Bosch Rexroth IndraControl VEH 30.1 Technical manual

Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics

Rexroth IndraControl VEH 30.1
Hand-Held Terminal
Project Planning Manual
DOK-SUPPL*-VEH*30.1***-PR04-EN-P
RS-4a0c9c5de41e390b0a6846a000575033-1-en-US-5
This documentation describes the hand-held terminal IndraControl VEH 30.1.
Edition Release Date Notes
120-2100-B389-02/EN 04/2007 First English edition
120-2100-B389-03/EN 11/2007 Additional chapter
120-2100-B389-04/EN 11/2008 Revised edition
© 2008 Bosch Rexroth AG
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).
The specified data is for product description purposes only and may not be
deemed to be guaranteed unless expressly confirmed in the contract. All rights
are reserved with respect to the content of this documentation and the availa‐
bility of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr am Main, Germany
Phone [phone] ■ Fax [phone]
http://www.boschrexroth.com/
Dept. BRC/EAY2 (CS)
Dept. BRC/EAP2 (EH/CS)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
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Record of Revision
Bosch Rexroth AG | Electric Drives
and Controls
Rexroth IndraControl VEH 30.1 |Project Planning Manual
Copyright
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Published by
Note

Table of Contents
Page
1 System Presentation...................................................................................................... 1
1.1 Short Description ................................................................................................................................... 1
1.1.1 General Information............................................................................................................................. 1
1.1.2 Foil Keyboard...................................................................................................................................... 1
1.1.3 Touch Screen...................................................................................................................................... 1
1.1.4 Front View of the IndraControl VEH 30.1............................................................................................ 2
IndraControl VEH 30.1 with Touch Screen and Keypad.................................................................. 2
1.1.5 Front View of the IndraControl VAC 30.2............................................................................................ 2
1.2 Operating System................................................................................................................................... 3
1.3 Commissioning....................................................................................................................................... 3
2 Important Instructions on Use ....................................................................................... 5
2.1 Appropriate Use ..................................................................................................................................... 5
2.1.1 Introduction.......................................................................................................................................... 5
2.1.2 Areas of Use and Application.............................................................................................................. 5
2.2 Inappropriate Use................................................................................................................................... 6
3 Safety Instructions for Electric Drives and Controls....................................................... 7
3.1 Safety Instructions - General Information............................................................................................... 7
3.1.1 Using the Safety Instructions and Passing them on to Others............................................................ 7
3.1.2 How to Employ the Safety Instructions................................................................................................ 7
3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness.............................................. 8
3.1.4 Hazards by Improper Use.................................................................................................................... 9
3.2 Instructions with Regard to Specific Dangers....................................................................................... 10
3.2.1 Protection Against Contact with Electrical Parts and Housings......................................................... 10
3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage................................................. 11
3.2.3 Protection Against Dangerous Movements....................................................................................... 11
3.2.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 14
3.2.5 Protection Against Contact with Hot Parts......................................................................................... 14
3.2.6 Protection During Handling and Mounting......................................................................................... 14
3.2.7 Battery Safety.................................................................................................................................... 15
3.2.8 Protection Against Pressurized Systems........................................................................................... 15
4 Technical Data............................................................................................................. 17
4.1 IndraControl VEH 30.1.......................................................................................................................... 17
4.2 Front Panel .......................................................................................................................................... 17
4.3 STOP Pushbutton ................................................................................................................................ 17
4.4 Enabling Device.................................................................................................................................... 18
4.5 Connection Module IndraControl VAC 30.2.......................................................................................... 18
4.6 Ambient Conditions............................................................................................................................... 18
4.7 Coding ................................................................................................................................................. 19
4.8 Weight................................................................................................................................................... 19
4.9 Used Standards.................................................................................................................................... 19
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Table of Contents

Page
4.10 UL/CSA Certified.................................................................................................................................. 20
4.11 Wear Parts............................................................................................................................................ 20
4.12 Compatibility Test................................................................................................................................. 21
5 Dimensions.................................................................................................................. 23
5.1 Housing Dimensions of the IndraControl VEH 30.1.............................................................................. 23
5.1.1 Top View: VEH 30.1 ......................................................................................................................... 23
5.1.2 Side View: VEH 30.1......................................................................................................................... 24
5.2 Housing and Mounting Dimensions of the IndraControl VAC 30.2....................................................... 25
5.3 Dimensions of the Wall Holder for the IndraControl VEH 30.1 ............................................................ 26
6 Display and Operating Components............................................................................ 27
6.1 Operating Components ........................................................................................................................ 27
6.1.1 General information........................................................................................................................... 27
6.1.2 Housing of the IndraControl VEH 30.1.............................................................................................. 27
6.1.3 Foil Keyboard.................................................................................................................................... 30
Position of the keys of the IndraControl VEH 30.1 ........................................................................ 30
6.1.4 Touch Screen.................................................................................................................................... 30
6.1.5 Safety Operating Components.......................................................................................................... 31
6.1.6 Optional Operating Components....................................................................................................... 33
6.2 Backlight Dimming................................................................................................................................ 33
7 Pin Assignment of IndraControl VEH 30.1................................................................... 35
7.1 Connection of the IndraControl VEH 30.1 via the IndraControl VAC 30.2........................................... 35
7.1.1 General Information........................................................................................................................... 35
7.1.2 Pin Assignment of the IndraControl VAC 30.2.................................................................................. 35
7.1.3 X1: 24 VDC Power Supply................................................................................................................ 36
7.1.4 X2.1: STOP Pushbutton ................................................................................................................... 38
Pin Assignment............................................................................................................................... 38
7.1.5 X2.2: Enabling Device....................................................................................................................... 39
Pin Assignment............................................................................................................................... 39
Circuit Diagram of the Enabling Device.......................................................................................... 39
Contact Travel Diagram of the Enabling Device............................................................................. 40
Wiring of the Enabling Device........................................................................................................ 40
7.1.6 X3: Ethernet Interface........................................................................................................................ 43
7.2 Personality Function............................................................................................................................. 44
8 Maintenance and Installation....................................................................................... 45
8.1 General Information.............................................................................................................................. 45
8.2 LCD Display.......................................................................................................................................... 45
8.3 Maintenance of the IndraControl VEH 30.1.......................................................................................... 45
8.4 Measures in Case of Malfunctions at the IndraControl VEH 30.1........................................................ 45
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Rexroth IndraControl VEH 30.1 |Project Planning Manual
Table of Contents

Page
9 Software....................................................................................................................... 47
9.1 General Information.............................................................................................................................. 47
9.2 First Commissioning............................................................................................................................. 47
9.3 Touch Screen Calibration..................................................................................................................... 47
9.4 Rexroth CE Settings............................................................................................................................. 48
9.4.1 General Information........................................................................................................................... 48
9.4.2 Ethernet Adapter............................................................................................................................... 48
9.4.3 Application Settings........................................................................................................................... 49
9.4.4 Data Server....................................................................................................................................... 50
9.4.5 System Info........................................................................................................................................ 50
9.5 Windows CE 4.2 .NET.......................................................................................................................... 51
9.5.1 General Information........................................................................................................................... 51
9.5.2 Operation........................................................................................................................................... 51
9.5.3 Microsoft Programs........................................................................................................................... 52
General Information........................................................................................................................ 52
9.5.4 FTP Server........................................................................................................................................ 53
9.5.5 Web Server........................................................................................................................................ 53
9.5.6 Telnet Server..................................................................................................................................... 53
9.5.7 CE User Configuration....................................................................................................................... 54
9.6 WinStudio............................................................................................................................................. 54
9.6.1 General Information........................................................................................................................... 54
9.6.2 Remote Agent Setup......................................................................................................................... 55
9.7 Evaluation of the Operating Element Commands ................................................................................ 55
9.7.1 General Information........................................................................................................................... 55
9.7.2 Evaluation of the Operating Status in the Control............................................................................. 55
9.7.3 Evaluation of the keys in the operating system................................................................................. 57
9.8 System Update..................................................................................................................................... 58
9.8.1 General Information........................................................................................................................... 58
9.8.2 Preparation........................................................................................................................................ 58
9.8.3 Upload via FTP Server...................................................................................................................... 59
10 Environmental Protection and Disposal ...................................................................... 61
10.1 Environmental Protection...................................................................................................................... 61
10.2 Disposal................................................................................................................................................ 61
11 Ordering Information.................................................................................................... 63
11.1 Type Designation Code........................................................................................................................ 63
11.1.1 General Information........................................................................................................................... 63
11.1.2 IndraControl VEH 30.1...................................................................................................................... 63
11.1.3 IndraControl VAC 30.2...................................................................................................................... 64
11.2 Accessories.......................................................................................................................................... 64
11.2.1 Extension Cable ............................................................................................................................... 64
11.2.2 Wall Holder........................................................................................................................................ 64
11.3 Spare Parts........................................................................................................................................... 64
11.3.1 Touch Pen......................................................................................................................................... 64
Project Planning Manual |Rexroth IndraControl VEH 30.1 Electric Drives
and Controls
|Bosch Rexroth AG III/IV
Table of Contents

Page
12 Service and Support.................................................................................................... 65
Index............................................................................................................................ 67
IV/IV Bosch Rexroth AG | Electric Drives
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Rexroth IndraControl VEH 30.1 |Project Planning Manual
Table of Contents

1 System Presentation
1.1 Short Description
1.1.1 General Information
The Embedded Terminal IndraControl VEH 30.1 is a portable, powerful, PC-
based operator and visualization device. The 2-circuit, 3-stage enabling device
as well as the 2-circuit STOP pushbutton ensure a safe operation of the controls
IndraLogic and IndraMotion. The device permits the comfortable configuration
of machines and installations located at widely distributed connection points.
VEH 30.1
Display 8.4" TFT
Keys Yes
Touch screen Yes
Enabling switch 2-circuit, 3-stage
STOP pushbutton 2-circuit
Interface Ethernet
Connection IndraControl VAC 30.2 with emergency
stop jumpering
Fig.1-1: IndraControl VEH 30.1
The VEH 30.1 can be used for:
1. Operation and visualization of IndraLogic, IndraMotion MLC, IndraMotion
MTX.
2. Configuration of machines and installations.
3. Operation and diagnostics of extendend handling installations.
4. Visualization of simple operating fields and assembly lines.
The specifications about the IndraControl VEH 30 devices made in
the documentation "Rexroth IndraControl VEP/VEH", "DOK-
SUPPL*-VEP/VEH*****-PR01-EN-P" are obsolete.
1.1.2 Foil Keyboard
The keypad consists of a chemical resistant polyester foil with embossed keys.
1.1.3 Touch Screen
The front panel with touch screen allows you to operate the application software
via the touch-sensitive surface of the display without keyboard and mouse.
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System Presentation

1.1.4 Front View of the IndraControl VEH 30.1
IndraControl VEH 30.1 with Touch Screen and Keypad
Fig.1-2: Front view: IndraControl VEH 30.1
1.1.5 Front View of the IndraControl VAC 30.2
You connect the hand-held terminal IndraControl VEH 30.1 to the control via
the connection module IndraControl VAC 30.2. At the rear side you find all in‐
terfaces to wire the connection module firmly to the control. At the front side a
17-pin female connector with screwed plug allows the comfortable connection
of an IndraControl VEH 30.1.
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Rexroth IndraControl VEH 30.1 |Project Planning Manual
System Presentation

Fig.1-3: Front view: IndraControl VAC 30.2
1.2 Operating System
For license reasons IndraControl VEH 30.1 type devices are only delivered with
already installed operating system. For further information about the operating
system please refer to chapter 9 "Software" on page 47.
1.3 Commissioning
Please mount the IndraControl VAC 30.2 connection module according to the
specifications in chapter 5 "Dimensions" on page 23. After this connect the
connection module to the following components:
● Voltage supply
● STOP circuit
● Enabling circuit
● Network
Before commissioning the IndraControl VEH 30.1 you have to ensure that the
installation, especially the safety devices, are in a proper status.
Before commissioning the IndraControl VEH 30.1 do observe that
the STOP pushbutton is not pressed. The connection of an Indra‐
Control VEH 30.1 with pressed STOP pushbutton, shuts down the
installation.
For connecting the IndraControl VEH 30.1 put – as shown in fig. 1-4 "Plug ori‐
entation at the IndraControl VAC 30.2" on page 4 – the angled connector
without effort with an angle of 45° to the horizontal on the flange of the Indra‐
Control VAC 30.2 connection module. Only if the connector snaps in properly,
Project Planning Manual |Rexroth IndraControl VEH 30.1 Electric Drives
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System Presentation
Connecting the device

the correct position is reached. Now turn the knurled nut with slight pressure
on the flange.
Fig.1-4: Plug orientation at the IndraControl VAC 30.2
While the connector is screwed on, a relay activates the STOP
pushbutton. In this way the IndraControl VEH 30.1 is supplied with
voltage. Screw the knurled nut as far as the end position is reached
to ensure the optimal connection of the contacts and to achieve the
specified degree of protection.
Verify all three positions of the enabling device from both sides for correct func‐
tion during commissioning of the IndraControl VEH 30.1 and regularly during
routine operation.
The device may only be commissioned and connected by qualified staff.
Find further details about commissioning in the documentation of the device or
installation manufacturer.
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Rexroth IndraControl VEH 30.1 |Project Planning Manual
System Presentation

2 Important Instructions on Use
2.1 Appropriate Use
2.1.1 Introduction
Rexroth products represent state-of-the-art developments and manufacturing.
They are tested prior to delivery to ensure operational safety and reliability.
Therefore the products may only be used for the intended purpose. If they are
not used as intended, situations causing personal injury as well as material
damage can occur.
Rexroth disclaims as manufacturer any warranty, liability or dam‐
ages occurring due to inappropriate use of the products. Further‐
more, Rexroth is not paying any compensation; the user is
responsible for any risks resulting from inappropriate use of the
products.
Before using Bosch Rexroth products, the following requirements must be met
to ensure appropriate use of the products:
● Anyone handling one of the Rexroth products in any way has to read and
understand the respective safety-related guidelines as well as the instruc‐
tions on appropriate use.
● Hardware products have to remain in their original state, i. e. no modifi‐
cation regarding the design is allowed. Software products must not be
decompiled and their source codes must not be modified.
● Damaged or faulty products must not be implemented or put into opera‐
tion.
● It must be ensured that the products are installed as specified in the doc‐
umentation.
2.1.2 Areas of Use and Application
The Embedded Terminal IndraControl VEH 30.1 is a PC-based operating and
visualization device that can also fulfill control functionalities, depending on the
application or configuration.
The Embedded Terminal IndraControl VEH 30.1 may only be used
with the accessories and add-on components specified in this doc‐
umentation. Components that are not mentioned explicitly must
neither be mounted nor connected. The same applies for cables
and wires.
An operation may only be carried out in the component configura‐
tions and combinations specified and with the software and firm‐
ware specified in the respective functional description.
The Embedded Terminal IndraControl VEH 30.1 was developed for use in con‐
trol tasks.
Typical areas of application of the IndraControl VEH 30.1 are:
● Handling systems and assembly systems
● Packaging and food processing machines
● Printing machines and paper processing machines
Project Planning Manual |Rexroth IndraControl VEH 30.1 Electric Drives
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|Bosch Rexroth AG 5/68
Important Instructions on Use

● Machine tools
The devices of the type IndraControl VEH 30.1 may only be operated under the
assembly conditions and installation conditions, in the specified position of ap‐
plication and under the specified ambient conditions (temperature, degree of
protection, humidity, EMC etc.) given in this documentation.
2.2 Inappropriate Use
Applications of the Embedded Terminal IndraControl VEH 30.1 that are not
within the specified areas of application or under operating conditions deviating
from the operating conditions and technical data specified in the documentation
are considered as "inappropriate".
The Embedded Terminal IndraControl VEH 30.1 may not be used if
● it is exposed to operating conditions that do not fulfill the ambient condi‐
tions specified. (for example, operation under water, under extreme tem‐
perature fluctuations or extreme maximum temperatures is not allowed).
● Bosch Rexroth has not explicitly released the intended applications.
Please also note the general statements in the general safety-related
guidelines.
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Rexroth IndraControl VEH 30.1 |Project Planning Manual
Important Instructions on Use

3 Safety Instructions for Electric Drives and Controls
3.1 Safety Instructions - General Information
3.1.1 Using the Safety Instructions and Passing them on to Others
Do not attempt to install or commission this device without first reading all doc‐
umentation provided with the product. Read and understand these safety
instructions and all user documentation prior to working with the device. If you
do not have the user documentation for the device, contact your responsible
Bosch Rexroth sales representative. Ask for these documents to be sent im‐
mediately to the person or persons responsible for the safe operation of the
device.
If the device is resold, rented and/or passed on to others in any other form,
these safety instructions must be delivered with the device in the official lan‐
guage of the user's country.
WARNING
Improper use of these devices, failure to follow the safety instructions in
this document or tampering with the product, including disabling of safe‐
ty devices, may result in material damage, bodily harm, electric shock
or even death!
Observe the safety instructions!
3.1.2 How to Employ the Safety Instructions
Read these instructions before initial commissioning of the equipment in order
to eliminate the risk of bodily harm and/or material damage. Follow these safety
instructions at all times.
● Bosch Rexroth AG is not liable for damages resulting from failure to ob‐
serve the warnings provided in this documentation.
● Read the operating, maintenance and safety instructions in your language
before commissioning the machine. If you find that you cannot completely
understand the documentation for your product, please ask your supplier
to clarify.
● Proper and correct transport, storage, assembly and installation, as well
as care in operation and maintenance, are prerequisites for optimal and
safe operation of this device.
● Only assign trained and qualified persons to work with electrical installa‐
tions:
– Only persons who are trained and qualified for the use and operation
of the device may work on this device or within its proximity. The
persons are qualified if they have sufficient knowledge of the assem‐
bly, installation and operation of the product, as well as an under‐
standing of all warnings and precautionary measures noted in these
instructions.
– Furthermore, they must be trained, instructed and qualified to switch
electrical circuits and devices on and off in accordance with technical
safety regulations, to ground them and to mark them according to the
requirements of safe work practices. They must have adequate safe‐
ty equipment and be trained in first aid.
● Only use spare parts and accessories approved by the manufacturer.
Project Planning Manual |Rexroth IndraControl VEH 30.1 Electric Drives
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|Bosch Rexroth AG 7/68
Safety Instructions for Electric Drives and Controls

● Follow all safety regulations and requirements for the specific application
as practiced in the country of use.
● The devices have been designed for installation in industrial machinery.
● The ambient conditions given in the product documentation must be ob‐
served.
● Only use safety-relevant applications that are clearly and explicitly ap‐
proved in the Project Planning Manual. If this is not the case, they are
excluded. Safety-relevant are all such applications which can cause dan‐
ger to persons and material damage.
● The information given in the documentation of the product with regard to
the use of the delivered components contains only examples of applica‐
tions and suggestions.
The machine and installation manufacturer must
– make sure that the delivered components are suited for his individual
application and check the information given in this documentation
with regard to the use of the components,
– make sure that his application complies with the applicable safety
regulations and standards and carry out the required measures,
modifications and complements.
● Commissioning of the delivered components is only permitted once it is
sure that the machine or installation in which they are installed complies
with the national regulations, safety specifications and standards of the
application.
● Operation is only permitted if the national EMC regulations for the appli‐
cation are met.
● The instructions for installation in accordance with EMC requirements can
be found in the section on EMC in the respective documentation (Project
Planning Manuals of components and system).
The machine or installation manufacturer is responsible for compliance
with the limiting values as prescribed in the national regulations.
● Technical data, connection and installation conditions are specified in the
product documentation and must be followed at all times.
National regulations which the user must take into account
● European countries: according to European EN standards
● United States of America (USA):
– National Electrical Code (NEC)
– National Electrical Manufacturers Association (NEMA), as well as
local engineering regulations
– regulations of the National Fire Protection Association (NFPA)
● Canada: Canadian Standards Association (CSA)
● Other countries:
– International Organization for Standardization (ISO)
– International Electrotechnical Commission (IEC)
3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness
The safety instructions describe the following degrees of hazard seriousness.
The degree of hazard seriousness informs about the consequences resulting
from non-compliance with the safety instructions:
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Rexroth IndraControl VEH 30.1 |Project Planning Manual
Safety Instructions for Electric Drives and Controls

Warning symbol Signal word
Degree of hazard serious‐
ness acc. to ANSI Z
535.4-2002
Danger Death or severe bodily harm
will occur.
Warning Death or severe bodily harm
may occur.
Caution
Minor or moderate bodily
harm or material damage
may occur.
Fig.3-1: Hazard classification (according to ANSI Z 535)
3.1.4 Hazards by Improper Use
DANGER
High electric voltage and high working current! Risk of death or severe
bodily injury by electric shock!
Observe the safety instructions!
DANGER
Dangerous movements! Danger to life, severe bodily harm or material
damage by unintentional motor movements!
Observe the safety instructions!
WARNING
High electric voltage because of incorrect connection! Risk of death or
bodily injury by electric shock!
Observe the safety instructions!
WARNING
Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electrical equipment!
Observe the safety instructions!
CAUTION
Hot surfaces on device housing! Danger of injury! Danger of burns!
Observe the safety instructions!
CAUTION
Risk of injury by improper handling! Risk of bodily injury by bruising,
shearing, cutting, hitting or improper handling of pressurized lines!
Observe the safety instructions!
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Safety Instructions for Electric Drives and Controls

CAUTION
Risk of injury by improper handling of batteries!
Observe the safety instructions!
3.2 Instructions with Regard to Specific Dangers
3.2.1 Protection Against Contact with Electrical Parts and Housings
This section concerns devices and drive components with voltages
of more than 50 Volt.
Contact with parts conducting voltages above 50 Volts can cause personal
danger and electric shock. When operating electrical equipment, it is unavoid‐
able that some parts of the devices conduct dangerous voltage.
DANGER
High electrical voltage! Danger to life, electric shock and severe bodily
injury!
● Only those trained and qualified to work with or on electrical equipment
are permitted to operate, maintain and repair this equipment.
● Follow general construction and safety regulations when working on pow‐
er installations.
● Before switching on the device, the equipment grounding conductor must
have been non-detachably connected to all electrical equipment in ac‐
cordance with the connection diagram.
● Do not operate electrical equipment at any time, even for brief measure‐
ments or tests, if the equipment grounding conductor is not permanently
connected to the mounting points of the components provided for this
purpose.
● Before working with electrical parts with voltage potentials higher than
50 V, the device must be disconnected from the mains voltage or power
supply unit. Provide a safeguard to prevent reconnection.
● With electrical drive and filter components, observe the following:
Wait 30 minutes after switching off power to allow capacitors to discharge
before beginning to work. Measure the electric voltage on the capacitors
before beginning to work to make sure that the equipment is safe to touch.
● Never touch the electrical connection points of a component while power
is turned on. Do not remove or plug in connectors when the component
has been powered.
● Install the covers and guards provided with the equipment properly before
switching the device on. Before switching the equipment on, cover and
safeguard live parts safely to prevent contact with those parts.
● A residual-current-operated circuit-breaker or r.c.d. cannot be used for
electric drives! Indirect contact must be prevented by other means, for
example, by an overcurrent protective device according to the relevant
standards.
● Secure built-in devices from direct touching of electrical parts by providing
an external housing, for example a control cabinet.
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Rexroth IndraControl VEH 30.1 |Project Planning Manual
Safety Instructions for Electric Drives and Controls

For electrical drive and filter components with voltages of more than
50 volts, observe the following additional safety instructions.
DANGER
High housing voltage and high leakage current! Risk of death or bodily
injury by electric shock!
● Before switching on, the housings of all electrical equipment and motors
must be connected or grounded with the equipment grounding conductor
to the grounding points. This is also applicable before short tests.
● The equipment grounding conductor of the electrical equipment and the
devices must be non-detachably and permanently connected to the power
supply unit at all times. The leakage current is greater than 3.5 mA.
● Over the total length, use copper wire of a cross section of a minimum of
10 mm2 for this equipment grounding connection!
● Before commissioning, also in trial runs, always attach the equipment
grounding conductor or connect to the ground wire. Otherwise, high vol‐
tages may occur at the housing causing electric shock.
3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage
Protective extra-low voltage is used to allow connecting devices with basic in‐
sulation to extra-low voltage circuits.
All connections and terminals with voltages between 5 and 50 volts at Rexroth
products are PELV systems. 1) It is therefore allowed to connect devices
equipped with basic insulation (such as programming devices, PCs, notebooks,
display units) to these connections and terminals.
WARNING
High electric voltage by incorrect connection! Risk of death or bodily
injury by electric shock!
If extra-low voltage circuits of devices containing voltages and circuits of more
than 50 volts (e.g. the mains connection) are connected to Rexroth products,
the connected extra-low voltage circuits must comply with the requirements for
PELV. 2)
3.2.3 Protection Against Dangerous Movements
Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:
● improper or wrong wiring of cable connections
● incorrect operation of the equipment components
● wrong input of parameters before operation
● malfunction of sensors, encoders and monitoring devices
● defective components
● software or firmware errors
Dangerous movements can occur immediately after equipment is switched on
or even after an unspecified time of trouble-free operation.
1) "Protective Extra-Low Voltage"
2) "Protective Extra-Low Voltage"
Project Planning Manual |Rexroth IndraControl VEH 30.1 Electric Drives
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|Bosch Rexroth AG 11/68
Safety Instructions for Electric Drives and Controls

The monitoring in the drive components will normally be sufficient to avoid faulty
operation in the connected drives. Regarding personal safety, especially the
danger of bodily harm and material damage, this alone cannot be relied upon
to ensure complete safety. Until the integrated monitoring functions become
effective, it must be assumed in any case that faulty drive movements will occur.
The extent of faulty drive movements depends upon the type of control and the
state of operation.
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Safety Instructions for Electric Drives and Controls

DANGER
Dangerous movements! Danger to life, risk of injury, severe bodily harm
or material damage!
● Ensure personal safety by means of qualified and tested higher-level
monitoring devices or measures integrated in the installation.
These measures have to be provided for by the user according to the
specific conditions within the installation and a hazard and fault analysis.
The safety regulations applicable for the installation have to be taken into
consideration. Unintended machine motion or other malfunction is possi‐
ble if safety devices are disabled, bypassed or not activated.
To avoid accidents, bodily harm and/or material damage:
● Keep free and clear of the machine’s range of motion and moving parts.
Possible measures to prevent people from accidentally entering the ma‐
chine’s range of motion:
– use safety fences
– use safety guards
– use protective coverings
– install light curtains or light barriers
● Fences and coverings must be strong enough to resist maximum possible
momentum.
● Mount the emergency stop switch in the immediate reach of the operator.
Verify that the emergency stop works before startup. Don’t operate the
device if the emergency stop is not working.
● Isolate the drive power connection by means of an emergency stop circuit
or use a safety related starting lockout to prevent unintentional start.
● Make sure that the drives are brought to a safe standstill before accessing
or entering the danger zone.
● Additionally secure vertical axes against falling or dropping after switching
off the motor power by, for example:
– mechanically securing the vertical axes,
– adding an external braking/ arrester/ clamping mechanism or
– ensuring sufficient equilibration of the vertical axes.
● The standard equipment motor brake or an external brake controlled di‐
rectly by the drive controller are not sufficient to guarantee personal
safety!
● Disconnect electrical power to the equipment using a master switch and
secure the switch against reconnection for:
– maintenance and repair work
– cleaning of equipment
– long periods of discontinued equipment use
● Prevent the operation of high-frequency, remote control and radio equip‐
ment near electronics circuits and supply leads. If the use of such devices
cannot be avoided, verify the system and the installation for possible mal‐
functions in all possible positions of normal use before initial startup. If
necessary, perform a special electromagnetic compatibility (EMC) test on
the installation.
Project Planning Manual |Rexroth IndraControl VEH 30.1 Electric Drives
and Controls
|Bosch Rexroth AG 13/68
Safety Instructions for Electric Drives and Controls

3.2.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐
ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors
and permanent magnets in motors represent a serious personal danger to
those with heart pacemakers, metal implants and hearing aids.
WARNING
Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electrical equipment!
● Persons with heart pacemakers and metal implants are not permitted to
enter following areas:
– Areas in which electrical equipment and parts are mounted, being
operated or commissioned.
– Areas in which parts of motors with permanent magnets are being
stored, repaired or mounted.
● If it is necessary for somebody with a pacemaker to enter such an area,
a doctor must be consulted prior to doing so. The noise immunity of pres‐
ent or future implanted heart pacemakers differs greatly so that no general
rules can be given.
● Those with metal implants or metal pieces, as well as with hearing aids,
must consult a doctor before they enter the areas described above. Oth‐
erwise health hazards may occur.
3.2.5 Protection Against Contact with Hot Parts
CAUTION
Hot surfaces at motor housings, on drive controllers or chokes! Danger
of injury! Danger of burns!
● Do not touch surfaces of device housings and chokes in the proximity of
heat sources! Danger of burns!
● Do not touch housing surfaces of motors! Danger of burns!
● According to the operating conditions, temperatures can be higher than
60 °C, 140°F during or after operation.
● Before accessing motors after having switched them off, let them cool
down for a sufficiently long time. Cooling down can require up to 140 mi‐
nutes! Roughly estimated, the time required for cooling down is five times
the thermal time constant specified in the Technical Data.
● After switching drive controllers or chokes off, wait 15 minutes to allow
them to cool down before touching them.
● Wear safety gloves or do not work at hot surfaces.
● For certain applications, the manufacturer of the end product, machine or
installation, according to the respective safety regulations, has to take
measures to avoid injuries caused by burns in the end application. These
measures can be, for example: warnings, guards (shielding or barrier),
technical documentation.
3.2.6 Protection During Handling and Mounting
In unfavorable conditions, handling and mounting certain parts and compo‐
nents in an improper way can cause injuries.
14/68 Bosch Rexroth AG | Electric Drives
and Controls
Rexroth IndraControl VEH 30.1 |Project Planning Manual
Safety Instructions for Electric Drives and Controls