REXROTH IndraControl L25 Series Technical manual

Project Planning Manual
Electric Drives
and Controls Pneumatics Service
Linear Motion and
Assembly Technologies
Hydraulics
Rexroth IndraControl
L25
R911328474
Edition 03

Rexroth IndraControl
L25
Project Planning Manual
DOK-CONTRL-IC*L25*****-PR03-EN-P
RS-7395430658d72e230a6846a00141db89-3-en-US-4
This documentation describes the IndraControl L25 controls.
Edition Release Date Notes
120-0401-B356/EN-01 08.2009 First edition
120-0401-B356/EN-02 10.2010 Second edition
120-0401-B356/EN-03 04.2011 Third edition
Copyright © 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).
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 Control Platform TL (CS)
Note This document has been printed on chlorine-free bleached paper.
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revision
Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25

Table of Contents
Page
1 System Presentation...................................................................................................... 5
1.1 Brief Description IndraControl L25.......................................................................................................... 5
1.2 Device Variants....................................................................................................................................... 5
1.3 View........................................................................................................................................................ 5
1.4 Further Documentation........................................................................................................................... 6
2 Important Instructions on Use........................................................................................ 7
2.1 Intended Use.......................................................................................................................................... 7
2.1.1 Introduction.......................................................................................................................................... 7
2.1.2 Areas of Use and Application.............................................................................................................. 7
2.2 Inappropriate Use................................................................................................................................... 8
3 Safety Instructions for Electric Drives and Controls....................................................... 9
3.1 Definitions of Terms................................................................................................................................ 9
3.2 General Information.............................................................................................................................. 10
3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 10
3.2.2 Requirements for Safe Use............................................................................................................... 10
3.2.3 Hazards by Improper Use.................................................................................................................. 11
3.3 Instructions with Regard to Specific Dangers....................................................................................... 13
3.3.1 Protection Against Contact With Electrical Parts and Housings........................................................ 13
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 14
3.3.3 Protection Against Dangerous Movements....................................................................................... 14
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 16
3.3.5 Protection Against Contact With Hot Parts........................................................................................ 16
3.3.6 Protection During Handling and Mounting......................................................................................... 17
3.3.7 Battery Safety.................................................................................................................................... 17
3.3.8 Protection Against Pressurized Systems........................................................................................... 18
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 18
4 Technical Data............................................................................................................. 21
4.1 Equipment............................................................................................................................................. 21
4.2 Voltage Supply...................................................................................................................................... 21
4.3 Ambient Conditions............................................................................................................................... 22
4.4 Used Standards.................................................................................................................................... 22
4.5 UL and CSA certified............................................................................................................................ 23
4.6 Compatibility Test................................................................................................................................. 23
4.7 Wear Parts............................................................................................................................................ 24
5 Dimensions.................................................................................................................. 25
5.1 General Information.............................................................................................................................. 25
5.2 Housing Dimensions............................................................................................................................. 25
5.3 Installation Notes.................................................................................................................................. 26
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Bosch Rexroth AG I/69
Table of Contents

Page
6 Display and Operating Components............................................................................ 27
6.1 General Information.............................................................................................................................. 27
6.2 Display and Operating Keys................................................................................................................. 27
6.3 Reset Button and Stop LED.................................................................................................................. 27
7 Connections and Interfaces......................................................................................... 29
7.1 Connections on the Front Panel – Overview........................................................................................ 29
7.2 Voltage Supply...................................................................................................................................... 31
7.2.1 Supply Voltages to be Connected Externally.................................................................................... 31
General Information........................................................................................................................ 31
24 V Voltage Supply ULS................................................................................................................ 33
24 V Voltage Supply of the Main Circuit UM................................................................................... 34
+24 V Supply of the Segment Circuit US ....................................................................................... 34
7.2.2 Internally Generated Voltages........................................................................................................... 36
+7.5 V Inline Supply UL................................................................................................................... 36
24 V Analog Supply (UANA)............................................................................................................. 36
7.3 Interfaces.............................................................................................................................................. 36
7.3.1 Ethernet Interfaces............................................................................................................................ 36
7.3.2 Ethernet Interface (only for Device Variant CML...PN ...).................................................................. 37
7.3.3 PROFIBUS DP (only for Device Variant CML...PN...)....................................................................... 38
7.3.4 SERCOS III (only for Device Variant CML...3N...)............................................................................. 39
7.3.5 Ready Contact................................................................................................................................... 40
7.3.6 Interface for Compact Flash Card..................................................................................................... 41
7.4 Inline Bus.............................................................................................................................................. 41
7.5 Function Module Connector.................................................................................................................. 41
8 Installation and Maintenance....................................................................................... 43
8.1 Mechanical Installation of IndraControl L25.......................................................................................... 43
8.1.1 General Information........................................................................................................................... 43
8.1.2 Mounting the IndraControl L25.......................................................................................................... 43
8.1.3 Dismounting the IndraControl L25..................................................................................................... 44
8.2 Mechanical Installation of Rexroth Inline Terminals............................................................................. 45
8.2.1 General Information........................................................................................................................... 45
8.2.2 Mounting the Inline Terminals........................................................................................................... 45
8.2.3 Demounting the Inline Terminals....................................................................................................... 46
8.2.4 Fuse Replacement............................................................................................................................ 47
8.3 Electrical Installation............................................................................................................................. 48
8.3.1 General Information........................................................................................................................... 48
8.3.2 External Power Supply Unit .............................................................................................................. 49
8.3.3 24 V Voltage Supply.......................................................................................................................... 49
Setup without Electrical Isolation ................................................................................................... 49
Setup with Electrical Isolation ........................................................................................................ 50
Reference Conductor Connected to the Protective Conductor...................................................... 50
Reference Conductor not Connected to the Protective Conductor................................................ 51
Programming Device and Grounding............................................................................................. 52
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Table of Contents

Page
Dimensioning the Voltage Supply................................................................................................... 52
8.3.4 Main Switches and Fuses.................................................................................................................. 52
Main Switches ............................................................................................................................... 52
Fuses.............................................................................................................................................. 52
8.3.5 Grounding
........................................................................................................................................................... 53
8.3.6 Shield System.................................................................................................................................... 53
General Information........................................................................................................................ 53
Shielding the PROFIBUS Cable..................................................................................................... 53
8.3.7 Connecting Lines to Tension Spring Connection Points................................................................... 54
General Information........................................................................................................................ 54
Connecting Unshielded Lines......................................................................................................... 54
8.4 Maintenance......................................................................................................................................... 54
9 Environmental Protection and Disposal ...................................................................... 57
9.1 Environmental Protection...................................................................................................................... 57
9.2 Disposal................................................................................................................................................ 57
10 Ordering Information.................................................................................................... 59
10.1 Type Designation Code........................................................................................................................ 59
10.1.1 General Information........................................................................................................................... 59
10.1.2 IndraControl L25................................................................................................................................ 59
10.2 Accessories.......................................................................................................................................... 60
10.2.1 Spare Part (Power Connector).......................................................................................................... 60
General Information........................................................................................................................ 60
10.2.2 Further Accessories (Rexroth Inline Terminals, Function Modules and Interface Cables)................ 60
Rexroth Inline Terminals................................................................................................................. 60
Rexroth Function Modules.............................................................................................................. 60
Interface Cables............................................................................................................................. 61
11 Service and Support.................................................................................................... 65
Index............................................................................................................................ 67
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Bosch Rexroth AG III/69
Table of Contents

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Rexroth IndraControl L25
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1 System Presentation
1.1 Brief Description IndraControl L25
The IndraControl L25 is a modular and scalable control. The control combines
the benefits of a compact small control with a standardized I/O system based
on terminal technology. The control is a universal hardware platform that can
be used for motion-logic and PLC applications. The control provides commu‐
nication interfaces such as Ethernet, EtherNet/IP as well as a SERCOS III
interface. Up to two function modules extend the IndraControl L25 via integra‐
ted PCI bus and additional fieldbus interfaces and technology interfaces. The
locally available I/O units can be extended by the Rexroth Inline I/O system,
just by simply mounting the components side by side. The complete application
programs, including runtime, are stored on an easily accessible Compact Flash
card.
1.2 Device Variants
The IndraControl L25 control is available in several device variants. The devi‐
ces differ mainly in the availability of SERCOS III and PROFIBUS DP interfaces
(see also fig. 1-1 "Device variants" on page 5 and chapter 7.1 "Connections
on the Front Panel – Overview" on page 29).
Connection Connection type Device variant
X7E1 and X7E2 Ethernet (SERCOS III) CML...3N...
X7E3 and X7E4 Ethernet (TCP/IP, RT Ethernet) CML...PN...
X7P RS485 (PROFIBUS DP) CML...PN...
Fig.1-1: Device variants
Further characteristic features are listed in the type designation code in chapter
10.1 "Type Designation Code" on page 59.
1.3 View
Operating elements and interfaces are arranged on the front panel:
In the left part is a display with eight characters and four operating keys, the
reset button, a LED, the Ethernet interface, the ready contact and a receptacle
for a Compact Flash card. The interfaces for SERCOS III are located in the
center. The voltage supply is located in the right part.
Fig.1-2: View of a typical IndraControl L25
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System Presentation

1.4 Further Documentation
Title Identification Parts number
PLC Programming with Rexroth
IndraLogic 1.0;
Operating and Programming
Guide
DOK-CONTRL-IL**PRO*V01-
AW02-EN-P
R911305036
RECO-Inline PROFIBUS DP;
Application Manual
DOK-CONTRL-R-IL-PBSSYS-
AW02-EN-P
R911289597
RECO Inline PROFIBUS DP Ter‐
minal and Module Supply;
Application Manual
DOK-CONTRL-R-IL-PB*-BK-
FK02-EN-P
R911289587
Rexroth IndraWorks 10VRS En‐
gineering;
Application Manual
DOK-IWORKS-ENGINEE*V10-
AW01-EN-P
R911327718
Rexroth WinStudio;
Application Manual
DOK-CONTRL-WIS*PC**V06-
KB01-DE-P
R911307630
Automation Terminals of the
Rexroth Inline Range;
Application Manual
DOK-CONTRL-ILSYSINS***-
AW01-EN-P
R911317021
Rexroth IndraControl L Function
Modules
Project Planning Manual
DOK-CONTRL-IC*L*FM****-
PR01-EN-P
R911326408
Fig.1-3: Further documentation
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System Presentation

2 Important Instructions on Use
2.1 Intended 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, 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 intended 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 intended use.
● Hardware products have to remain in their original state, in other words,
no modification regarding the design are 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 Bosch Rexroth IndraControl L25 is suitable for logic and motion applica‐
tions.
The IndraControl L25 may only be used with the accessories and
mounting parts which are listed in this documentation. Components
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 con‐
figurations and component combinations as well as with the soft‐
ware and firmware which is given and specified in the respective
functional description.
In case of non-compliance, the guarantee and warranty claims shall
automatically expire.
Typical fields of use of the IndraControl L25 are:
●Handling systems and assembly systems
● Packaging and food processing machines
● Printing machines and paper converting machines
● Machine tools
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Important Instructions on Use

The IndraControl L25 may only be operated under the assembly and installation
conditions, in the position of application and under the ambient conditions (tem‐
perature, degree of protection, humidity, EMC, etc.) specified in this documen‐
tation.
2.2 Inappropriate Use
Any use of IndraControl L25 in applications other than those specified above
or under operating conditions other than those described in the documentation
and the technical specifications is considered to be "non-intended use".
IndraControl L25 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.
● they are used in household devices or devices belonging to categories 1
to 7 and 10 specified in Appendix IA of the Directive 2002/96/EC
("WEEE").
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Important Instructions on Use

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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Safety Instructions for Electric Drives and Controls

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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Safety Instructions for Electric Drives and Controls

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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Safety Instructions for Electric Drives and Controls

● 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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Safety Instructions for Electric Drives and Controls

3.3 Instructions with Regard to Specific Dangers
3.3.1 Protection Against Contact With Electrical Parts and Housings
This section concerns components of the electric drive and control
system with voltages of more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal
danger and electric shock. When operating components of the electric drive
and control system, it is unavoidable that some parts of these components
conduct dangerous voltage.
High electrical voltage! Danger to life, risk of injury by electric shock or serious
injury!
● Only qualified persons are allowed to operate, maintain and/or repair the
components of the electric drive and control system.
● Follow the general installation and safety regulations when working on
power installations.
● Before switching on, the equipment grounding conductor must have been
permanently connected to all electric components in accordance with the
connection diagram.
● Even for brief measurements or tests, operation is only allowed if the
equipment grounding conductor has been permanently connected to the
points of the components provided for this purpose.
● Before accessing electrical parts with voltage potentials higher than 50 V,
you must disconnect electric components from the mains or from the pow‐
er supply unit. Secure the electric component from reconnection.
● With electric components, observe the following aspects:
Always wait 30 minutes after switching off power to allow live capacitors
to discharge before accessing an electric component. Measure the elec‐
trical voltage of live parts before beginning to work to make sure that the
equipment is safe to touch.
● Install the covers and guards provided for this purpose before switching
on.
● Never touch electrical connection points of the components while power
is turned on.
● Do not remove or plug in connectors when the component has been pow‐
ered.
● Under specific conditions, electric drive systems can be operated at mains
protected by residual-current-operated circuit-breakers sensitive to uni‐
versal current (RCDs/RCMs).
● Secure built-in devices from penetrating foreign objects and water, as well
as from direct contact, by providing an external housing, for example a
control cabinet.
High housing voltage and high leakage current! Danger to life, risk of injury by
electric shock!
● Before switching on and before commissioning, ground or connect the
components of the electric drive and control system to the equipment
grounding conductor at the grounding points.
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Safety Instructions for Electric Drives and Controls

● Connect the equipment grounding conductor of the components of the
electric drive and control system permanently to the main power supply at
all times. The leakage current is greater than 3.5 mA.
● Establish an equipment grounding connection with a minimum cross sec‐
tion according to the table below. With an outer conductor cross section
smaller than 10 mm2 (8 AWG), the alternative connection of two equip‐
ment grounding conductors is allowed, each having the same cross
section as the outer conductors.
Cross section outer con‐
ductor
Minimum cross section equipment grounding conductor
Leakage current ≥ 3.5 mA
1 equipment grounding
conductor
2 equipment grounding con‐
ductors
1.5 mm2 (16 AWG)
10 mm2 (8 AWG)
2 × 1.5 mm2 (16 AWG)
2.5 mm2 (14 AWG) 2 × 2.5 mm2 (14 AWG)
4 mm2 (12 AWG) 2 × 4 mm2 (12 AWG)
6 mm2 (10 AWG) 2 × 6 mm2 (10 AWG)
10 mm2 (8 AWG) -
16 mm2 (6 AWG)
16 mm2 (6 AWG)
-
25 mm2 (4 AWG) -
35 mm2 (2 AWG) -
50 mm2 (1/0 AWG) 25 mm2 (4 AWG) -
70 mm2 (2/0 AWG) 35 mm2 (2 AWG) -
... ... ...
Fig.3-1: Minimum Cross Section of the Equipment Grounding Connection
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock
Protective extra-low voltage is used to allow connecting devices with basic in‐
sulation to extra-low voltage circuits.
On components of an electric drive and control system provided by Bosch
Rexroth, all connections and terminals with voltages between 5 and 50 volts
are PELV ("Protective Extra-Low Voltage") systems. It is allowed to connect
devices equipped with basic insulation (such as programming devices, PCs,
notebooks, display units) to these connections.
Danger to life, risk of injury by electric shock! High electrical voltage by incorrect
connection!
If extra-low voltage circuits of devices containing voltages and circuits of more
than 50 volts (e.g., the mains connection) are connected to Bosch Rexroth
products, the connected extra-low voltage circuits must comply with the re‐
quirements for PELV ("Protective Extra-Low Voltage").
3.3.3 Protection Against Dangerous Movements
Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:
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Safety Instructions for Electric Drives and Controls

● Improper or wrong wiring or cable connection
●Operator errors
● Wrong input of parameters before commissioning
● Malfunction of sensors and encoders
● Defective components
● Software or firmware errors
These errors can occur immediately after equipment is switched on or even
after an unspecified time of trouble-free operation.
The monitoring functions in the components of the electric drive and control
system will normally be sufficient to avoid malfunction in the connected drives.
Regarding personal safety, especially the danger of injury and/or property dam‐
age, this alone cannot be relied upon to ensure complete safety. Until the
integrated monitoring functions become effective, it must be assumed in any
case that faulty drive movements will occur. The extent of faulty drive move‐
ments depends upon the type of control and the state of operation.
Dangerous movements! Danger to life, risk of injury, serious injury or property
damage!
A risk assessment must be prepared for the installation or machine, with its
specific conditions, in which the components of the electric drive and control
system are installed.
As a result of the risk assessment, the user must provide for monitoring func‐
tions and higher-level measures on the installation side for personal safety. The
safety regulations applicable to the installation or machine must be taken into
consideration. Unintended machine movements or other malfunctions are pos‐
sible if safety devices are disabled, bypassed or not activated.
To avoid accidents, injury and/or property damage:
● Keep free and clear of the machine’s range of motion and moving machine
parts. Prevent personnel from accidentally entering the machine’s range
of motion by using, for example:
– Safety fences
– Safety guards
– Protective coverings
– Light barriers
● Make sure the safety fences and protective coverings are strong enough
to resist maximum possible kinetic energy.
● Mount emergency stopping switches in the immediate reach of the oper‐
ator. Before commissioning, verify that the emergency stopping equip‐
ment works. Do not operate the machine if the emergency stopping switch
is not working.
● Prevent unintended start-up. Isolate the drive power connection by means
of OFF switches/OFF buttons or use a safe starting lockout.
● Make sure that the drives are brought to safe standstill before accessing
or entering the danger zone.
● Additionally secure vertical axes against falling or dropping after switching
off the motor power by, for example,
– mechanically securing the vertical axes,
– adding an external braking/arrester/clamping mechanism or
– ensuring sufficient counterbalancing of the vertical axes.
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 15/69
Safety Instructions for Electric Drives and Controls

● The standard equipment motor holding brake or an external holding brake
controlled by the drive controller is not sufficient to guarantee personal
safety!
● Disconnect electrical power to the components of the electric drive and
control system using the master switch and secure them from reconnec‐
tion ("lock out") for:
– Maintenance and repair work
– Cleaning of equipment
– Long periods of discontinued equipment use
● Prevent the operation of high-frequency, remote control and radio equip‐
ment near components of the electric drive and control system and their
supply leads. If the use of these devices cannot be avoided, check the
machine or installation, at initial commissioning of the electric drive and
control system, for possible malfunctions when operating such high-fre‐
quency, remote control and radio equipment in its possible positions of
normal use. It might possibly be necessary to perform a special electro‐
magnetic compatibility (EMC) test.
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐
ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors
or permanent magnets of electric motors represent a serious danger to persons
with heart pacemakers, metal implants and hearing aids.
Health hazard for persons with heart pacemakers, metal implants and hearing
aids in proximity to electric components!
● Persons with heart pacemakers and metal implants are not allowed to
enter the following areas:
– Areas in which components of the electric drive and control systems
are mounted, commissioned and operated.
– Areas in which parts of motors with permanent magnets are stored,
repaired or mounted.
● If it is necessary for somebody with a heart pacemaker to enter such an
area, a doctor must be consulted prior to doing so. The noise immunity of
implanted heart pacemakers differs so greatly that no general rules can
be given.
● Those with metal implants or metal pieces, as well as with hearing aids,
must consult a doctor before they enter the areas described above.
3.3.5 Protection Against Contact With Hot Parts
Hot surfaces of components of the electric drive and control system. Risk of
burns!
● Do not touch hot surfaces of, for example, braking resistors, heat sinks,
supply units and drive controllers, motors, windings and laminated cores!
● According to the operating conditions, temperatures of the surfaces can
be higher than 60 °C (140 °F) during or after operation.
● Before touching motors after having switched them off, let them cool down
for a sufficient period of time. Cooling down can require up to 140 mi‐
nutes! The time required for cooling down is approximately five times the
thermal time constant specified in the technical data.
Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
16/69
Safety Instructions for Electric Drives and Controls

● After switching chokes, supply units and drive controllers off, wait 15 mi‐
nutes to allow them to cool down before touching them.
● Wear safety gloves or do not work at hot surfaces.
● For certain applications, and in accordance with the respective safety reg‐
ulations, the manufacturer of the machine or installation must take meas‐
ures to avoid injuries caused by burns in the final application. These
measures can be, for example: Warnings at the machine or installation,
guards (shieldings or barriers) or safety instructions in the application
documentation.
3.3.6 Protection During Handling and Mounting
Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!
● Observe the relevant statutory regulations of accident prevention.
● Use suitable equipment for mounting and transport.
● Avoid jamming and crushing by appropriate measures.
● Always use suitable tools. Use special tools if specified.
● Use lifting equipment and tools in the correct manner.
● Use suitable protective equipment (hard hat, safety goggles, safety shoes,
safety gloves, for example).
● Do not stand under hanging loads.
● Immediately clean up any spilled liquids from the floor due to the risk of
falling!
3.3.7 Battery Safety
Batteries consist of active chemicals in a solid housing. Therefore, improper
handling can cause injury or property damage.
Risk of injury by improper handling!
● Do not attempt to reactivate low batteries by heating or other methods (risk
of explosion and cauterization).
● Do not attempt to recharge the batteries as this may cause leakage or
explosion.
● Do not throw batteries into open flames.
● Do not dismantle batteries.
● When replacing the battery/batteries, do not damage the electrical parts
installed in the devices.
● Only use the battery types specified for the product.
Environmental protection and disposal! The batteries contained in
the product are considered dangerous goods during land, air, and
sea transport (risk of explosion) in the sense of the legal regulations.
Dispose of used batteries separately from other waste. Observe the
national regulations of your country.
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 17/69
Safety Instructions for Electric Drives and Controls

3.3.8 Protection Against Pressurized Systems
According to the information given in the Project Planning Manuals, motors and
components cooled with liquids and compressed air can be partially supplied
with externally fed, pressurized media, such as compressed air, hydraulics oil,
cooling liquids and cooling lubricants. Improper handling of the connected sup‐
ply systems, supply lines or connections can cause injuries or property damage.
Risk of injury by improper handling of pressurized lines!
● Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐
sion).
● Observe the respective manufacturer's operating instructions.
● Before dismounting lines, relieve pressure and empty medium.
● Use suitable protective equipment (safety goggles, safety shoes, safety
gloves, for example).
● Immediately clean up any spilled liquids from the floor due to the risk of
falling!
Environmental protection and disposal! The agents (e.g., fluids)
used to operate the product might not be environmentally friendly.
Dispose of agents harmful to the environment separately from other
waste. Observe the national regulations of your country.
3.4 Explanation of Signal Words and the Safety Alert Symbol
The Safety Instructions in the available application documentation contain spe‐
cific signal words (DANGER, WARNING, CAUTION or NOTICE) and, where
required, a safety alert symbol (in accordance with ANSI Z535.6-2006).
The signal word is meant to draw the reader's attention to the safety instruction
and identifies the hazard severity.
The safety alert symbol (a triangle with an exclamation point), which precedes
the signal words DANGER, WARNING and CAUTION, is used to alert the
reader to personal injury hazards.
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
could occur.
CAUTION
In case of non-compliance with this safety instruction, minor or moderate injury
could occur.
Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
18/69
Safety Instructions for Electric Drives and Controls