview . . . . . . . . . . . . . . . . . . . . . .182
9.4 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
9.4.1 Actual values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
9.4.2 Stored values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
9.4.3 Actual graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
9.4.4 Stored graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
9.5 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
9.5.1 Structure of the Mode tab. . . . . . . . . . . . . . . . . . . . 187
9.5.2 Mode steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
9.5.3 Change mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
9.6 Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
9.6.1 Structure of the Job tab. . . . . . . . . . . . . . . . . . . . . . 193
9.6.2 Job steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
9.6.3 Create new job/change job . . . . . . . . . . . . . . . . . . 194
9.7 Tightening programs . . . . . . . . . . . . . . . . . . .200
9.7.1 Definition: Target, monitoring, additional function. 200
9.7.2 Programs tab structure . . . . . . . . . . . . . . . . . . . . . . 201
9.7.3 Steps of tightening programs . . . . . . . . . . . . . . . . . 202
9.7.4 Creating a new tightening program/editing an
existing tightening program. . . . . . . . . . . . . . . . . . . 202
9.8 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
9.8.1 Time & date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
9.8.2 User accounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
9.8.3 Tool display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
9.8.4 Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.8.5 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
9.8.6 Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
9.8.7 PLC signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
9.8.8 OK/NOK counter . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
9.8.9 Quality code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
9.8.10 WLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9.8.11 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
9.8.12 LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
9.8.13 ID assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
9.8.14 Scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
9.8.15 Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
9.8.16 Backup/Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
9.9 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
9.9.1 System information. . . . . . . . . . . . . . . . . . . . . . . . . . 251
9.9.2 Log book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
9.9.3 Open Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
9.9.4 BMW-TPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
9.9.5 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
9.9.6 System errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
9.9.7 Web server log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
9.9.8 Screenshot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
9.9.9 Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
9.9.10 Export logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
9.10 Help menu . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
10 Tightening processes 257
10.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
10.2 Torque-controlled tightening process . . .259
10.3 Angle-of-turn-controlled tightening
process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
11 Troubleshooting 265
11.1 Error codes and classes . . . . . . . . . . . . . . . .266
11.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
11.1.2 Error code assignment table . . . . . . . . . . . . . . . . . . 266
11.1.3 Error classes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
11.2 Detecting and acknowledging errors
with the NEXO-OS operating system . . . .267
11.2.1 Error lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
11.2.2 WLAN errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
11.3 Complete error list . . . . . . . . . . . . . . . . . . . . .268
11.4 Replacing defective components . . . . . . . . 273
11.5 Shortening of power supply on battery
change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273
12 License agreement 275
13 Service and sales 277

1About this
documentation
This chapter contains general information on the present documentation.
•Overview of this documentation (page 8)
•Validity of the documentation (page 8)
•Additional documentation (page 8)
•Representation of information (page 9)

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1.1 Overview of this documentation
This documentation describes the tightening system in the following chapters:
1.2 Validity 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
Tightening 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
documentation of the machine or system manufacturer.
You can find current documentation for project planning, as well as related documents, in the media
directory at:
http://www.boschrexroth.com/mediadirectory
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
applicable 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
systems. 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
between 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
injury or damage to equipment. The hazard avoidance measures described must be observed.
Safety instructions are structured as follows:
•Safety sign (warning triangle): draws attention to the danger
•Signal word: identifies the degree of the risk (hazard class)
•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
corresponding 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
currents. 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.
NOTICE
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
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> Angled brackets mark a variable value that you need to replace with a specific value in the respective
case.

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1.4.3 Designations
CS351 IL Compact system 350 with integrated logic. With the integrated logic in the compact system, single
channel control can be implemented as a gateway between the PLC fieldbus and the Nexo cordless
Wi-Fi nutrunner.
DMS Strain gauges. Measuring device that changes its electrical resistance even with slight deformation
and is thus used as a strain gauge sensor.
Torque filter factor Additional parameter for determining the gradient.
NX-SD The NX-SD Micro SD card is already plugged into the nutrunner as delivered.
NEXO-OS Nexo browser-based operating system NEXO-OS. On delivery, the operating software is pre-
installed as an integral part of the Nexo cordless Wi-Fi nutrunner.
NXA Nexo cordless Wi-Fi nutrunner NXA angle nutrunner with slim angle head.
NXP Nexo cordless Wi-Fi nutrunner - NXP pistol grip nutrunner.
NXV...A Nexo cordless Wi-Fi nutrunner VarioLine nutrunner NXV, standard machine angle nutrunner without
angle head.
NXV...P Nexo cordless Wi-Fi nutrunner VarioLine nutrunner NXV, pistol grip nutrunner with extended
interface for special output drives.
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
parameterized 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
tightening. This includes the complete tightening spindle, controller, servo amplifier, and connection
cable.
Tightening program The tightening program coordinates the tightening process/sequence. It is divided into various
tightening steps, where tightening parameters are set.
Tightening position The tightening position is the defined location where tightening is performed using a tightening
channel 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.

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Torque threshold The torque threshold is a parameter to help measure the angle of turn for a target or monitoring
function. The monitoring function of the angle is started as soon as the measured torque for the bolt
reaches 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
integrated in the nutrunner.
Monitoring function The monitoring function keeps track that the upper and lower limits are complied with during the
tightening 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
parameter (e.g. torque) and ends the step if the parameter value 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 interrupt it. They do not carry out an OK/NOK evaluation.
Additional parameters Additional parameters are the parameter values in a tightening step, which influence the tightening
process (e.g. target speed, torque threshold), but which cannot interrupt the tightening process.

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1.4.4 Abbreviations
The following abbreviations are used in this documentation:
Table 1–3: Abbreviations for the components of the Nexo cordless Wi-Fi nutrunner
Abbreviation Explanation
DIN German Institute for Standardization
EMC Electromagnetic Compatibility
EN European standard
HMI Human-machine interface
ISO International Organization for Standardization
IP International Protection
PLC Programmable logic controller

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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 16)
•General power tools safety warnings (page 16)
•Work area safety (page 16)
•Electrical safety (page 17)
•Personal safety (page 17)
•Power tool use and care (page 18)
•Battery tool use and care (page 18)
•Service (page 19)
•Safety Instructions for nutrunners (page 19)
•Intended use (page 16)
•Improper use (page 16)
•Personnel qualifications (page 16)
•Symbol on the product (page 22)

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2.1 About this chapter
The product has been manufactured according to the accepted rules of current technology. There is,
however, still the risk of personal injury or damage to equipment if this chapter and the safety instructions
in this documentation are not complied with.
• Read this documentation thoroughly and completely before commissioning and working with the
product.
• Follow all safety instructions referring to transport, storage, assembly, commissioning, and operation.
• 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.
2.2 General power tool safety warnings
2.3 Work area safety
•
•
•
WARNING
4!"!! %! $ $$
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3 608 870 A47 Tightening Technology | Bosch Rexroth AG 17/279
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2.4 Electrical safety
•
•
•
•
•
•
2.5 Personal safety
•
•
•
•
•
•
•
•
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 #&#-/ &#) ##CE !& !#(E
3"! = %!!!!!  /!  !  "###-/ &#) 
##  & " ,!#!
3M3! %&M=M$! ! %!!M" %
!##! "#/ !( )  E##/" "/ C#*&!
-" !"  $:! ! !   8$!
!M$! #-,!"# "#" ," ,!p  ,/%,!
3!  ! M%! E$$ !M$!! %
s!M  "  !!"#""! ! *  (E)/-"##-! "#,

18/279 Bosch Rexroth AG | Tightening Technology 3 608 870 A47
Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10
2.6 Power tool use and care
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2.7 Battery tool use and care
37 M$! ! / "# "&#) ##),#
/ (#  ,!- /  -#)/"/)!, ! ,
3$  $  !E&#) ##/"# "## ,
)// !)"/!, #!,C!  & ,
3 $%$!B"!M!#8 !!8-
 !# %!M!&$8!% %! 8 %"/& * *
!- EC ! ! ," / !'#-!/ &#) ## "", E
4 $! !!$!  ! 
  $ !F#)  ##! , #!/ /,!#- ,
! !
M! ! !! ,# ! %  %" %!8!#!%
!!!M  !!M! O! -!!%8!"
! $E"", ! "! ,E &##EC ,&#) ##!
=$ %!!!F#& EC ,"##!)/!/&" , !  !!
' E#,,  ! #"##
78! !   !!  $ 8!# % !
$# %  !#! #-/ &#) ##-##& #!,--  
-#C/#!  , ,"#, !/%,#!!#
=!!%! %$!M8!!  !%!&& E/, !,
!& !-" !,###)-#!- /,,"###-/ ## & " ,!#!
!%M !%  M!$!$"/ /!! -## E& #-
 E&"'CE"  !'#-- )/ ! ,)/#/  E&"'
7M   !M %!!M!#! #-E#/  E&"'!CE
"  !'#-(E,- 
6!M!#  $8# !!M !&8 #! 8 8#M8
! 8!!&8!!!#!  !!
/#/  E C!# / CE"! !#- 
7!$ "  8 E$ !M& !MP!" !-!! !M
$8$ !- E$ !M8!  !M# !°, ( " ,-#C/ 
 ECE"! ##!
<!!% % $ !!% !M!#$ !$!%
    $ /C&#& E# C&  !#!, / !& "- ,  CE,C 
/  E," ! / !'#-- 
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3:!!M!# : "!$&#! #- # C&  
#* CE"!  &#!#
3$!!M!#! !!%   tC ,#C#,- ,  !CE
/ & ,"  /*# !-  &#!##!' #-(E

3 608 870 A47 Tightening Technology | Bosch Rexroth AG 19/279
Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10
2.8 Service
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2.9 Safety Instructions for nutrunners
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•Observe all notes on the power tool.
•Observe the safety regulations of the country in which the power tool is used/operated.
•Observe the applicable accident prevention and environmental protection regulations.
•Observe the technical data and ambient conditions specified in the product documentation.
•Only use a power tool if this use is expressly specified and permitted in the documentation of the product.
If unsuitable electric tools are installed or used in safety-relevant applications, unintended operating states may
occur in the application that may cause personal injuries and/or damage to property.
WARNING
!"M$" M!E$!  !  $ %M  !!!/!
) ! // !- E#-/ &#) ##!C ,
("" !!%!M!# *" #- E&"'!!/#,#E & -#C ,E/ 
C-"  #/#% ,! *" &#*, !
$$M! %8 sawing, grinding, drilling and other similar activities may cause cancer,
congenital defects or genetic mutations.
#C #-/ ! ,!!"# !!" !!"/!
 , ,p! ,&,*!/"E! !" "'!" C ,#/ ,C !! ",
"/#C "/ C"E  ,)##,/ !'#- "#C , & ,!#/#)- ° EE#  &#! ,#
/ ! !!" !# ," / &# , E#!/#,)E! ) , ° & !#&# "* 
°&C  !& "E C,  /&&!/"- # * / !C !#-,!&" !,
)#'#E) p*  , !
M $!%  %$!8  %!! !
!M!   %u!  !"#"¨* ¨ ) CEC'  &#! ,C &!#-/ &#) 
## ¨* ¨,"#,* / #& #  ""!/#"'
7$ !  ! $M !!$  M
!M ! !#")/  """ !""! f ,  ""!/#"'tC! !
"l , # &#!#+ ') && !"! !&#& E,C 
H$M/ / , ##! !" )! & & ,-# C&#E//
#°  "#!
S$# )#'& " "C& ,)/ "C&, *" !#*" !/ ,C# ! " /E
/,
!M! $ !!! % / &&"#
## "(C,"! E###! "###-/ &#) ##
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4   !M ! ! #! %
E$!  !$# #!#/ &&"### "#C !#"' ,)/  "#C !(CC ,
 / )#'& " #)/ / &#) ## "#C !#* #, ,
3$! ! !! w !  t - "* 
&&"# ##!" '-# C& "!C ,C ,& !#(E
6  %!! ! 8!#$!   $M $-/ &&"#
##! #/ ,! " E/ ##/#, CE "#C ##! ,"#! ° E"## 
!$ % %Q ! #  %$ %! $!!
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"##E

20/279 Bosch Rexroth AG | Tightening Technology 3 608 870 A47
Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10
•Use power tools only when they are in good technical order and condition.
•You may only commission the power tool if it has been determined that the end product (e.g., machinery or
a system) in which the Rexroth products are installed complies with the country-specific conditions,
safety regulations and standards of the application.
•
•Do not open the battery. There is a risk of short-circuiting.
•
•
•
•Do not short-circuit the battery. The battery might explode.
•Do not use batteries if their housing or contacts are damaged. There is a risk of short-circuit.
•Defective batteries must be stored in fire-resistant containers. There is a risk of fire.
2.10 Intended use
The electric tools NXA, NXP, NXV are complete machines within the meaning of the currently valid
Machinery Directive, see "EU Declaration of Conformity" in the "Nexo" operating manual.
You may use the electric tool as follows:
• For integration in partly completed machinery or in a machine and/or system,
• For performing tightenings requiring a continuous course of the torque.
• Electric tools with protective insulation for battery assembly (accessory NXAP030 or NXPP012) may
be used for tightening of individual live cell modules of voltage class up to 800 V.
This electric tool is not suitable for tightening processes requiring stepwise tightening of the connection
elements, e. g. impact wrenches.
Never use this electric tool as a lever or hammer. This electric tool is not suitable as a drill.
The electric tool is intended for industrial use and not for private use.
The electric tool may be commissioned only after it is has been integrated into the machine/system for
which it is designed and the machine/system fully complies with the EC Machinery Directive. Observe the
operating conditions and performance limits specified in the technical data.
Operation of the electric tool is only permitted in accordance with the national regulations for the
electromagnetic compatibility (EMC) for the respective application.
For instructions on EMC-compliant installation, refer to the documentation for the respective component.
Only accessories and add-on units that have been approved for use in Rexroth tightening systems may
be used therein. Non-approved components may neither be added nor connected to the system. The
same applies to cables, lines and batteries which belong to the Rexroth Tightening System. Otherwise,
functional and system safety is jeopardized.
Intended use includes having read and understood this documentation and especially the chapter "Safety
instructions".
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