Bosch Rexroth IndraControl VAU 01.1Z User manual

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

Rexroth IndraControl VAU 01.1Z
UPS
Project Planning Manual
DOK-SUPPL*-VAU*01.1Z**-PR01-EN-P
RS-6a915a0364e53ab60a6846a001bf9072-1-en-US-7
Edition Release Date Notes
120-2100-B390-01/EN 04.2009 First edition
© Bosch Rexroth AG, 2009
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. DCC/EAY2 (MaKo/CaSp)
This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Record of Revision
Bosch Rexroth AG | Electric Drives
and Controls
Rexroth IndraControl VAU 01.1Z |Project Planning Manual
Copyright
Validity
Published by
Note

Table of Contents
Page
1 System Presentation...................................................................................................... 3
1.1 Short Description of the UPS.................................................................................................................. 3
1.2 Software.................................................................................................................................................. 4
1.3 Further Documentation........................................................................................................................... 4
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................................................................................................................................... 5
3 Safety Instructions for Electric Drives and Controls ...................................................... 7
3.1 Introduction............................................................................................................................................. 7
3.2 General Explanations............................................................................................................................. 7
3.3 Hazards by Improper Use....................................................................................................................... 7
3.4 General................................................................................................................................................... 8
3.5 Protection Against Contact with Electric Parts........................................................................................ 9
3.6 Protection Against Electric Shock (PELV) by Protective Extra-Low Voltage........................................ 11
3.7 Protection Against Dangerous Movements.......................................................................................... 11
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting................. 13
3.9 Protection Against Contact with Hot Parts............................................................................................ 13
3.10 Protection During Handling and Mounting............................................................................................ 13
3.11 Battery Safety....................................................................................................................................... 14
3.12 Protection Against Pressurized Systems ............................................................................................. 14
4 Technical Data............................................................................................................. 15
4.1 Degree of Protection and Weight.......................................................................................................... 15
4.2 Input and Output Voltage...................................................................................................................... 15
4.2.1 +24 V Input Voltage........................................................................................................................... 15
4.2.2 115/230 VAC Input Voltage............................................................................................................... 15
4.2.3 Output Voltage................................................................................................................................... 15
4.3 Ambient Conditions............................................................................................................................... 16
4.4 Standards............................................................................................................................................. 16
4.4.1 Used Standards................................................................................................................................. 16
4.4.2 CE Marking........................................................................................................................................ 17
Declaration of Conformity .............................................................................................................. 17
Note for the Machine Manufacturer................................................................................................ 17
4.4.3 UL/CSA Certified............................................................................................................................... 18
4.5 Compatibility Test................................................................................................................................. 18
5 Dimensions.................................................................................................................. 19
5.1 Housing Dimensions............................................................................................................................. 19
5.2 Installation............................................................................................................................................. 19
Project Planning Manual |Rexroth IndraControl VAU 01.1Z Electric Drives
and Controls
|Bosch Rexroth AG I/II
Table of Contents

Page
5.2.1 Installation Notes............................................................................................................................... 19
5.2.2 Mounting............................................................................................................................................ 19
6 Interfaces, Display and Operating Components.......................................................... 21
6.1 Connector panel................................................................................................................................... 21
6.1.1 General Information........................................................................................................................... 21
6.1.2 Connection Overview........................................................................................................................ 22
6.2 Voltage Connection.............................................................................................................................. 22
6.2.1 General Information........................................................................................................................... 22
6.2.2 Wiring the Power Connection............................................................................................................ 23
6.2.3 UPS Wiring, Cable Lengths and Cable Cross-Sections.................................................................... 25
6.2.4 Example for a Voltage Supply of Several UPS Integrated in Control Cabinets by a High-performance
Main UPS.......................................................................................................................................... 26
6.3 Serial Interface XCOM1........................................................................................................................ 26
6.3.1 General Information........................................................................................................................... 26
6.3.2 Description of the COM Interface...................................................................................................... 27
6.4 Operating Display and Error Display.................................................................................................... 28
6.5 Fuses.................................................................................................................................................... 29
6.6 Rotary Switch S1.................................................................................................................................. 29
6.6.1 General Information........................................................................................................................... 29
6.6.2 Timing with Regard to the Position of Rotary Switch S1................................................................... 30
7 Maintenance and Installation....................................................................................... 35
7.1 General Information.............................................................................................................................. 35
8 Environmental Protection and Disposal ...................................................................... 37
8.1 Environmental Protection...................................................................................................................... 37
8.2 Disposal................................................................................................................................................ 37
9 Ordering Information.................................................................................................... 39
9.1 Type Designation Code........................................................................................................................ 39
9.2 VAU 01.1S Accessories........................................................................................................................ 40
9.3 VAU 01.1U Accessories....................................................................................................................... 40
10 Service and Support.................................................................................................... 41
Index............................................................................................................................ 43
II/II Bosch Rexroth AG | Electric Drives
and Controls
Rexroth IndraControl VAU 01.1Z |Project Planning Manual
Table of Contents

1 System Presentation
1.1 Short Description of the UPS
The UPS (uninterruptible power supply) supplies the connected device for a
certain period of time with voltage if the supply voltage (+24 VDC) fails.
This UPS is a DC UPS. That means that the input voltage as well as the output
voltage of the UPS is +24 VDC. Instead of an accumulator, an AC power supply
unit is installed that is supplied by a main UPS when the 24 V voltage supply
fails. Thus, an output voltage of 24 V remains.
The UPS is able to provide the connected device with 24 V and 2.5 A for three
minutes max. The communication between UPS and connected device occurs
via a serial interface (XCOM1). The UPS consists of the following components:
● Enclosed metal housing.
● Power unit 115/230 VAC on +24 VDC integrated in the device. This power
supply unit functions as an accumulator if the +24 V supply voltage for the
UPS fails or is switched off.
● Display and operating components are arranged accessibly on the front
panel.
● Integrated burst and surge protection for the connected device.
Project Planning Manual |Rexroth IndraControl VAU 01.1Z Electric Drives
and Controls
|Bosch Rexroth AG 3/45
System Presentation

Fig.1-1: View of the UPS
1.2 Software
The communication between UPS and connected control cabinet PC occurs
via a serial interface (XCOM1). Therefore, the UPS software has to be installed
on the connected device. The installation is described in the documentation of
the control cabinet PC (see chapter 1.3 "Further Documentation" on page
4).
1.3 Further Documentation
The UPS belongs to the accessories of the VPP 21 devices that are described
in the the following documentations:
Rexroth Indra Control VPP 21.1 DOK-SUPPL*-VPP*21.1***-PR03-EN-P
Rexroth Indra Control VPP 21.2 DOK-SUPPL*-VPP*21.2***-PR01-EN-P
Fig.1-2: Further documentation for permitted devices on the VAU 01.1Z
4/45 Bosch Rexroth AG | Electric Drives
and Controls
Rexroth IndraControl VAU 01.1Z |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.
Bosch Rexroth disclaims as manufacturer any warranty, liability or
damages occurring due to inappropriate use of the products. Fur‐
thermore, 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 modifica‐
tion 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 may only be used with the accessories and add-on components
specified in this documentation. Components not named expressly
mentioned must neither be mounted nor connected. The same ap‐
plies to cables and conduits.
An operation may only be carried out in the hardware component
configurations and combinations specified and with the software
and firmware specified in this documentation and in the corre‐
sponding functional description.
The UPS may only be operated under the assembly and installation conditions,
in the position of application and under the ambient conditions (temperature,
degree of protection, humidity, EMC, etc.) specified in this documentation.
2.2 Inappropriate Use
The application of the UPS that are not within the specified areas of application
or under operating conditions deviating from the operating conditions and tech‐
nical data specified in the documentation is considered as "inappropriate".
The UPS 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
Project Planning Manual |Rexroth IndraControl VAU 01.1Z Electric Drives
and Controls
|Bosch Rexroth AG 5/45
Important Instructions on Use

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!
6/45 Bosch Rexroth AG | Electric Drives
and Controls
Rexroth IndraControl VAU 01.1Z |Project Planning Manual
Important Instructions on Use

3 Safety Instructions for Electric Drives and Controls
3.1 Introduction
The following information must be read before the system is used for the first
time to avoid physical injury and/or damage to property. This safety information
must be observed at all times.
Do not attempt to install or commision the 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!
3.2 General Explanations
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:
Warning symbol with signal word Hazard classification according to ANSI Z 535
DANGER
Death or severe bodily harm will occur.
WARNING
Death or severe bodily harm may occur.
CAUTION
Bodily harm or material damage may occur.
Fig.3-1: Hazard classification (according to ANSI Z 535)
3.3 Hazards by Improper Use
DANGER
High electric voltage and high working current! Risk of death or severe
bodily injury by electric shock!
Project Planning Manual |Rexroth IndraControl VAU 01.1Z Electric Drives
and Controls
|Bosch Rexroth AG 7/45
Safety Instructions for Electric Drives and Controls

DANGER
Dangerous movements! Danger to life, severe bodily harm or material
damage by unintentional motor movements!
WARNING
High electric voltage by incorrect connection! Risk of death or bodily
injury by electric shock!
WARNING
Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electrical equipment!
CAUTION
Hot surfaces on device housing! Danger of injury! Danger of burns!
CAUTION
Risk of injury by improper handling! Risk of bodily injury by bruising,
shearing, cutting, hitting or improper handling of pressurized lines!
CAUTION
Risk of injury by improper handling of batteries!
3.4 General
● 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
8/45 Bosch Rexroth AG | Electric Drives
and Controls
Rexroth IndraControl VAU 01.1Z |Project Planning Manual
Safety Instructions for Electric Drives and Controls