Bosch rexroth ctrlX SAFETY SafeMotion Instructions for use

ctrlX SAFETY
"SafeMotion"
ctrlX DRIVEplus
– Original version –
Application Manual
R911404905,
Edition 02

Copyright
© Bosch Rexroth AG 2022
All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the
event of applications for industrial property rights.
Liability
The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed
characteristic unless expressly stipulated in the contract. All rights are reserved with respect to the content of this
documentation and the availability of the product.
DOK-XDRV**-SI-MX******-AP02-EN-P
DC-AE (SvAn, ThKl, ReBa)
9d500be60c7091790a347e880cd13525, 1, en_US

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Table of contents
1 About this documentation 7
2 Trademark information 9
3 Important directions on use 11
3.1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1.2 Areas of use and application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Unintended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Safety instructions for electric drive and control systems 13
4.1 Basic information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1.1 Using and passing on the safety instructions. . . . . . . . . . . . . . . . . . . 13
4.1.2 Requirements for safe use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1.3 Hazards due to incorrect use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Instructions with regard to specific dangers. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2.1 Protection against contact with electrical parts and housings. . . . . . 14
4.2.2 Protective extra-low voltage as protection against electric shock. . . . 16
4.2.3 Protection against dangerous movements. . . . . . . . . . . . . . . . . . . . . . 16
4.2.4 Protection against electromagnetic and magnetic fields during opera-
tion and mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.5 Protection against contact with hot parts. . . . . . . . . . . . . . . . . . . . . . 18
4.2.6 Protection during handling and mounting. . . . . . . . . . . . . . . . . . . . . . 18
4.2.7 Battery safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.8 Protection against pressurized systems. . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.9 Explanation of signal words and the safety alert symbol. . . . . . . . . . . 19
5 System presentation 21
5.1 Motivation and objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.2 Comparison with conventional safety technology. . . . . . . . . . . . . . . . 21
6 Product presentation 23
6.1 What is "integrated safety technology"ctrlX DRIVE?. . . . . . . . . . . . . . . . . . . . . 23
6.2 Integrated safety technology in ctrlX DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.1 Characteristics of ctrlX DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.3 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.1 Time response and reaction times. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.2 Reaction time of “Safe zone error” (SZE). . . . . . . . . . . . . . . . . . . . . . 29
6.4 Safety characteristics of the safety system. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.4.2 Optional safety technology module "M5" . . . . . . . . . . . . . . . . . . . . . . 29
6.4.3 Calculating the PFH component of an axis. . . . . . . . . . . . . . . . . . . . . 30
6.4.4 Calculating the total PFH value of a safety zone. . . . . . . . . . . . . . . . . 31
7 Functional principle 33
7.1 Dynamization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1.1 Brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1.2 Functional principle of dynamization in the selection signals. . . . . . . 33
7.2 Encoder evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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7.3 Scaling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3.1 Brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3.2 Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3.3 Notes on commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4 Diagnostic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4.2 Firmware identifiers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.3 Status messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.4 Error reaction and escalation strategy. . . . . . . . . . . . . . . . . . . . . . . . . 47
7.5 SafeMotion state machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.5.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.5.2 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.6 SafeMotion profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.6.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.6.2 SafeMotion profile "Bosch Rexroth" . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8 Safety functions 69
8.1 Global safety functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1.1 Safe maximum speed (SMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1.2 Safe speed monitor (SSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.2 Safety functions in normal operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.2.1 Safe direction (SDI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.3 Safety functions in special mode "Safe standstill". . . . . . . . . . . . . . . . . . . . . . . 73
8.3.1 Safety function “Safe torque off (STO)”. . . . . . . . . . . . . . . . . . . . . . . 73
8.3.2 Safe operating stop (SOS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.3.3 Safe brake control (SBC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.4 Safety functions in special mode “Safe motion SMMx”. . . . . . . . . . . . . . . . . . . 81
8.4.1 Safely-limited speed (SLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.4.2 Safely-monitored transient oscillation (SLS-LT) . . . . . . . . . . . . . . . . . 84
8.4.3 Safe direction (SDI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.4.4 Safely-limited increment (SLI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.5 Transition functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.5.1 Safe stop 1 (SS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.5.2 Safe stop 2 (SS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.5.3 Safely-monitored deceleration (SMD) . . . . . . . . . . . . . . . . . . . . . . . . 110
8.6 Additional and auxiliary functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
8.6.1 Limiting the positioning velocity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9 Selection and acknowledgment 131
9.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.2 Discrete selection and acknowledgment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.2.1 Brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.2.2 Functional principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.3 ctrlX SAFETYlink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
9.4 Safety bus communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.4.1 Brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.4.2 Functional principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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9.4.3 Configuring the consumer and producer connection. . . . . . . . . . . . . 136
9.4.4 FailSafe over EtherCAT (FSoE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
9.5 IO mapper inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
9.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
9.5.2 I/O mapper block types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
9.6 Signal control of outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.7 Safety zone acknowledge (SZA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.7.1 Brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
9.7.2 Safety function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
9.7.3 Notes on commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.8 Safe zone error (SZE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.8.1 Brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.8.2 Safety function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10 Commissioning 163
10.1 Risk assessment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.2 First use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10.2.1 Safety instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
10.2.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.2.3 Prerequisites for using integrated safety technology. . . . . . . . . . . . . . 165
10.2.4 Commissioning steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.3 Serial commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
10.4 Axis acceptance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
10.5 Machine acceptance test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
10.5.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
10.5.2 Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
10.5.3 Global monitoring functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
10.5.4 Monitoring functions in normal operation. . . . . . . . . . . . . . . . . . . . . . 226
10.5.5 Special mode "EMERGENCY STOP" and special mode "Safe stand-
still". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
10.5.6 Special mode "Safe motion". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
10.5.7 Error reaction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
10.5.8 Safety zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
10.5.9 Signal control of outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
11 Maintenance 243
11.1 Repairing safety-relevant components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
11.2 Replacing drive components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
11.2.1 Replacing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
11.2.2 Replacing the optional brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
11.2.3 Replacing the optional encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
11.2.4 Replacing the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
11.2.5 Replacing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
11.2.6 Firmware replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
11.3 Decommissioning drive components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
12 Declaration of conformity 251

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13 Project planning 253
13.1 SafeMotion M5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
13.1.1 XG42, XG43, Safe Motion safety technology (communication) . . . . . 254
13.1.2 XG44, SafeMotion M5 safety technology . . . . . . . . . . . . . . . . . . . . . . 255
13.2 XF21 P1, XF22 P2, communication (RJ-45) . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
13.3 Motor connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
13.3.1 XZ03, hybrid connection (motor, motor temperature monitoring and
motor holding brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
13.3.2 XD03, motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
13.3.3 XG03, motor temperature monitoring and motor holding brake . . . . . 268
13.4 Encoder connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
13.4.1 XG20, digital motor encoder connection . . . . . . . . . . . . . . . . . . . . . . 273
13.4.2 XG21, multi-encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
13.5 Specifying the digital/analog inputs/outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . 275
13.5.1 Digital inputs type A (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
13.5.2 Digital inputs (safety technology SafeMotion) . . . . . . . . . . . . . . . . . . 276
13.5.3 Digital outputs (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
13.5.4 Digital outputs (safety technology SafeMotion) . . . . . . . . . . . . . . . . . 278
13.6 Diagnostic display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
13.6.1 PF01 LED (Device State) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
13.6.2 Sercos/EtherCAT/PROFINET IO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
13.6.3 Diagnostic display of optional safety technology modules “M5” . . . . 284
14 ctrlX AUTOMATION Community 287
14.1 What is the ctrlX AUTOMATION Community?. . . . . . . . . . . . . . . . . . . . . . . . . . . 287
14.2 Application examples of ctrlX DRIVE with SafeMotion. . . . . . . . . . . . . . . . . . . . 287
15 Reference documentations 288
16 Service and support 291
17 Glossary 293
18 Index 297

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1 About this documentation
With “SafeMotion” in ctrlX DRIVE, universally parameterizable safety functions
for safe motion or standstill monitoring are provided.
●The purpose of this document is to get familiar with the “SafeMotion” safety
functions in the ctrlX DRIVE product line.
●The safety function characteristics, as well as information about the wiring,
commissioning and for the intended and safe operation as well as debugging
can be found in this section.
●The content is intended for users configuring, commissioning and operating
functionally secure products.
Editions of this documentation
Edition Release date Comment
01 2020‑11‑30 Edition for the certification date for RM21.11
2022‑02‑10 Revised editor for the certification date for
RM21.11
●Dynamization
●...
02 2022‑04‑22 Revised edition for the EnDat 2.2 certification
date:
●⮫ PFH value for XG21/EnDat 2.2 (chapter
“Optional safety technology module "M5"”)
●⮫ Chapter “Encoder evaluation"
●⮫ Chapter "Configuring the SMO encoder"
●Description of the encoder interfaces added
–⮫ Chapter 13.4.1 XG20, digital motor
encoder connection on page 273
–⮫ Chapter 13.4.2 XG21, multi-encoder
on page 274
●Requirements for use extended:⮫ Chapter
Third-party motors/optional measuring systems
on page 168
Other changes:
●⮫ Declaration of conformity inserted
●It has to be ensured that the encoder assign-
ment of the axis is not interchanged when
replacing drive components:
–⮫ Chapter 11.2.1 Replacing the motor
on page 243
–⮫ Chapter 11.2.3 Replacing the optional
encoder on page 244
–⮫ Chapter 11.2.5 Replacing the cables
on page 245
About this documentation

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Feedback on this documentation
Your experience is an important part of the product and documentation
improvement process.
In case of any errors or if you want to suggest changes to this documentation,
please do not hesitate to contact us.
Please send your feedback to:
Bosch Rexroth AG
Dept. DC-AE/EPI5
Buergermeister-Dr.-Nebel-Str. 2
97816 Lohr a.Main
Germany
E-mail: ⮫ [e-mail]

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2 Trademark information
Sercos® is registered trademark of ⮫ Sercos International e.V.
EtherCAT® is a registered trademark and patented technology licensed by
the Beckhoff Automation GmbH, Germany.
Safety over EtherCAT® is a registered trademark and patented technology,
licensed by Beckhoff Automation GmbH, Germany.
EtherNet/IP™ is a trademark under license of ⮫ Open DeviceNet Vendor
Association, Inc.
Ethernet POWERLINK is a real-time capable field bus based on Ethernet.
Originally designed by B&R and released in 2001, Ethernet POWERLINK
has been specified and enhanced since 2003 by the ⮫ Ethernet POWER-
LINK Standardization Group (EPSG) user organization. The protocol speci-
fication is open and in the public domain.
PROFINET® (Process Field Network) is the open Industrial Ethernet
standard of ⮫ Profibus & Profinet International (PI) for automation.
ProfiNet® is a registered trademark of the user organization
PROFIBUS Nutzerorganisation e. V.
CIP Safety™ is a trademark under license of ⮫ Open DeviceNet Vendor
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ctrlX SAFETY "SafeMotion"
Bosch Rexroth AG
R911404905,
Edition 02

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ctrlX SAFETY "SafeMotion"
Intended use
Bosch Rexroth AG
R911404905,
Edition 02
3 Important directions on use
3.1 Intended use
3.1.1 Introduction
The products of Rexroth are developed and manufactured to the state-of-the-
art. Prior to delivery, the products are checked for their fail-safe state.
WARNING Personal injury and property damage due to incorrect
use of the products!
The products have been designed for use in an industrial
environment and may only be used as intended. If the
products are not used as intended, this may lead to sit-
uations resulting in property damage and personal injury.
NOTICE Damages resulting from unintended use
The user shall solely bear the risks for damages arising of
unintended use of the products; Rexroth as manufacturer
shall not assume any warranty, liability or compensation
for damages.
Before using Rexroth products, make sure that all the prerequisites for an
intended use of the products are satisfied:
●Anyone that in any way, shape or form uses our products must have read
and understood the relevant safety instructions and the intended use.
●Do not change the original state of the hardware products, i.e., do not make
any structural modifications. Software products must not be decompiled
and their source codes must not be modified.
●Damaged or defective products must not be installed or commissioned.
●It has to be ensured that the products are installed according to the provi-
sions specified in the documentation.
3.1.2 Areas of use and application
Antriebsregelgeräte by Rexroth are designed to control electric motors and
monitor their operation. Controlling and monitoring the Antriebsregelgeräte
may require additional sensors and actuators.
The Antriebsregelgeräte may only be used with the accessories and attach-
ments specified in this documentation. Components that are not expressly
mentioned may neither be attached nor connected. The same applies to cables
and lines.
Operation is only allowed in the specified configurations and combinations of
the components using the software and firmware as specified in the relevant
functional descriptions.
Antriebsregelgeräte have to be programmed before commissioning to ensure
that the motor executes the functions specific to the application.
Antriebsregelgeräte of the ctrlX DRIVE series have been developed for use in
single-axis and multi-axis drive and control tasks.
Device types with different drive power and interfaces are available for using
the Antriebsregelgeräte in specific applications.
Typical applications include, for example:
●Handling and assembly systems
●Packaging and food machines
●Printing and paper converting machines
●Machine tools
Important directions on use

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ctrlX SAFETY "SafeMotion"
Unintended use
Bosch Rexroth AG
R911404905,
Edition 02
Antriebsregelgeräte may only be operated under the assembly and installation
conditions specified in this documentation, in the specified position of normal
use and under the specified ambient conditions (temperature, degree of pro-
tection, humidity, EMC, etc.).
3.2 Unintended use
"Unintended use" refers to using the Antriebsregelgeräte outside of the oper-
ating conditions, technical data and specifications described in this documen-
tation.
●Antriebsregelgeräte must not be used if they are exposed to operating con-
ditions that do not meet the specified ambient conditions. This includes, for
example, operation under water, under extreme temperature fluctuations or
extreme maximum temperatures.
●Furthermore, Antriebsregelgeräte may not be used in applications that have
not been expressly authorized by Rexroth. Please refer to the specifications
in the general safety instructions!
Components of the ctrlX DRIVE drive system are products of category 3 (with
limited availability) according to IEC 61800-3. This category comprises EMC
limit values for conducted and radiated emission. To comply with this category
(limit values), use appropriate measures to suppress inteferences in the drive
system (e.g., mains filters, shielding measures).
These components are not intended for use in a public low voltage system for
residential areas. If these components are operating in such a network, high
frequency interferences are to be expected. Additional measures for interfer-
ence suppression can be required.

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ctrlX SAFETY "SafeMotion"
Basic information
Bosch Rexroth AG
R911404905,
Edition 02
4 Safety instructions for electric drive and
control systems
4.1 Basic information
4.1.1 Using and passing on the safety instructions
Do not install and operate any components of the electric drive and control
system before carefully reading all provided documents. These safety instruc-
tions and all other user instructions have to be read prior to working with these
components. If you do not have the user documentation for the components,
contact our Rexroth sales representative. Request the immediate delivery of
these documents to the person or persons in charge of the safe operation of
the components.
In the case of vending, rental and/or distribution of the components in any
other form, include these safety instructions in the national language of the
user.
Improper use of these components, failure to follow the safety instructions
in this document or tampering with the product, including disabling of safety
devices, could result in property damage, personal injury, electric shock or
even death.
4.1.2 Requirements for safe use
Prior to initial commissioning of the components of the electric drive and con-
trol system, read the following instructions to avoid personal injury and/or
property damage. You must comply with these safety instructions.
●In the case of damage due to non-compliance with the safety instructions,
Rexroth shall not assume any liability.
●Prior to commissioning, read the operating, maintenance and safety instruc-
tions. If you are not able to sufficiently understand the language used in the
application documentation, please contact and inform your vendor.
●Appropriate and professional transport, storage, assembly and installation,
as well as thorough operation and maintenance, are the basis of correct and
safe operation of the component.
●Only qualified personnel may use components of the electric drive and con-
trol system or work in its close proximity.
●Only use accessories and spare parts approved by Rexroth.
●Comply with the safety instructions and regulations of the country in which
the components of the electric drive and control system are operated.
●Only use components of the electric drive and control system as intended.
Please refer to chapter Intended use.
●The ambient and operating conditions specified in this application docu-
mentation have to be complied with.
●Applications for functional safety are only allowed if they are explicitly
and unambiguously specified in the application documentation "Integrated
Safety Technology". If this is not the case, these applications are excluded.
Functional safety includes parts of the overall safety in which measures of
risk reduction for personal safety depend on electric, electronic or program-
mable controls.
●The specifications contained in the application documentation regarding the
use of the provided components are only application examples and recom-
mendations.
Safety instructions for electric
drive and control systems

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Instructions with regard to specific dangers
Bosch Rexroth AG
R911404905,
Edition 02
●For their individual application, the machine manufacturer and the system
installer have to
–verify the applicability of the provided components and the specifications
made for their use in this application documentation,
–synchronize the applicability with the safety regulations and standards
applicable for their application and to execute the required measures,
modifications and additions.
●Commissioning of the provided components is prohibited until is has been
established that the machine or the system in which the components are
installed corresponds to the country-specific provisions, safety regulations
and standards of the application.
●Operation is only allowed when complying with the national EMC regulations
for the relevant application.
●For information about EMC-compliant installation, refer to the section on
EMC in the relevant application documentation.
●The system or machine manufacturer is responsible for compliance with the
limit values specified in the national regulations.
●The technical data, connection and installation conditions of the compo-
nents are contained in the relevant application documentations and must be
complied with.
●Country-specific laws and regulations must be observed.
4.1.3 Hazards due to incorrect use
●High electrical voltage and high operating current! Danger to life or serious
personal injury due to electric shock!
●High electrical voltage due to incorrect connection! Danger to life or per-
sonal injury due to electric shock!
●Dangerous movements! Danger to life, serious personal injury or property
damage due to unintended motor movements!
●Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electric drive systems!
●Risk of burns by hot housing surfaces!
●Risk of injury by improper handling! Personal injury by crushing, shearing,
cutting, hitting!
●Risk of injury by improper handling of batteries!
●Risk of injury by improper handling of pressurized lines!
4.2 Instructions with regard to specific dangers
4.2.1 Protection against contact with electrical parts and housings
This section concerns components of the electric drive and control system with
voltages of more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal
danger and electric shock. When operating components of the electric drive
and control system, it is unavoidable that some parts of these components
conduct dangerous voltage.
High electrical voltage! Danger to life, risk of injury by electric shock or serious
personal injury!
●Only qualified persons are allowed to operate, maintain and/or repair the
components of the electric drive and control system.
●Follow the general installation and safety regulations when working on
power installations.

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ctrlX SAFETY "SafeMotion"
Instructions with regard to specific dangers
Bosch Rexroth AG
R911404905,
Edition 02
●Before switching on, the equipment grounding conductor must have been
permanently connected to all electrical components in accordance with the
connection diagram.
●Even for short measurements or tests, operation is only allowed with the
equipment grounding conductor permanently connected to the specified
points of the components.
●Before accessing electrical parts with voltage potentials higher than 50 V,
disconnect electrical components from the mains or from the voltge source.
Protect the electrical component against restart.
●Observe the following aspects in the case of electrical components:
Prior to touching an electrical component, always wait for 30 minutes after
switching off power in order for live capacitors to discharge. Before begin-
ning to work, measure the electrical voltage of live parts to make sure that
the equipment is safe to touch.
●Install the provided covers and safety devices for protection against contact
prior to switch-on.
●Do not touch any electrical connection points of the components while
power is turned on.
●Do not connect or disconnect live parts.
●Under certain conditions, electric drive systems can be operated at mains
protected by residual-current-operated circuit-breakers sensitive to universal
current (RCDs/RCMs).
●Secure built-in devices from penetrating foreign objects and water, as well
as from direct contact, by providing an external housing, for example a con-
trol cabinet.
High housing voltage and high leakage current! Danger to life, risk of injury by
electric shock!
●Prior to switching on and commissioning, ground or connect the electric
drive and control system components to the equipment grounding con-
ductor at the grounding points.
●Connect the equipment grounding conductor of the electric drive and con-
trol system components permanently to the main power supply at all times.
The leakage current is greater than 3.5 mA.
●Establish an equipment grounding connection with a minimum cross sec-
tion according to the table below. With an outer conductor cross section
smaller than 10 mm2 (8 AWG), the alternative connection of two equipment
grounding conductors is allowed, each having the same cross section as the
outer conductors.
Table 1: Minimum cross section of equipment grounding connection
Cross section of outer con-
ductor
Minimum cross section of equipment grounding conductor
Leakage current ≥ 3.5 mA
1 equipment grounding con-
ductor
2 equipment grounding conduc-
tors
1.5 mm2 (AWG 16) 10 mm2 (AWG 8) 2 × 1.5 mm2 (AWG 16)
2.5 mm2 (AWG 14) 2 × 2.5 mm2 (AWG 14)
4 mm2 (AWG 12) 2 × 4 mm2 (AWG 12)
6 mm2 (AWG 10) 2 × 6 mm2 (AWG 10)
10 mm2 (AWG 8) -
16 mm2 (AWG 6) 16 mm2 (AWG 6) -
25 mm2 (AWG 4) -
35 mm2 (AWG 2) -
50 mm2 (AWG 1/0) 25 mm2 (AWG 4) -
Safety instructions for electric
drive and control systems

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ctrlX SAFETY "SafeMotion"
Instructions with regard to specific dangers
Bosch Rexroth AG
R911404905,
Edition 02
Cross section of outer con-
ductor
Minimum cross section of equipment grounding conductor
Leakage current ≥ 3.5 mA
1 equipment grounding con-
ductor
2 equipment grounding conduc-
tors
70 mm2 (AWG 2/0) 35 mm2 (AWG 2) -
4.2.2 Protective extra-low voltage as protection against electric shock
Protective extra-low voltage is used to connect devices with basic insulation at
extra-low voltage circuits.
At components of an electric drive and control system provided by Rexroth,
all connections and terminals with voltages up to 50 volts are PELV (Protec-
tive Extra-Low Voltage) systems. It is allowed to connect devices equipped with
basic insulation, such as programming devices, PCs, notebooks, display units,
to these connections.
Danger to life, risk of injury by electric shock! High electrical voltage by incor-
rect connection!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 PELV (Protective Extra-Low Voltage).
4.2.3 Protection against dangerous movements
Dangerous movements can be caused by incorrect control of connected
motors. In the following, the different reasons are listed:
●Improper or wrong wiring or cable connection
●Operating errors
●Incorrect parameter input prior to commissioning
●Malfunction of sensors and encoders
●Defective components
●Errors in the software or firmware
These errors can occur immediately after switch-on or after an undefined time
of operation.
As far as possible, the monitoring functions in the components of the elec-
tric drive and control system rule out malfunction in the connected drives.
Regarding personal safety, in particular the danger of personal injury and/or
property damage, this alone cannot be relied upon to ensure complete safety.
Until the implemented monitoring functions are active, it must be assumed in
any case that faulty drive movements will occur. The faulty movements depend
on the type of control and the operating state.
Dangerous movements! Danger to life, risk of injury, serious injury or property
damage!
Prepare a risk assessment for the system or machine, with their specific condi-
tions, in which the components of the electric drive and control system are
installed.
As specified in the risk assessment, the user has to provide monitoring func-
tions and higher-level measures in the system for personal safety. The safety
regulations applicable to the system or machine have to be included. Unin-
tended machine movements or other malfunctions are possible if safety devices
are disabled, bypassed or not activated.

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ctrlX SAFETY "SafeMotion"
Instructions with regard to specific dangers
Bosch Rexroth AG
R911404905,
Edition 02
To avoid accidents, personal injury and/or property damage:
●Keep free and clear of the machine’s range of motion and moving machine
parts. Prevent personnel from accidentally entering the machine’s range of
motion by using, for example:
–Safety fences
–Safety guards
–Protective covering
–Light barriers
●Make sure the safety fences and protective coverings are strong enough to
resist maximum possible kinetic energy.
●Mount emergency stop switches in the immediate reach of the operator.
Before commissioning, verify that the emergency stop equipment works. Do
not operate the machine if the emergency stop switch is not working.
●Prevent unintended start-up. Isolate the drive power connection by means of
OFF switches/OFF buttons or use a safe starting lockout.
●Make sure that the drives are brought to 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 axis,
–adding an external braking/arrester/clamping mechanism or
–ensuring sufficient counterweight for the axis.
●The standard equipment motor holding brake or an external holding brake
controlled by the drive controller is not sufficient to guarantee personal
safety!
●De-energize the components of the electric drive and control system using
the master switch, and make sure they cannot be switched back on in the
case of:
–Maintenance and repairs
–Cleaning work
–Long service interruptions
●Avoid operating high-frequency, remote control and radio equipment in
close proximity to components of the electric drive and control system and
their supply leads. If the use of these devices cannot be avoided, check
the machine or installation, at initial commissioning of the electric drive
and control system, for possible malfunctions when operating such high-fre-
quency, remote control and radio equipment in its possible positions of
normal use. It might possibly be necessary to perform a special electromag-
netic compatibility (EMC) test.
4.2.4 Protection against electromagnetic and magnetic fields during
operation and mounting
Electromagnetic and magnetic fields!
Health hazard for persons with active implantable medical devices (AIMD) such
as pacemakers or passive metallic implants.
●Hazards for the above-mentioned groups of persons by electromagnetic and
magnetic fields in the immediate vicinity of drive controllers and the associ-
ated current-carrying conductors.
●Access to these areas can pose an increased risk to the above-mentioned
groups of persons. They should seek advice from their attending doctor.
●If overcome by possible effects on above-mentioned persons during opera-
tion of drive controllers and accessories, remove the exposed persons from
the vicinity of conductors and devices.
Safety instructions for electric
drive and control systems

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Instructions with regard to specific dangers
Bosch Rexroth AG
R911404905,
Edition 02
4.2.5 Protection against contact with hot parts
●Do not touch hot surfaces of, for example, braking resistors, heat sinks,
supply units and drive controllers, motors, windings and laminated cores!
●According to the operating conditions, temperatures of the surfaces can be
higher than 60 °C (140 °F) during or after operation.
●After having switched them off, allow the motors to cool down long enough
before touching them. Cooling down may require up to 140 minutes. The
time required for cooling down is approximately five times the thermal time
constant specified in the technical data.
●After switching off chokes, supply units and drive controllers, 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, and in accordance with the respective safety regu-
lations, the manufacturer of the machine or system must take measures to
avoid injuries caused by burns in the final application. Possible measures:
warnings at the machine or system, guards (shieldings or barriers) or safety
instructions in the application documentation.
4.2.6 Protection during handling and mounting
Risk of injury by improper handling! Personal injury by crushing, shearing, cut-
ting, hitting!
●Comply with the relevant statutory regulations of accident prevention.
●Use suitable mounting and transport equipment.
●Avoid jamming and crushing by appropriate measures.
●Always use suitable tools. Use special tools if specified.
●Use lifting equipment and tools in the correct manner.
●Use suitable protective equipment (hard hat, safety goggles, safety shoes,
safety gloves, for example).
●Do not stand under hanging loads.
●Immediately clean up any spilled liquids from the floor due to the risk of
falling!
4.2.7 Battery safety
Batteries consist of active chemicals in a solid housing. Therefore, improper
handling can cause injury or property damage. Risk of injury by improper han-
dling!
●Do not attempt to reactivate low batteries by heating or other methods (risk
of explosion and cauterization).
●Do not attempt to recharge the batteries since this may cause leakage or
explosion.
●Do not throw batteries into open flames.
●Do not disassemble any batteries.
●When replacing the battery/batteries, do not damage the electrical parts
installed in the devices.
●Only use the battery types specified for the product.
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. Dispose of used batteries sepa-
rately from other waste. Comply with the national regulations of your country.

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ctrlX SAFETY "SafeMotion"
Instructions with regard to specific dangers
Bosch Rexroth AG
R911404905,
Edition 02
4.2.8 Protection against pressurized systems
According to the information given in the Project Planning Manuals, motors and
components cooled with liquids and compressed air can be partially supplied
with externally fed, pressurized media, such as compressed air, hydraulics oil,
cooling liquids and cooling lubricants. Improper handling of the connected
supply systems, supply lines or connections can cause injuries or property
damage.
Risk of injury by improper handling of pressurized lines!
●Do not attempt to disconnect, open or cut pressurized lines (risk of explo-
sion).
●Comply with the respective manufacturer's operating instructions.
●Before dismounting lines, relieve pressure and empty medium.
●Use suitable protective equipment (safety goggles, safety shoes, safety
gloves, for example).
●Immediately clean up any spilled liquids from the floor due to the risk of
falling!
Environmental protection and disposal! The agents (e.g., fluids) used to
operate the product might not be environmentally friendly. Dispose of agents
harmful to the environment separately from other waste. Comply with the
national regulations of your country.
4.2.9 Explanation of signal words and the safety alert symbol
The safety instructions in the available application documentation contain
specific signal words (DANGER, WARNING, CAUTION, NOTICE) and, where
required, a safety alert symbol (in accordance with ANSI Z535.6-2011).
The signal word is intended to draw the reader's attention to the safety instruc-
tion and describes the hazard severity.
The safety alert symbol (a triangle with an exclamation point), which precedes
the signal words DANGER, WARNING and CAUTION, is used to alert the reader
to personal injury hazards.
DANGER Non-compliance with this safety instruction will result in
death or serious personal injury.
WARNING Non-compliance with this safety instruction can result in
death or serious personal injury.
CAUTION Non-compliance with this safety instruction can result in
moderate or minor personal injury.
NOTICE Non-compliance with this safety instruction can result in
property damage.
Safety instructions for electric
drive and control systems

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ctrlX SAFETY "SafeMotion"
Instructions with regard to specific dangers
Bosch Rexroth AG
R911404905,
Edition 02