Bosch rexroth IndraControl VAU 02.1 User manual

IndraControl
VAU 02.1
Uninterruptible Power Supply
Operating Instructions
R911384727
Edition 03

IndraControl VAU 02.1 Uninterruptible
Power Supply
Change Record
Edition 03, 2020-07
Refer to tab. 1-1 "Change Record" on page 1
Copyright
© Bosch Rexroth AG 2020
All rights reserved, also regarding any disposal, exploitation, reproduction, edit-
ing, distribution, as well as in the event of applications for industrial property
rights.
Liability
The specified data is intended for product description purposes only and shall
not be deemed to be a guaranteed characteristic unless expressly stipulated in
the contract. All rights are reserved with respect to the content of this documen-
tation and the availability of the product.
Editorial Department
Development Automation Systems Control Platform JüKö (MaKo/MePe)
RS-f61fc313475d5dd9c0a80286516958d8-3-en-US-3

Table of Contents
Page
1 About this documentation..................................................................... 1
1.1 Overview on target groups and product phases.................................... 1
1.2 Purpose.................................................................................................. 2
1.3 Scope..................................................................................................... 2
1.4 Related documents................................................................................ 2
1.5 Terms and abbreviations........................................................................ 2
1.6 Customer feedback................................................................................ 3
2 Product identification and scope of delivery......................................... 3
2.1 Product identification............................................................................ 3
2.2 Scope of delivery................................................................................... 4
3 Using safety instructions........................................................................ 4
3.1 Structure of the safety instructions....................................................... 4
3.2 Explaining signal words and safety alert symbol................................... 4
3.3 Symbols used......................................................................................... 5
3.4 Explaining the signal alert symbol on the device................................... 5
4 Intended use.......................................................................................... 5
5 Spare parts, accessories and wear parts.............................................. 6
5.1 External 24 V power supply unit ........................................................... 6
6 Ambient conditions................................................................................ 6
7 Technical data........................................................................................ 8
7.1 Degree of protection and weight........................................................... 8
7.2 Input and output voltage....................................................................... 8
7.3 Battery................................................................................................... 9
7.4 Response upon voltage failure............................................................. 11
8 Standards............................................................................................ 11
8.1 CE marking........................................................................................... 12
8.1.1 Declaration of conformity.................................................................... 12
8.2 UL/CSA certified.................................................................................. 12
9 Interfaces............................................................................................. 13
IndraControl VAU 02.1 Uninterruptible
Power Supply
I
Table of Contents
R911384727_Edition 03 Bosch Rexroth AG

Page
9.1 24 V voltage supply and output voltage XD1....................................... 14
9.2 Serial interface XF50........................................................................... 14
10 Mounting, demounting and electric installation.................................. 15
10.1 Housing dimensions............................................................................. 15
10.2 Installation notes................................................................................. 15
10.3 Mounting.............................................................................................. 15
10.4 Electric connection.............................................................................. 17
10.4.1 Connecting 24 V DC to the UPS and panel or control cabinet PC....... 17
10.4.2 Connecting control cabinet PC to XF50............................................... 18
10.5 Demounting......................................................................................... 19
10.6 Overall connection scheme.................................................................. 20
11 Commissioning.................................................................................... 20
12 Device description............................................................................... 20
12.1 Operating and display components..................................................... 21
12.1.1 Reset button........................................................................................ 21
12.2 Operating and error display................................................................. 22
12.3 Battery protective devices................................................................... 22
13 Troubleshooting and debugging........................................................... 23
14 Maintenance........................................................................................ 23
14.1 Regular maintenance tasks.................................................................. 23
14.2 Storing the UPS................................................................................... 23
15 Ordering information........................................................................... 24
15.1 Accessories and spare parts................................................................ 24
15.2 Type code............................................................................................. 24
16 Disposal............................................................................................... 25
16.1 Return.................................................................................................. 26
16.2 Packaging............................................................................................. 26
16.3 Batteries and accumulators................................................................. 26
17 Service and support............................................................................ 26
Index.................................................................................................... 29
II/31
Table of Contents
IndraControl VAU 02.1 Uninterruptible
Power Supply
Bosch Rexroth AG R911384727_Edition 03

1 About this documentation
Editions of this documentation
Edition Release
Date
Note
01 2018-07 First edition
02 2019-07 Safety and warning instructions supplemented
03 2020-07 Cable lengths supplemented
Tab. 1-1: Change Record
1.1 Overview on target groups and product phases
In the following illustration, the framed activities, product phases and target
groups refer to the present documentation.
Example:
In the product phase "Mounting (assembly/installation)", the "mechanic/electri-
cian" can execute the activity "install" using this documentation.
Presales Aftersales
Selection Mounting
(assembly/installation)
Engineering Commissioning Operation Decommissioning
Product
phases
Target
groups
Activities
Design engineer
Programmer
Technologist
Process
specialist
Select
Prepare
Design
Construct
Mechanic/
electrician
Unpack
Mount
Install
Programmer
Commissioning engineer
Parameterize
Program
Configure
Simulate
Technologist
Process specialist
Optimize
Test
Machine
operator
Maintenance
technician
Service
Operate
Maintain
Remove
faults
Create
the NC program
Mechanic/
electrician
Disposal company
Dismount
Dispose
Fig. 1-1: Assigning the present documentation to the target groups, product phases and ac-
tivities of the target group
IndraControl VAU 02.1 Uninterruptible
Power Supply
1/31
About this documentation
R911384727_Edition 03 Bosch Rexroth AG

1.2 Purpose
This document instructs the technical staff of the machine manufacturer on how
to perform the mechanical and electrical installation safely and on how to com-
mission the device.
Required qualification: Individual who is able to assess the tasks assigned and
to identify possible safety risks owing to qualification in the subject, knowledge
and experience. The individual should also be familiar with the standards and
regulations.
1.3 Scope
These operating instructions apply for the following UPS:
●VAU 02.1S (UPS with COM interface and integrated accumulator, type code
VAU02.1S-024-024-072-NN, part number R911385289)
The type code specifications are located on the type plate of the device (refer to
chapter 2.1 "Product identification" on page 3 and chapter 15.2 "Type code"
on page 24).
1.4 Related documents
Title Part number and document type
Rexroth IndraControl
VAP 01
Power Supply Unit
R911339613
Operating Instructions
Tab. 1-2: Power supply unit documentation
Title Part number and document type
IndraControl PR4 and VR4
Control Cabinet PC
R911384699
Operating Instructions
Rexroth IndraControl
PR, VR, DR and DE Devices
Software Applications
R911384733
Project Planning Manual
Tab. 1-3: Further documents for the VAU 02.1S
1.5 Terms and abbreviations
Name Explanation
UPS Uninterruptible power supply. The UPS is used for timely-limited volt-
age supply of the connected device if the voltage supply (24 V DC) fails
2/31
About this documentation
IndraControl VAU 02.1 Uninterruptible
Power Supply
Bosch Rexroth AG R911384727_Edition 03

PR and VR dashboard Already installed software on PR- and VR-devices to display device in-
formation and to modify device settings.
The menu item "UPS" shows the UPS status.
The device settings can be modified via the menu item "Monitor serv-
ice". The following settings can be made for the UPS:
●Communication interface "COM" of the PC to which the communica-
tion interface of the UPS is connected to
●Action in case of supply voltage failure "DC-In Lost Emergency Ac-
tion"
●Time between supply voltage failure and PC shutdown. "Time to
Shutdown PC after Power Outtage"
●Enabling warning messages
●Monitoring frequency of the input voltage
Shutdown Shutting down the PC
Tab. 1-4: Terms and abbreviations
1.6 Customer feedback
Customer requests, comments or suggestions for improvement are of great im-
portance to us. Please email your feedback on the documentations to Feed-
[e-mail]. Directly insert comments in the elec-
tronic PDF document and send the PDF file to Bosch Rexroth.
2 Product identification and scope of delivery
2.1 Product identification
Description Example
Part number PN: R911385289
Type code TYPE: VAU02.1...
Serial number SN: 123456789123456
Plant (7260)
Manufacturing date MD: 17W40
Name of origin Made in...
Company address Bosch Rexroth AG, 97816 Lohr, Germany
CE conformity marking CE
Voltage specification UN 24 V DC
Current specification IN 4.2 A, Out 3.0 A
IndraControl VAU 02.1 Uninterruptible
Power Supply
3/31
Product identification and scope of delivery
R911384727_Edition 03 Bosch Rexroth AG

Description Example
Ambient temperature T(amb) 0-45 °C (as per the temperature values of
the battery)
Certification markings UL, FCC, China-RoHS,...
Tab. 2-1: Specifications on the type plate, example
2.2 Scope of delivery
●UPS
●Safety instructions
●Connecting cables (3 m) between the UPS and the COM interface of the pan-
el PC or the control cabinet PC
●Connecting cables (3 m) between the UPS and the voltage supply interface of
the panel PC or the control cabinet PC
3 Using safety instructions
3.1 Structure of the safety instructions
The safety instructions are structured as follows:
Burns and chemical burns due to wrong
battery treatment!
CAUTION
Safety alert symbol
Signal word
Avoiding danger
Do not open the batteries and do not heat them over 80 °C.
Consequences and
source of danger
Fig. 3-1: Structure of the safety instructions
3.2 Explaining signal words and safety alert symbol
The safety instructions in this documentation contain specific signal words
(danger, warning, caution, notice) and, if necessary, a safety alert symbol
(according to ANSI Z535.6-2006).
The signal word draws attention to the safety instruction and indicates the risk
potential.
The safety alert symbol (triangular safety reflector with exclamation marks),
preceding the signal words Danger, Warning, Caution indicates hazards for
persons.
4/31
Using safety instructions
IndraControl VAU 02.1 Uninterruptible
Power Supply
Bosch Rexroth AG R911384727_Edition 03

DANGER
In case of non-compliance with this safety instruction, death or serious injury
will occur.
WARNING
In case of non-compliance with this safety instruction, death or serious injury
can occur.
CAUTION
In case of non-compliance with this safety instruction, minor or moderate injury
can occur.
NOTICE
In case of non-compliance with this safety instruction, material damage can
occur.
3.3 Symbols used
Pointers are displayed as follows:
This is a note.
Tips are displayed as follows:
This is a tip.
3.4 Explaining the signal alert symbol on the device
krax
If this symbol is on your device, you have to observe the documentation
on the device. The respective documentation informs on the type of
hazard as well as the steps required to avoid this hazard.
4 Intended use
The Bosch Rexroth VAU 02.1S is and uninterruptible power supply (UPS).
IndraControl VAU 02.1 Uninterruptible
Power Supply
5/31
Intended use
R911384727_Edition 03 Bosch Rexroth AG

Risk of damaging the device if not expressly sta-
ted accessories, mounting parts and other com-
ponents, cables, lines, software and firmware
are used.
NOTICE
The UPS may be used only as intended and with the accessories, mounting parts
and other components specified in this documentation. Components that are
not expressly mentioned must neither be attached nor connected. The same ap-
plies to cables and lines.
Only to be operated with the component configurations and combinations ex-
pressly defined and with the software and firmware specified in the correspond-
ing functional description.
The UPS can be used for the following panel PCs and control cabinet PCs:
●Panel PC Rexroth IndraControl VR4
●Panel PC Rexroth IndraControl VR3
●Control cabinet PC Rexroth IndraControl PR4
●Control cabinet PC Rexroth IndraControl PR3
The UPS may only be operated under the mounting and installation conditions,
in the position of application and under the ambient conditions (temperature,
degree of protection, humidity, EMC, etc.) specified in this documentation.
5 Spare parts, accessories and wear parts
5.1 External 24 V power supply unit
Ordering code Part number Description
VAP01.1H-W23-024-010-NN R911171065 External 24 V power supply unit for UPS
and IndraControl V-devices
Tab. 5-1: Ordering data, 24 V power supply unit for UPS and IndraControl V-devices
6 Ambient conditions
Humidity 85% at 40°C (non-condensing)
Operating temperature 0 to 45°C (with airflow 0.3 m/s)
Storage temperature -20 to 50 °C
Shock protection IEC 60068-2-27
Overvoltage category 2
Contamination level 2, no condensation allowed
Mechanical strength IEC 60068-2-64, acceleration: 2G
Tab. 6-1: Ambient conditions
6/31
Ambient conditions
IndraControl VAU 02.1 Uninterruptible
Power Supply
Bosch Rexroth AG R911384727_Edition 03

Failure of the product due to contaminated air
NOTICE
●The ambient air must not contain acids, alkaline solutions, corrosive agents,
salts, metal vapors and other electrically conductive contaminants in high
concentrations
●The devices to be installed into the housing and installation compartments
must at least comply with the degree of protection IP 54 according to DIN EN
60529.
●The device shall be provided in a suitable fire enclosure in the end-use appli-
cation.
Defective product due to gases jeopardizing
functions
NOTICE
Due to the risk of corrosion, avoid sulphurous gases (e.g. sulphur dioxide (SO2)
and hydrogen suphide (H2S)). The product is not resistant against these gases.
Risk to damage the device due to external influ-
ences
NOTICE
Keep the device away from oils and emulsions.
Short circuit due to damage or deformation of
the housing
NOTICE
Do not use a UPS with a damage or deformed housing.
This is a product that corresponds to the limit values of the emitted
interference of class A (industrial environments), but not of class B
(residential area and small enterprises).
When using the product in residential areas or small enterprises, the
operator has to take actions to prevent radio interferences (also re-
fer to DIN EN 55022).
IndraControl VAU 02.1 Uninterruptible
Power Supply
7/31
Ambient conditions
R911384727_Edition 03 Bosch Rexroth AG

7 Technical data
7.1 Degree of protection and weight
Degree of protection IP 20
Weight 0.94 kg
Tab. 7-1: Degree of protection and weight
7.2 Input and output voltage
Nominal input voltage 24 V DC (use a 24 V power supply unit acc. to DIN EN
60742, classification VDE 0551, for example the power sup-
ply unit VAP01.1H-W23-024-010-NN, part number
R911171065)
Input voltage range 24 V DC +20 %, -20 %
Current consumption at UN4.2 A
Current consumption (max.) at UN -20% 5.2 A
Max. power consumption 100 W
Tab. 7-2: Input voltage 24 V
Nominal output voltage 24 V DC
Current output at UN3 A max.
Bridging time 3 minutes max. if battery charged by 50%
5 minutes max. if battery charged by 85%
Max. output power 72 W
Short-circuit protection Yes
Tab. 7-3: Output voltage 24 V
Explosion hazard due to short-circuiting of the
connections
CAUTION
Do not short-circuit the UPS connections.
Overheating and possible damage to the UPS if
the max. power consumption is exceeded.
NOTICE
The max. power consumption of the connected control cabinet or panel PC must
not exceed the max. output power of the UPS of 72 W.
8/31
Technical data
IndraControl VAU 02.1 Uninterruptible
Power Supply
Bosch Rexroth AG R911384727_Edition 03

Destruction of electronics and accumulators us-
ing unsuitable power supply units
NOTICE
Use only approved power supply units for the UPS, e.g. the power supply unit
VAP01.1H-W23-024-010-NN, part number R911171065.
7.3 Battery
Risk of injury due to an unintended use of the
accumulator of the UPS
CAUTION
●Do no replace the accumulators. Contact the Bosch Rexroth Service instead.
●Do not use third-party accumulators in the UPS.
●Never use the accumulators of the UPS for other devices.
●Never charge the accumulators of the UPS using a third-party charging device.
●Note that exposed connections of the UPS can cause a short circuit.
Explosion hazard due to heat or direct and con-
tinuous solar radiation
CAUTION
Protect the UPS against heat and direct and continuous solar radiation.
Irritation of the respiratory tracts due to unin-
tended use
CAUTION
Immediately stop using defective devices. Exchange the ambient air when vapors
escapes. In case of breathing difficulties, contact a doctor immediately.
Skin irritations and burnings due to leaking liq-
uids causes an unintended use of the UPS
CAUTION
Immediately stop using defective devices. In case of skin or eye contact with
leaking liquid, immediately contact a doctor
Short circuit due to humidity
NOTICE
Protect the UPS while operated and against rain and humidity while stored.
IndraControl VAU 02.1 Uninterruptible
Power Supply
9/31
Technical data
R911384727_Edition 03 Bosch Rexroth AG

Battery capacity 1560 mAh (lithium battery 14.4 V DC)
Service life absolute of the battery 300 complete charging cycles
Battery service life, example calculation
for real applications
Example application:
One switch-off cycle corresponds to 0.15 complete cycles.
This results in calculated 2,000 machine switch-offs with the
UPS buffering the PC and executing a controlled shutdown.
●If the machine is switched off once a week, a service life
of 2,000 weeks (38 years) is calculated.
●If the machine is switched off once a day, a service life of
2,000 days (5.4 years) is calculated.
Tab. 7-4: Technical battery data
10/31
Technical data
IndraControl VAU 02.1 Uninterruptible
Power Supply
Bosch Rexroth AG R911384727_Edition 03

7.4 Response upon voltage failure
The UPS response upon voltage failure is described in the following.
PC failure due to faulty operation!
NOTICE
After the UPS has been issued the shutdown command, wait until the UPS buf-
fer time elapses before disconnecting the connecting cable to the PC or restart-
ing the PC.
Normal
mode
24 V In
UPS switch-off 150 s
after voltage failure
24 V Out
Time between shutdown command
and UPS switch-off: 120 s
PC shutdown
24 V Out
24 V In
UPS switch-off 150 s
after voltage failure
Default: 30 s
Time between voltage
failure and issuing
shutdown command
24 V Out
24 V In
No UPS switch-off, as
voltage failure <30 s
2
10 to 180 s +120 s 0 s
Time of
voltage failure
completed
PC shutdown
1
①The connection between PC and UPS may neither be disconnected nor established again
during this period! If the connection is restored, the PC restarts and there is an uncon-
trolled switch-off when the UPS buffer time elapses.
②The period between the voltage failure and the shutdown can be set between 10 and 180
seconds in the dashboard; "Time to Shutdown after Power Outage"
Fig. 7-1: Pulse diagram of the UPS
8 Standards
Standard Description
EN 61000-6-4 Generic standards - Emission standard (industrial environments)
EN 61000-6-2 Generic standards – Noise immunity (industrial environments)
IndraControl VAU 02.1 Uninterruptible
Power Supply
11/31
Standards
R911384727_Edition 03 Bosch Rexroth AG

Standard Description
EN 60 068-2-6 Vibration test
EN 60068-2-27 Shock test
UL EN 60950-1 Information technology equipment - Safety
Tab. 8-1: Standards used
8.1 CE marking
8.1.1 Declaration of conformity
The electronic products described in the present operating instructions comply
with the requirements and the target of the following EU directive and with the
following harmonized European standards:
EMC directive 2014/30/EC
The electronic products described in the present operating instructions are in-
tended for use in industrial environments and comply with the following require-
ments:
Standard Title
DIN EN 61000-6-2 Electromagnetic compatibility (EMC)
Part 6-2: Generic standards – Immunity for industrial envi-
ronments
DIN EN 61000-6-4 Electromagnetic compatibility (EMC)
Part 6-4: Generic standards – Emission standard for indus-
trial environments
Tab. 8-2: Standards for electromagnetic compatibility (EMC)
Loss of CE conformity due to modifications at the device.
CE marking applies only to the device upon delivery. After modifying
the device, verify the CE conformity.
8.2 UL/CSA certified
The devices are certified acc. to
●UL 60950-1 (Information Technology Equipment) and
●CAN/CSA C22.2 No. 60950-1-07
UL file no. E477559
However, there can be combinations or extension stages with a limited or miss-
ing certification. Thus, verify the registration according to the UL marking on the
device.
12/31
Standards
IndraControl VAU 02.1 Uninterruptible
Power Supply
Bosch Rexroth AG R911384727_Edition 03

Loss of UL/CSA conformity due to modifications at the device.
UL and CSA marking applies only to the device upon delivery. After
modifying the device, verify the UL and the CSA conformity.
9 Interfaces
1
2
3
4
5
①Reset button
②LED for status and error display
③COM interface XF50
④Voltage connection and voltage output
XD1
⑤Functional earth
Fig. 9-1: Connector panel of the UPS
IndraControl VAU 02.1 Uninterruptible
Power Supply
13/31
Interfaces
R911384727_Edition 03 Bosch Rexroth AG

Name at housing Connection type Connector type
(Integrated)
Mating connector or line
(From outside)
XD1 Voltage supply 24 V DC
Output voltage DC 24 V
Male connector, 5-pin Female connector terminal,
5-pin
XF50 COM interface, Refer to
chapter 10.4.2 "Con-
necting control cabinet
PC to XF50" on page
18.
Male connector, 3-pin Female connector terminal,
3-pin
Functional earth (FE) M5 Ring cable lug
Tab. 9-1: UPS – interfaces and connections
9.1 24 V voltage supply and output voltage XD1
The 24 V voltage supply and the 24 V output voltage for the PC are connected to
the "XD1" connection. Upon delivery, there is a ready-made cable to connect the
USB and the PC. Connect the supply voltage to the UPS.
Fig. 9-2: Connecting the voltage supply and the output voltage
Pin name Description
24 V Out 24 V connection, output to PC
0 V Out 0 V connection, output to PC
24 V In 24 V voltage supply, input of power supply unit
0 V In 0 V voltage supply, input of power supply unit
Tab. 9-2: Pin assignment XD1
9.2 Serial interface XF50
The serial UPS connection to the PC is connected to the plug "XD50". Upon de-
livery, there is a ready-made cable to connect the UPS and the PC.
14/31
Interfaces
IndraControl VAU 02.1 Uninterruptible
Power Supply
Bosch Rexroth AG R911384727_Edition 03

Fig. 9-3: Serial interface XF50
Pin name Description
Rx COM interface – Receive Data (Rx)
Tx COM interface – Transmit Data (Tx)
GND COM interface Ground
Tab. 9-3: Pin assignment XF50
10 Mounting, demounting and electric installation
10.1 Housing dimensions
UPS Width Height Depth (without plugs)
VAU 02.1S 55 mm 214 mm 86.6 mm
Tab. 10-1: Dimensions
10.2 Installation notes
●The UPS is intended for front upright mounting
●The LED displays may not be hidden
●Provide the following minimum distances for sufficient cooling and mounting:
– 50 mm to the bottom side
– 80 mm to the upper side
– 85 mm to the front side
●Provide cables with strain relief
●Attach freely moving cables (e.g. by routing them in a cable channel)
●Keep as much distance as possible to noise sources when installing the UPS
10.3 Mounting
Use drilling holes to mount the UPS in front upright mounting. Use M4 screws.
IndraControl VAU 02.1 Uninterruptible
Power Supply
15/31
Mounting, demounting and electric installation
R911384727_Edition 03 Bosch Rexroth AG

55
27
201,5
214
193
4,5
Fig. 10-1: Mounting dimensions of the UPS
16/31
Mounting, demounting and electric installation
IndraControl VAU 02.1 Uninterruptible
Power Supply
Bosch Rexroth AG R911384727_Edition 03