Bosch Rexroth IndraControl VPP 21.2 Technical manual

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Project Planning Manual
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics
Rexroth IndraControl VPP 21.2
R911323258
Edition 01

Rexroth IndraControl VPP 21.2
Project Planning Manual
DOK-SUPPL*-VPP*21.2***-PR01-EN-P
RS-d77326f2aae956830a6846a000efe8d1-1-en-US-6
This documentation describes the operator terminal IndraControl VPP 21.2.
Edition Release Date Notes
120-2100-B393-01/EN 02.2008 First 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/
Dep. BRC/EAY2 (MK/MePe)
Dep. BRC/EAP1 (HP/MePe)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revision
Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraControl VPP 21.2 |Project Planning Manual
Copyright
Validity
Published by
Note

Table of Contents
Page
1 System Representation.................................................................................................. 1
1.1 Short Description.................................................................................................................................... 1
1.2 Device Variants ...................................................................................................................................... 1
1.2.1 Overview.............................................................................................................................................. 1
1.2.2 Device Variant BQ............................................................................................................................... 1
1.2.3 Device Variant BP............................................................................................................................... 2
1.3 Operating System................................................................................................................................... 3
1.4 BIOS Settings......................................................................................................................................... 3
1.5 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 Front Panel .......................................................................................................................................... 17
4.2 Technical Data of the Total Device ...................................................................................................... 17
4.3 PC......................................................................................................................................................... 17
4.4 Ambient Conditions............................................................................................................................... 18
4.5 Used Standards.................................................................................................................................... 18
4.6 Wear Parts............................................................................................................................................ 19
4.7 Compatibility Test................................................................................................................................. 20
5 Dimensions.................................................................................................................. 21
5.1 Housing Dimensions ............................................................................................................................ 21
Project Planning Manual |Rexroth IndraControl VPP 21.2 Electric Drives
and Controls
|Bosch Rexroth AG I/III
Table of Contents

Page
5.1.1 Housing Dimensions of the VPP 21 BQ............................................................................................ 21
5.1.2 Housing Dimensions of the VPP 21 BP............................................................................................. 21
5.2 Installation............................................................................................................................................. 22
5.2.1 Installation Notes............................................................................................................................... 22
5.2.2 Installation......................................................................................................................................... 22
6 Display and Operating Components............................................................................ 25
6.1 Display.................................................................................................................................................. 25
6.1.1 General Information........................................................................................................................... 25
6.1.2 Backlight Switch-off........................................................................................................................... 25
General Information........................................................................................................................ 25
Activate Backlight Switch-off:......................................................................................................... 25
6.2 Operator Terminals with Keypad.......................................................................................................... 25
6.2.1 Overview............................................................................................................................................ 25
6.2.2 Navigation Keys................................................................................................................................. 26
6.2.3 Key Block "Machine".......................................................................................................................... 27
6.2.4 Function Key Blocks.......................................................................................................................... 27
6.2.5 Key Blocks "Operation"...................................................................................................................... 27
6.2.6 Numeric Block................................................................................................................................... 28
6.2.7 Block with Cursor and Special Keys.................................................................................................. 28
6.2.8 Key Mouse......................................................................................................................................... 29
6.2.9 Labeling the Front Panel................................................................................................................... 29
6.2.10 Keyboard Controller........................................................................................................................... 30
General Information........................................................................................................................ 30
Transmission of the Key Codes...................................................................................................... 30
START, STOP, E-STOP................................................................................................................. 34
6.3 Operator Terminal with Touch Screen.................................................................................................. 35
6.3.1 Overview............................................................................................................................................ 35
6.3.2 Navigation Keys................................................................................................................................. 36
6.3.3 Key Block "Machine".......................................................................................................................... 36
6.3.4 Touch Screen Controller.................................................................................................................... 37
7 VPP 21-Box................................................................................................................. 39
7.1 Connector Panel................................................................................................................................... 39
7.2 Operating Display and Error Display.................................................................................................... 40
7.3 Interfaces.............................................................................................................................................. 41
7.3.1 General Information........................................................................................................................... 41
7.3.2 Overview............................................................................................................................................ 41
7.3.3 Serial Interface COM1 ...................................................................................................................... 41
7.3.4 Settings of the Serial Interface.......................................................................................................... 42
7.3.5 USB Interface.................................................................................................................................... 42
7.3.6 Ethernet Interfaces............................................................................................................................ 43
7.3.7 PROFIBUS DP (Optional)................................................................................................................. 44
7.3.8 CAN (Optional).................................................................................................................................. 44
7.3.9 VGA Interface.................................................................................................................................... 45
II/III Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraControl VPP 21.2 |Project Planning Manual
Table of Contents

Page
7.3.10 Combined Keyboard/Mouse Interface............................................................................................... 46
7.3.11 Mouse Interface................................................................................................................................. 47
7.3.12 Power Supply, Digital Outputs, Ready Contact................................................................................. 47
Overview......................................................................................................................................... 47
Pin 1 and Pin 2: 24 VDC Supply..................................................................................................... 48
Pin 3 and Pin 4: Fan Supply........................................................................................................... 50
Pin 5 and Pin 6: Digital Outputs 1 and 2......................................................................................... 51
Pin 7 and Pin 8: Ready Contact..................................................................................................... 51
7.3.13 Hard Disk........................................................................................................................................... 51
7.3.14 Compact Flash Card.......................................................................................................................... 52
8 Maintenance and Installation....................................................................................... 53
8.1 General................................................................................................................................................. 53
8.2 Hard Disc.............................................................................................................................................. 53
8.3 Display.................................................................................................................................................. 54
8.4 Buffer Battery........................................................................................................................................ 54
8.5 Extension cards.................................................................................................................................... 55
8.5.1 General Notes................................................................................................................................... 55
8.5.2 PCI Card Installation.......................................................................................................................... 56
9 Disposal and Environmental Protection....................................................................... 59
9.1 Disposal................................................................................................................................................ 59
9.1.1 Products............................................................................................................................................ 59
9.1.2 Packaging Materials.......................................................................................................................... 59
9.2 Environmental Protection...................................................................................................................... 59
9.2.1 No Release of Hazardous Substances.............................................................................................. 59
9.2.2 Materials Contained in the Products.................................................................................................. 59
Electronic Devices.......................................................................................................................... 59
Motors............................................................................................................................................. 59
9.2.3 Recycling........................................................................................................................................... 60
10 Ordering Information.................................................................................................... 61
10.1 Type Code............................................................................................................................................ 61
10.2 Accessories.......................................................................................................................................... 62
11 Service and Support.................................................................................................... 63
11.1 Helpdesk............................................................................................................................................... 63
11.2 Service Hotline...................................................................................................................................... 63
11.3 Internet.................................................................................................................................................. 63
11.4 Helpful Information................................................................................................................................ 63
Index............................................................................................................................ 65
Project Planning Manual |Rexroth IndraControl VPP 21.2 Electric Drives
and Controls
|Bosch Rexroth AG III/III
Table of Contents

Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraControl VPP 21.2 |Project Planning Manual

1 System Representation
1.1 Short Description
The hand-held terminal VPP 21.2 is a computer-based machine operator ter‐
minal consisting of
● an enclosed plastic housing (degree of protection, total device: IP 40, de‐
gree of protection, front panel: IP 64)
● a TFT display with and without touch screen,
● depending on the variant, different display and operating components and
● an integrated efficient industrial PC.
VPP 21-type operator terminals are provided for bracket mounting. Because of
its design they are predestinated as "operator panel control". For this, special
buttons (control ON, control OFF, E-STOP) are mounted in the housing. On the
left and right three navigation keys are integrated. To communicate with exter‐
nal components standardized field bus systems are used.
The restricted extensible computer unit with power supply unit and field bus
connection is located in the so-called VPP 21 box installed in the plastic housing
of the VPP 21.
1.2 Device Variants
1.2.1 Overview
The hand-held terminals VPP 21 are available as device variant BQ (with key‐
pad) or as device variant BP ( with touch screen).
1.2.2 Device Variant BQ
This variant provides – below the 14" TFT display - for a keypad with function
keys, a numeric block, cursor keys and further keys to be labeled by slide-in
strips.
Project Planning Manual |Rexroth IndraControl VPP 21.2 Electric Drives
and Controls
|Bosch Rexroth AG 1/65
System Representation

Fig.1-1: Front panel – device variant BQ
1.2.3 Device Variant BP
In contrast, the VPP 21.2 BP has no keypad, but a touch screen.
The front panel with touch screen allows to operate the application software via
the touch-sensitive surface of the display without keyboard and mouse.
2/65 Bosch Rexroth AG |Electric Drives
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Rexroth IndraControl VPP 21.2 |Project Planning Manual
System Representation

Fig.1-2: Front panel – device variant BP
1.3 Operating System
For license reasons the hand-held terminals VPP 21 are only delivered with
already installed operating system. At present, Windows XP is used.
The delivered operating systems may only be used in the industrial environ‐
ment. Use in the office area, e. g. on a secretary's computer, is not allowed.
1.4 BIOS Settings
When leaving the factory, the BIOS settings have been made according to the
respective device variant.
1.5 Commissioning
Mount the device properly (for this, see chapter chapter 5.2 "Installation" on
page 22). Then, connect the device to the power supply ( 24 V) and, if re‐
quired, to the network.
Project Planning Manual |Rexroth IndraControl VPP 21.2 Electric Drives
and Controls
|Bosch Rexroth AG 3/65
System Representation

Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraControl VPP 21.2 |Project Planning Manual

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 operating safety and reliability.
WARNING
Physical and property damage due to the inappropriate use of products!
The products are designed for their use within the industrial environment and
may therefore only be used for the intended purpose. If the use is inappropriate,
situations causing physical damage as well as property damage can occur.
Rexroth disclaims as manufacturer any warranty, liability or for
damages occurring due to inappropriate use of the products. Fur‐
thermore, Rexroth is not paying any compensation. The user is
responsible for any risks resulting from the products not being used
as intended.
Before using Rexroth products, the following pre-requisites must be fulfilled to
ensure an appropriate use of the products:
● Anyone handling one of the Rexroth products in any way has to read and
understand the respective safety instructions as well as the instructions
on the appropriate use.
● Hardware products have to remain in their original state, in other words,
no modification regarding the design are allowed. Software products may
not be decompiled and their source codes may not be modified.
● Damaged or faulty products are not to be implemented or put into opera‐
tion.
● It is to be ensured that the corresponding products are installed according
to the specifications of the documentation.
2.1.2 Areas of Use and Application
hand-held terminal VPP 21.2 of Rexroth are machine operating fields devel‐
oped for control tasks. Typical areas of application of the hand-held terminal
VPP 21.2 are:
● Lathes
● Milling machines
● Processing machine
It can be necessary to connect additional sensors and actuators to control and
monitor the hand-held terminal VPP 21.2.
The hand-held terminal VPP 21.2may only be used with the acces‐
sories and add-on components specified in this documentation.
Components that are not named explicitly may neither be mounted
nor connected. Same is applicable for cables and wires.
Operation my only be carried out in the configurations and combi‐
nations of the components specified and with the software and
firmware determined in the respective functional description.
Each drive control device has to be programmed before commissioning so that
the motor carries out the specific functions for the application.
Project Planning Manual |Rexroth IndraControl VPP 21.2 Electric Drives
and Controls
|Bosch Rexroth AG 5/65
Important Instructions on Use

The hand-held terminal VPP 21.2 were developed for the single axis as well as
for the multiple axes drive tasks and control tasks.
For the application-specific use of the hand-held terminal VPP 21.2, device
types with a different drive performance and different interfaces are available.
For the application-specific use of the machine operating terminals and visual‐
ization terminals , device types with a different equipment and different inter‐
faces are available.
Typical areas of application of the hand-held terminal VPP 21.2 are:
● [Handling systems and assembly systems]
● [Packaging and processing machines]
● [Printing machines and paper processing machines]
● [Machine tools]
hand-held terminal The VPP 21.2 may only be operated under the assembly
conditions and installation conditions, in the specified position of application
and under the specified ambient conditions (temperature, degree of protection,
humidity, EMC etc.) given in this documentation.
2.2 Inappropriate Use
The application of hand-held terminal that are VPP 21.2 not within the specified
areas of application or under operating conditions deviating from the operating
conditions and technical data specified in the documentation is considered as
"inappropriate".
hand-held terminal VPP 21.2 may not be used if ...
● they are exposed to operating conditions that do not fulfill the ambient
conditions specified. Operation under water, under extreme temperature
fluctuations or extreme maximum temperatures is not allowed for exam‐
ple:.
● the Rexroth applications that are not released explicitly. Please note the
general statements in the general safety instructions!
6/65 Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraControl VPP 21.2 |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 VPP 21.2 Electric Drives
and Controls
|Bosch Rexroth AG 7/65
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:
8/65 Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraControl VPP 21.2 |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!
Project Planning Manual |Rexroth IndraControl VPP 21.2 Electric Drives
and Controls
|Bosch Rexroth AG 9/65
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.
10/65 Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraControl VPP 21.2 |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 VPP 21.2 Electric Drives
and Controls
|Bosch Rexroth AG 11/65
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.
12/65 Bosch Rexroth AG |Electric Drives
and Controls
Rexroth IndraControl VPP 21.2 |Project Planning Manual
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
machine’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 VPP 21.2 Electric Drives
and Controls
|Bosch Rexroth AG 13/65
Safety Instructions for Electric Drives and Controls