Bosch Rexroth VCH 08.1 User manual

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

Rexroth IndraControl
VCH 08.1
Hand-held Terminal
Project Planning Manual
DOK-SUPPL*-VCH*08.1***-PR02-EN-P
RS-9dbe22ee76daf77d0a6846a0018e2a10-2-en-US-4
This documentation describes the IndraControl VCH 08.1 Hand-held Termi‐
nals.
Edition Release Date Notes
120-2100-B391-01/EN 10/07 First edition
120-2100-B391-02/EN 09/10 Revised edition
Copyright © Bosch Rexroth AG, 2007
Copying this document, giving it to others and the use or communication of the
contents thereof without express authority, are forbidden. Offenders are liable
for the payment of damages. All rights are reserved in the event of the grant of
a patent or the registration of a utility model or design (DIN 34-1).
Validity The specified data is for product description purposes only and may not be
deemed to be 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.
Published by Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr am Main, Germany
Phone [phone] ■ Fax [phone]
http://www.boschrexroth.com/
Development Compact HMI EH (CS)
Note This documentation 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 DOK-SUPPL*-VCH*08.1***-PR02-EN-P
Rexroth IndraControl VCH 08.1 Hand-held Terminal

Table of Contents
Page
1 System Presentation...................................................................................................... 5
1.1 Overview................................................................................................................................................. 5
1.2 Device Variants....................................................................................................................................... 5
1.3 Housing................................................................................................................................................... 6
1.4 Foil Keyboard.......................................................................................................................................... 6
1.5 Front Panel of the IndraControl VCH 08.1.............................................................................................. 6
1.6 Connection to the Control....................................................................................................................... 6
1.7 Operating System................................................................................................................................... 8
1.8 Commissioning....................................................................................................................................... 8
2 Important Instructions on Use, Target Group and Purpose of the Document.............. 11
2.1 General Information.............................................................................................................................. 11
2.2 Purpose of the Document..................................................................................................................... 11
2.3 Target Group, Pre-conditions............................................................................................................... 11
2.4 Appropriate Use ................................................................................................................................... 12
2.4.1 Introduction........................................................................................................................................ 12
2.4.2 Areas of Use and Application............................................................................................................ 13
2.5 Inappropriate Use................................................................................................................................. 14
3 Safety Instructions for Electric Drives and Controls..................................................... 15
3.1 Definitions of Terms.............................................................................................................................. 15
3.2 General Information.............................................................................................................................. 16
3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 16
3.2.2 Requirements for Safe Use............................................................................................................... 16
3.2.3 Hazards by Improper Use.................................................................................................................. 17
3.3 Instructions with Regard to Specific Dangers....................................................................................... 19
3.3.1 Protection Against Contact with Electrical Parts and Housings......................................................... 19
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 20
3.3.3 Protection Against Dangerous Movements....................................................................................... 20
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 22
3.3.5 Protection Against Contact With Hot Parts........................................................................................ 22
3.3.6 Protection During Handling and Mounting......................................................................................... 23
3.3.7 Battery Safety.................................................................................................................................... 23
3.3.8 Protection Against Pressurized Systems........................................................................................... 24
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 24
4 Technical Data............................................................................................................. 27
4.1 IndraControl VCH 08.1......................................................................................................................... 27
4.2 Keyboard, Housing, Display................................................................................................................. 27
4.3 Stop Button and Emergency Stop Button............................................................................................. 28
4.4 Enabling Button.................................................................................................................................... 28
4.5 IndraControl VAC 30.2 Connection Module.......................................................................................... 29
4.6 IndraControl VAC 31.1 Connection Module.......................................................................................... 29
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Table of Contents

Page
4.7 Ambient Conditions............................................................................................................................... 30
4.8 Accessories.......................................................................................................................................... 30
4.9 Coding ................................................................................................................................................. 30
4.10 Weight................................................................................................................................................... 31
4.11 Used Standards.................................................................................................................................... 31
4.12 Directives.............................................................................................................................................. 34
4.12.1 General Information........................................................................................................................... 34
4.12.2 European Union Directives................................................................................................................ 34
4.12.3 Machinery Safety............................................................................................................................... 35
4.13 Further Information on the Machinery Directive (MD)........................................................................... 37
4.14 Electromagnetic Compatibility (EMC)................................................................................................... 43
4.14.1 General Information........................................................................................................................... 43
4.14.2 Electromagnetic environment – interference sources, interference sinks and coupling paths.......... 44
4.14.3 EMC Measures.................................................................................................................................. 46
4.14.4 EMC Measures IndraControl VCH 08.1............................................................................................ 49
4.15 EC Declaration of Conformity............................................................................................................... 51
4.16 Type-Examination Certificate................................................................................................................ 51
4.17 UL/CSA Certified.................................................................................................................................. 51
4.18 Compatibility Test................................................................................................................................. 52
5 Dimensions.................................................................................................................. 53
5.1 Housing Dimensions of the IndraControl VCH 08.1............................................................................. 53
5.2 Housing and Mounting Dimensions of the IndraControl VAC Connection Module............................... 54
5.3 Dimensions of the VAS 01.1 Wall Holder ............................................................................................ 57
6 Display and Operating Components............................................................................ 59
6.1 Operating Components ........................................................................................................................ 59
6.1.1 Overview............................................................................................................................................ 59
6.1.2 Housing of the IndraControl VCH 08.1.............................................................................................. 59
Overview......................................................................................................................................... 59
Ergonomics..................................................................................................................................... 60
6.1.3 Foil Keyboard.................................................................................................................................... 61
Key PositionIndraControl VCH 08.1............................................................................................... 61
6.1.4 Safety Operating Elements................................................................................................................ 61
Safety Concept............................................................................................................................... 61
6.1.5 Optional Operating Elements............................................................................................................ 62
Additional components................................................................................................................... 62
Override Potentiometer.................................................................................................................. 62
Electronic Handwheel..................................................................................................................... 62
6.2 Display.................................................................................................................................................. 63
6.2.1 Overview............................................................................................................................................ 63
6.2.2 Contrast Setting................................................................................................................................. 63
6.3 Attributes .............................................................................................................................................. 63
6.4 Fonts..................................................................................................................................................... 64
6.5 Keyboard.............................................................................................................................................. 64
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Table of Contents

Page
6.5.1 Overview............................................................................................................................................ 64
6.5.2 Editing Keys....................................................................................................................................... 64
6.5.3 Function Keys.................................................................................................................................... 64
6.5.4 Shift key............................................................................................................................................. 65
6.5.5 Navigation Keys................................................................................................................................. 65
6.5.6 Special keys...................................................................................................................................... 65
7 Pin Assignments of the IndraControl VCH 08.1........................................................... 67
7.1 Laying the Cables in the Cable Chamber............................................................................................. 67
7.1.1 Image of the Cable Chamber............................................................................................................ 67
7.1.2 Laying the Cables.............................................................................................................................. 67
7.2 Emergency Stop Button and Gray Stop Button.................................................................................... 69
7.3 Enabling Button ................................................................................................................................... 73
7.3.1 General Information........................................................................................................................... 73
7.3.2 Enabling Function.............................................................................................................................. 73
7.3.3 Functioning........................................................................................................................................ 74
7.3.4 Enabling............................................................................................................................................. 74
7.3.5 Panic.................................................................................................................................................. 75
7.3.6 Foreseeable Misuse of the Enabling Switch...................................................................................... 76
7.4 Connection of the IndraControl VCH 08.1 via the IndraControl VAC 30.2/31.1 Connection Module....
76
7.4.1 Overview and Important Notes ......................................................................................................... 76
7.4.2 Pin Assignment of the IndraControl VAC 30.2/31.1 Connection Module.......................................... 78
7.4.3 X1: DC 24 V Voltage Supply ............................................................................................................ 79
7.4.4 X2.1: STOP Button............................................................................................................................ 82
Pin assignment............................................................................................................................... 82
7.4.5 X2.1: Emergency Stop Button........................................................................................................... 82
Pin assignment............................................................................................................................... 82
7.4.6 X2.2: Enabling Button........................................................................................................................ 82
Pin assignment............................................................................................................................... 82
Connection Examples of the Enabling Button................................................................................ 83
7.4.7 X3: Ethernet Interface ....................................................................................................................... 85
7.5 Personality Function............................................................................................................................. 85
8 Maintenance and Installation....................................................................................... 89
8.1 General Information.............................................................................................................................. 89
8.2 LCD Display.......................................................................................................................................... 89
8.3 Maintenance of the IndraControl VCH 08.1.......................................................................................... 89
9 Software....................................................................................................................... 91
9.1 Overview............................................................................................................................................... 91
9.2 Starting IndraControl VCH 08.1............................................................................................................ 91
9.2.1 General Information........................................................................................................................... 91
9.2.2 StartUp Application............................................................................................................................ 93
9.2.3 Customer Application........................................................................................................................ 94
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Table of Contents

Page
9.2.4 Service Dialog................................................................................................................................... 94
9.2.5 Config Tool........................................................................................................................................ 95
9.2.6 Rexroth Settings................................................................................................................................ 95
9.2.7 Basic Settings.................................................................................................................................... 97
9.3 Evaluating Commands of the Operating Elements............................................................................... 98
9.3.1 General Information........................................................................................................................... 98
9.3.2 Evaluation of the Operating Status in the Control............................................................................. 98
9.4 Remote Software ActiveSync............................................................................................................. 100
9.5 Operating Notes for the IndraControl VCH 08.1................................................................................. 100
9.5.1 General information......................................................................................................................... 100
9.5.2 Setting Data and Time..................................................................................................................... 100
9.5.3 Configuration Tool (Config Tool)..................................................................................................... 100
General Information...................................................................................................................... 100
Calibration Potentiometer............................................................................................................. 101
Display Settings............................................................................................................................ 101
Zero Point Setting of the Handwheel ........................................................................................... 101
Restart Options (Start-up)............................................................................................................ 102
System Update............................................................................................................................. 102
Version Information...................................................................................................................... 103
Testing the Keyboard................................................................................................................... 104
9.5.4 Saving Files..................................................................................................................................... 104
9.5.5 File Transmission............................................................................................................................ 104
10 Environmental Protection and Disposal .................................................................... 105
10.1 Environmental Protection.................................................................................................................... 105
10.2 Disposal.............................................................................................................................................. 105
11 Ordering Information.................................................................................................. 107
11.1 Type Designation Code...................................................................................................................... 107
11.1.1 General Information......................................................................................................................... 107
11.1.2 IndraControl VCH 08.1.................................................................................................................... 107
11.1.3 IndraControl VCH 08.1 (Special Device)......................................................................................... 108
11.1.4 IndraControl VAC 30.2.................................................................................................................... 108
11.1.5 IndraControl VAC 31.1.................................................................................................................... 109
11.2 Accessories........................................................................................................................................ 109
11.2.1 Wall Holder...................................................................................................................................... 109
11.3 Spare Parts......................................................................................................................................... 109
11.3.1 Connecting Cables.......................................................................................................................... 109
12 Service and Support.................................................................................................. 111
Index.......................................................................................................................... 113
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Table of Contents

1 System Presentation
1.1 Overview
The Hand-held Terminal IndraControl VCH 08.1 is a portable operator and vis‐
ualization device in robust design with Windows CE compatible electronics. The
Hand-held Terminal IndraControl VCH 08.1 is equipped optimally for different
applications due to the use of a powerful processor and the Ethernet interface,
see also chapter 2.4 "Appropriate Use " on page 12.
Rotating mass storage devices, floppy-disk drives and hard-disk drives are not
suitable for harsh operating environments. Therefore the IndraControl VCH
08.1 provides FLASH and RAM memories.
IndraControl VCH 08.1 provides a Windows CE platform. With the VI Composer
applicatons can be added to this platform.
Optional operating and control elements allow to adapt the IndraControl VCH
08.1 to the particular use case.
The IndraControl VCH 08.1 is suitable for the following application ranges:
● Operation and visualization of IndraLogic, IndraMotion MLC, IndraMotion
MTX.
● Configuration of machines and installations.
● Operation and diagnostics of extendend handling installations.
● Visualization of simple operating fields and assembly lines.
E.g. the "automatic" operation mode is available in normal operation modes.
Test runs, configuring, teaching and further options are available in semi-au‐
tomatic or manual special operation modes.
An enabling button and an emergency stop button serve as safety functions on
the IndraControl VCH 08.1.
The machine manufacturer is responsible for the selection of a suitable hand-
held terminal, the wiring of safety components, and the projecting of possible
additional options, based on the risk and hazard analysis.
1.2 Device Variants
The Hand-held Terminals IndraControl VCH 08.1 are available in different var‐
iants.
Device Optional elements Safety Parts number
VCH08.1EAB-064ET-
A1D-064-DS-E4-PW
Handwheel, 16-stage over‐
ride
Black-gray stop button, ena‐
bling button
R911171955
VCH08.1EAB-064ET-
A1D-064-CS-E4-PW
16-stage override Black-gray stop button, ena‐
bling button
R911171956
VCH08.1EAB-064ET-
A1D-064-CS-E2-PW
16-stage override, short ex‐
tension cable
Black-gray stop button, ena‐
bling button
R911171057
VCH08.1EAB-064ET-
A1D-064-FS-B2-PW
16-stage override, short ex‐
tension cable
Red-yellow emergency stop
button, enabling button
R911172138
Fig.1-1: Device Variants IndraControl VCH 08.1
For further information on "Selection of technical safety", please refer to the
sections on the new Machinery Directive in chapter 4 "Technical Data" on page
27.
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System Presentation

1.3 Housing
The vibration and shock resistant housing consists of low-inflammable material
(UL 94-V0). The housing is resistant to impact, water, detergents (alcohol and
tensides), oil, cutting oil (drilling oil), grease, and lubricants. The double panel
and extremely robust housing was tested on free fall onto industrial floor (height
1.5 m).
1.4 Foil Keyboard
The keypad consists of a chemical resistant polyester foil with embossed keys.
1.5 Front Panel of the IndraControl VCH 08.1
① Installation point for override potentiometer
② Installation point for electronic handwheel
③ Emergency stop button, 2-circuit, or stop button
④ Foil Keyboard
⑤ Display
Fig.1-2: Front view of the IndraControl VCH 08.1
1.6 Connection to the Control
The IndraControl VCH 08.1 hand-held terminal is connected to the control via
a connection module in front panel mounting. At the front side a 17-pin female
connector allows the comfortable connection of a IndraControl VCH 08.1. All
clamps for fix wiring to the control are located on the rear side of the connection
module in the control cabinet.
Depending on the used safety component on the IndraControl VCH 08.1, two
different connection modules (see the following table) are available.
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System Presentation

Connection Module IndraCon‐
trol VAC 30.2
Connection Module IndraCon‐
trol VAC 31.1
For hand-held terminals with stop button
●VCH08.1EAB-064ET-A1D-064-DS-
E4-PW
● VCH08.1EAB-064ET-A1D-064-CS-
E4-PW
● VCH08.1EAB-064ET-A1D-064-CS-
E2-PW
For hand-held terminals with red-yellow
emergency stop button
●VCH08.1EAB-064ET-A1D-064-FS-
B2-PW
The connection module VAC 30.2 for
hand-held terminals with stop button is
equipped with a fine thread screwed plug
on the front side. The integrated "automat‐
ic stop button jumpering" allows to loop in
the hand-held terminal into the safety cir‐
cuits of the running machine without acci‐
dental shutdown of the machine.
Hand-held terminals with red-yellow emer‐
gency stop buttons may be only looped in
safety circuits if the plant is in safe state or
if a certified jumpering mechanism is avail‐
able. The connection module VAC 31.1 is
equipped for such devices with a bayonet
ending with additional short-circuit con‐
nector. The hand-held terminal may be
only connected if the plant is in safe state.
Plugging or unplugging a hand-held termi‐
nal during the operation would shut down
the plant immediately.
Fig.1-3: Connection modules VAC 30.2 and VAC 31.1
Fig.1-4: Front view: IndraControl VAC 30.2
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System Presentation

1.7 Operating System
For license reasons IndraControl VCH 08.1 are only delivered with already in‐
stalled operating system. For further information about the operating system,
please refer to chapter 9 "Software" on page 91.
1.8 Commissioning
Mount the IndraControl VAC 30.1 connection module according to the specifi‐
cations in chapter "Dimensions". After this connect the connection module to
the following components:
● Voltage supply
● Stop circuit and emergency stop circuit
● Enabling circuit
● Network
Before commissioning the IndraControl VCH 08.1 the operator has to assure
that the plant, especially the safety devices, are in a proper state.
Shutdown of the plant due to connecting a In‐
draControl VCH 08.1 with pressed stop button
or emergency stop button.
NOTICE
Before putting the IndraControl VCH 08.1 into operation do observe that the
STOP button or emergency stop button is not pressed.
For connecting the IndraControl VCH 08.1 put the connector without effort to
the flange of the VAC connection module. Observe the latch position of the
connection. Older connecting cables with angled plug, are fitted in a 45° angle
to the horizontal. Only if the connector snaps in properly, the correct position is
reached. Now turn the knurled nut with slight pressure on the flange. Devices
with red-yellow emergency stop button are equipped with a bayonet connector
and snap in automatically.
Loss of specified degree of protection due to
incorrect connection of contacts.
NOTICE
While the connector is screwed on a VAC connection module, a relay activates
the stop button. In this way the IndraControl VCH 08.1 is supplied with voltage.
Screw the knurled nut as far as the rubber seal is completely covered and the
end position is reached to ensure the optimal connection of the contacts and
to achieve the specified degree of protection.
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System Presentation

Possible shutdown of the plant due to not con‐
nected short-circuit connector or not connec‐
ted device.
NOTICE
The emergency stop circuits of the VAC 31.1 connection module are jumpered
via the short-circuit connector. To connect the IndraControl VEH 30.2 or VCH
08.1 to the control, it has to be disconnected. If neither the short-circuit con‐
nector nor a device are plugged, the emergency stop circuits are open. The
machine/plant manufacturer must ensure that the plant does not shut down
unintentionally in such cases. The plant has to be shutdown for connecting or
disconnecting the hand-held terminal, if applicable. Devices with red-yellow
emergency stop button are equipped with a bayonet ending and must snap in
properly when plugged.
Verify all three positions of the enabling button from both sides for correct func‐
tion during commissioning of the IndraControl VCH 08.1 and regularly during
routine operation.
Verify the stop button or emergency stop button for correct function in safe state
of the plant of the IndraControl VCH 08.1 in regular intervals and during com‐
missioning.
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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System Presentation

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2 Important Instructions on Use, Target Group and Pur‐
pose of the Document
2.1 General Information
Read the present chapter as well as chapter 3 "Safety Instructions for Electric
Drives and Controls" on page 15 before taking the product into operation.
Read the information carefully. For any questions, please contact your sales
representative or the Bosch Rexroth Support, see chapter 12 "Service and
Support" on page 111.
This document contains all specifications required by machinery directive
2006/42/EC.
In terms of the machinery, the present project planning manual
serves as assembly instructions.
2.2 Purpose of the Document
This documentation describes the Hand-held Terminals IndraControl VCH
08.1.
2.3 Target Group, Pre-conditions
This document is intended for the following persons with corresponding pre‐
conditions:
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Important Instructions on Use, Target Group and Purpose of the Document

Target group Prerequisite knowledge and ability
Project engineer Technical basic education (advanced
technical education, engineering degree
or corresponding professional experi‐
ence),
Knowledge about:
●the method of operation of a PLC
● safety regulations
● the application
Start-up technician Technical basic education (advanced
technical education, engineering degree
or corresponding professional experi‐
ence),
Knowledge about:
●safety regulations
● the method of operation of the ma‐
chine or system
● fundamental functions of the appli‐
cation
● system analysis and troubleshooting
● the setting options at the operating
devices
Service technician Technical basic education (advanced
technical education, engineering degree
or corresponding professional experi‐
ence),
Knowledge about:
●the method of operation of a PLC
● safety regulations
● the method of operation of the ma‐
chine or system
● Diagnostic Configurations
● systematic error analysis and trou‐
bleshooting
Fig.2-1: Target group, prerequisites
2.4 Appropriate Use
2.4.1 Introduction
Rexroth products represent state-of-the-art developments and manufacturing.
They are tested prior to delivery to ensure operational safety and reliability.
Physical injury and material damage might re‐
sult from an inappropriate use of the products!
WARNING
The products are designed for the use in an industrial environment and may
therefore only be used for the intended purpose. If they are not used as inten‐
ded, situations causing personal injury as well as material damage can occur.
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Important Instructions on Use, Target Group and Purpose of the Document

Rexroth disclaims as manufacturer any warranty, liability or dam‐
ages occurring due to inappropriate use of the products. Further‐
more, Bosch 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.
2.4.2 Areas of Use and Application
The IndraControl VCH 08.1 Hand-held Terminal is a PC-based operating and
visualization device that can also fulfill control functionalities, depending on the
application or configuration.
Danger of destruction of the device if not ex‐
pressly stated accessories, add-on compo‐
nents and other components, cables, conduits,
software and firmware is used.
NOTICE
The IndraControl VCH 08.1 Hand-held Terminal may exclusively be used with
the accessories and add-on components specified in this documentation. Com‐
ponents not named expressly mentioned must neither be mounted nor con‐
nected. The same applies to cables and conduits.
The products may only be operated with the expressly stated configurations
and component combinations as well as with the software and firmware which
is given and specified in the respective functional description.
The IndraControl VCH 08.1 Hand-held Terminal was developed for control
tasks.
Typical areas of application of the Hand-held Terminal IndraControl VCH
08.1 are:
● Handling systems and assembly systems
● Packaging and food processing machines
● Printing machines and paper processing machines
● Machine tools
The devices of the IndraControl VCH 08.1 design 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.
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Important Instructions on Use, Target Group and Purpose of the Document

2.5 Inappropriate Use
The application of Hand-held TerminalIndraControl VCH 08.1 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 is
considered as "inappropriate".
Hand-held TerminalIndraControl VCH 08.1 must not be used if
● it is exposed to operating conditions that do not fulfill the ambient condi‐
tions specified. For instance, operation under water, in case of extreme
variations of temperature or in extreme maximum temperatures is not al‐
lowed.
● Bosch Rexroth has not explicitly released the intended applications. It is
imperative that you also note the information given in the general notes
on safety!
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Important Instructions on Use, Target Group and Purpose of the Document

3 Safety Instructions for Electric Drives and Controls
3.1 Definitions of Terms
Application Documentation Application documentation comprises the entire documentation used to inform
the user of the product about the use and safety-relevant features for config‐
uring, integrating, installing, mounting, commissioning, operating, maintaining,
repairing and decommissioning the product. The following terms are also used
for this kind of documentation: User Guide, Operation Manual, Commissioning
Manual, Instruction Manual, Project Planning Manual, Application Manual, etc.
Component A component is a combination of elements with a specified function, which are
part of a piece of equipment, device or system. Components of the electric drive
and control system are, for example, supply units, drive controllers, mains
choke, mains filter, motors, cables, etc.
Control System A control system comprises several interconnected control components placed
on the market as a single functional unit.
Device A device is a finished product with a defined function, intended for users and
placed on the market as an individual piece of merchandise.
Electrical Equipment Electrical equipment encompasses all devices used to generate, convert, trans‐
mit, distribute or apply electrical energy, such as electric motors, transformers,
switching devices, cables, lines, power-consuming devices, circuit board as‐
semblies, plug-in units, control cabinets, etc.
Electric Drive System An electric drive system comprises all components from mains supply to motor
shaft; this includes, for example, electric motor(s), motor encoder(s), supply
units and drive controllers, as well as auxiliary and additional components, such
as mains filter, mains choke and the corresponding lines and cables.
Installation An installation consists of several devices or systems interconnected for a de‐
fined purpose and on a defined site which, however, are not intended to be
placed on the market as a single functional unit.
Machine A machine is the entirety of interconnected parts or units at least one of which
is movable. Thus, a machine consists of the appropriate machine drive ele‐
ments, as well as control and power circuits, which have been assembled for
a specific application. A machine is, for example, intended for processing,
treatment, movement or packaging of a material. The term "machine" also cov‐
ers a combination of machines which are arranged and controlled in such a way
that they function as a unified whole.
Manufacturer The manufacturer is an individual or legal entity bearing responsibility for the
design and manufacture of a product which is placed on the market in the in‐
dividual's or legal entity's name. The manufacturer can use finished products,
finished parts or finished elements, or contract out work to subcontractors.
However, the manufacturer must always have overall control and possess the
required authority to take responsibility for the product.
Product Examples of a product: Device, component, part, system, software, firmware,
among other things.
Project Planning Manual A project planning manual is part of the application documentation used to
support the sizing and planning of systems, machines or installations.
Qualified Persons In terms of this application documentation, qualified persons are those persons
who are familiar with the installation, mounting, commissioning and operation
of the components of the electric drive and control system, as well as with the
hazards this implies, and who possess the qualifications their work requires. To
comply with these qualifications, it is necessary, among other things,
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1) to be trained, instructed or authorized to switch electric circuits and devices
safely on and off, to ground them and to mark them
2) to be trained or instructed to maintain and use adequate safety equipment
3) to attend a course of instruction in first aid
User A user is a person installing, commissioning or using a product which has been
placed on the market.
3.2 General Information
3.2.1 Using the Safety Instructions and Passing Them on to Others
Do not attempt to install and operate the components of the electric drive and
control system without first reading all documentation provided with the product.
Read and understand these safety instructions and all user documentation prior
to working with these components. If you do not have the user documentation
for the components, contact your responsible Bosch Rexroth sales partner. Ask
for these documents to be sent immediately to the person or persons respon‐
sible for the safe operation of the components.
If the component is resold, rented and/or passed on to others in any other form,
these safety instructions must be delivered with the component in the official
language of the user's country.
Improper use of these components, failure to follow the safety instructions in
this document or tampering with the product, including disabling of safety de‐
vices, could result in property damage, injury, electric shock or even death.
3.2.2 Requirements for Safe Use
Read the following instructions before initial commissioning of the components
of the electric drive and control system in order to eliminate the risk of injury
and/or property damage. You must follow these safety instructions.
● Bosch Rexroth is not liable for damages resulting from failure to observe
the safety instructions.
● Read the operating, maintenance and safety instructions in your language
before commissioning. If you find that you cannot completely understand
the application documentation in the available language, please ask your
supplier to clarify.
● Proper and correct transport, storage, mounting and installation, as well
as care in operation and maintenance, are prerequisites for optimal and
safe operation of the component.
● Only qualified persons may work with components of the electric drive and
control system or within its proximity.
● Only use accessories and spare parts approved by Bosch Rexroth.
● Follow the safety regulations and requirements of the country in which the
components of the electric drive and control system are operated.
● Only use the components of the electric drive and control system in the
manner that is defined as appropriate. See chapter "Appropriate Use".
● The ambient and operating conditions given in the available application
documentation must be observed.
● Applications for functional safety are only allowed if clearly and explicitly
specified in the application documentation "Integrated Safety Technolo‐
gy". If this is not the case, they are excluded. Functional safety is a safety
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concept in which measures of risk reduction for personal safety depend
on electrical, electronic or programmable control systems.
● The information given in the application documentation with regard to the
use of the delivered components contains only examples of applications
and suggestions.
The machine and installation manufacturers must
– make sure that the delivered components are suited for their individ‐
ual application and check the information given in this application
documentation with regard to the use of the components,
– make sure that their individual application complies with the appli‐
cable safety regulations and standards and carry out the required
measures, modifications and complements.
● Commissioning of the delivered components is only allowed once it is sure
that the machine or installation in which the components are installed
complies with the national regulations, safety specifications and standards
of the application.
● Operation is only allowed if the national EMC regulations for the applica‐
tion are met.
● The instructions for installation in accordance with EMC requirements can
be found in the section on EMC in the respective application documenta‐
tion.
The machine or installation manufacturer is responsible for compliance
with the limit values as prescribed in the national regulations.
● The technical data, connection and installation conditions of the compo‐
nents are specified in the respective application documentations and must
be followed at all times.
National regulations which the user must take into account
● European countries: In accordance with 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)
3.2.3 Hazards by Improper Use
● High electrical voltage and high working current! Danger to life or serious
injury by electric shock!
● High electrical voltage by incorrect connection! Danger to life or injury by
electric shock!
● Dangerous movements! Danger to life, serious injury or property damage
by 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!
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● Risk of injury by improper handling! Injury by crushing, shearing, cutting,
hitting!
● Risk of injury by improper handling of batteries!
● Risk of injury by improper handling of pressurized lines!
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