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3 RE30159-WA Bosch Rexroth AG I/229 Table of Contents Table of Contents 1 General Information About this Documentation Documentation for HNC100-3X Important Directions for Use Appropriate Use Introduction Areas of Use and Application Inappropriate Use Page 3 Safety Instructions for Electric and Hydraulic Drives and Controls Definition of terms Basic Information Using the Safety Instructions and Passing Them on to Third Parties Requirements for Safe Use Hazards due to Improper Use Hazard-related Instructions Protection Against Contact with Electrical Parts and Housings Protective Extra-Low Voltage as Protection Against Electric Shock Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Protections Against Contact with Hot Parts Protection During Handling and Mounting Battery Safety Protection Against Pressurized Lines Explanation of Signal Words and the Safety Alert Symbol Status Diagnoses (Axxxx) A0000 Communication phase A0001 Communication phase A0002 Communication phase A0003 Communication phase A0009 Automatic baud rate detection for SERCOS interface A0010 Drive HALT A0011 Starting lockout active A0012 Control and power sections ready for operation A0013 Ready for power on A0014 Drive interlock active A0015 Safety related standstill active A0016 Safety related operational stop active A0018 Special mode motion 1 active A0019 Special mode motion 2 active A0020 Special mode motion 3 active... 36

4 II/229 Bosch Rexroth AG RE30159-WA Table of Contents 4.16 A0021 Special mode motion 4 active A0050 Parameterization level 1 active A0051 Operating mode A0100 Torque control A0101 Velocity control A0102 Position mode, encoder A0103 Position mode, encoder A0104 Position mode lagless, encoder A0105 Position mode lagless, encoder A0106 Drive-internal interpolation, encoder A0107 Drive-internal interpolation, encoder A0108 Drive controlled interpolation, lagless, encoder A0109 Drive controlled interpolation, lagless, encoder A0110 Velocity synchronization, virtual master axis A0111 Velocity synchronization, real master axis A0112 Phase synchronization, encoder 1, virtual master axis A0113 Phase synchronization, encoder 2, virtual master axis A0114 Phase synchronization, encoder 1, real master axis A0115 Phase synchronization, encoder 2, real master axis A0116 Phase synchr. lagless, encoder 1, virtual master axis A0117 Phase synchr. lagless, encoder 2, virtual master axis A0118 Phase synchr. lagless, encoder 1, real master axis A0119 Phase synchr. lagless, encoder 2, real master axis A0128 Cam, encoder 1, virtual master axis A0129 Cam, encoder 2, virtual master axis A0130 Cam, encoder 1, real master axis A0131 Cam, encoder 2, real master axis A0132 Cam, lagless, encoder 1, virt. master axis A0133 Cam, lagless, encoder 2, virt. master axis A0134 Cam, lagless, encoder 1, real master axis A0135 Cam, lagless, encoder 2, real master axis A0136 Motion profile, encoder 1, virtual master axis A0137 Motion profile, encoder 2, virtual master axis A0138 Motion profile, encoder 2, real master axis A0139 Motion profile, encoder 1, real master axis A0140 Motion profile lagless, encoder 1, virtual master axis A0141 Motion profile lagless, encoder 2, virtual master axis A0142 Motion profile lagless, encoder 1, real master axis A0143 Motion profile lagless, encoder 2, real master axis A0150 Drive-controlled positioning, encoder A0151 Drive-controlled positioning, encoder 1, lagless A0152 Drive-controlled positioning, encoder A0153 Drive-controlled positioning, encoder 2, lagless A0154 Position mode drive controlled, encoder A0155 Position mode drive controlled, encoder A0156 Position mode lagless, encoder 1 drive controlled Page

5 RE30159-WA Bosch Rexroth AG III/229 Table of Contents 4.62 A0157 Position mode lagless, encoder 2 drive controlled A0158 Direct valve control A0160 Position mode drive controlled A0161 Drive-controlled positioning A0162 Positioning block mode A0163 Position synchronization A0164 Velocity synchronization A0206 Positioning block mode, encoder A0207 Positioning block mode lagless, encoder A0210 Positioning block mode, encoder A0211 Positioning block mode lagless, encoder A0403 Quick stop with probe detection is active A0500 Supply module in voltage control A0502 Supply module in operation A0503 DC bus charging active A0520 DC bus quick discharge active A0800 Unknown operating mode A4000 Automatic drive check and adjustment A4001 Drive deceleration to standstill A4002 Drive in automatic mode A4003 Setting-up mode is active Page 5 Error Messages Fatal System Errors (F9xxx and E-0000) F9001 Error internal function call F9002 Error internal RTOS function call F9003 Watchdog F9004 Hardware trap Fatal Errors (F8xxx) F8000 Fatal hardware error F8018 Device overtemperature shutdown F8022 Enc. 1: Enc. signals incorr. (can be cleared in ph. 2) F8042 Encoder 2 error: Signal amplitude incorrect F8057 Device overload shutdown F8060 Overcurrent in power section F8069 +/-15Volt DC error F Volt DC error F8078 Speed loop error F8079 Velocity limit value exceeded F8091 Power section defective F8096 Encoder 1: Extended bit 1 reports error F8097 Encoder 1: Extended bit 2 reports error F8100 Error when initializing the parameter handling F8102 Error when initializing power section F8118 Invalid power section/firmware combination F8120 Invalid control section/firmware combination... 64

6 IV/229 Bosch Rexroth AG RE30159-WA Table of Contents F8122 Control section defective F8129 Incorrect optional module firmware F8813 Connection error mains choke Errors of Category F6xxx F6028 Position limit value exceeded (overflow) F6029 Positive position limit exceeded F6030 Negative position limit exceeded F6034 Emergency-Stop activated F6042 Both travel range limit switches activated F6043 Positive travel range limit switch activated F6044 Negative travel range limit switch activated Interface Errors (F4xxx) F4001 Double MST failure shutdown F4002 Double MDT failure shutdown F4003 Invalid communication phase shutdown F4004 Error during phase progression F4005 Error during phase regression F4006 Phase switching without ready signal F4009 Bus failure F4011 Communication watchdog: Overload of cyclic communication F4012 Incorrect I/O length F4017 S-III: Incorrect sequence during phase switch F4034 Emergency-Stop activated Non-fatal Errors (F2xxx) F2002 Assignment of encoder for synchronization is not allowed F2003 Motion step skipped F2004 Error in motion profile F2005 Cam shaft invalid F2006 MMC was removed F2007 Switching to non-initialized operation mode F2008 RL The motor type has changed F2009 PL Load parameter default values F2010 Error when initializing digital I/O (-> S ) F2018 Device overtemperature shutdown F2019 Motor overtemperature shutdown F2021 Motor temperature monitor defective F2022 Device temperature monitor defective F2025 Drive not ready for control F2026 Undervoltage in power section F2028 Excessive deviation F2031 Encoder 1 error: Signal amplitude incorrect F2033 External power supply X10 error F2036 Excessive position feedback difference F2037 Excessive position command difference F2039 Maximum acceleration exceeded F2040 Device overtemperature 2 shutdown Page

7 RE30159-WA Bosch Rexroth AG V/229 Table of Contents F2042 Encoder 2: Encoder signals incorrect F2043 Measuring encoder: Encoder signals incorrect F2044 External power supply X15 error F2048 Low battery voltage F2050 Overflow of target position preset memory F2051 No sequential block in target position preset memory F2055 External power supply X31/X32 error F2057 Target position out of travel range F2058 Internal overflow by positioning input F2059 Incorrect command value direction when positioning F2067 Synchronization to master communication incorrect F2068 Brake error F2074 Actual pos. value 1 outside absolute encoder window F2075 Actual pos. value 2 outside absolute encoder window F2076 Actual pos. value 3 outside absolute encoder window F2077 Current measurement trim wrong F2086 Error supply module F2087 Module group communication error F2100 Incorrect access to command value memory F2101 It was impossible to address MMC F2102 It was impossible to address I2C memory F2103 It was impossible to address EnDat memory F2104 Commutation offset invalid F2105 It was impossible to address Hiperface memory F2110 Error in non-cyclical data communic. of power section F2120 MMC: Defective or missing, replace F2121 MMC: Incorrect data or file, create correctly F2122 MMC: Incorrect IBF file, correct it F2130 Error comfort control panel F2174 Loss of motor encoder reference F2175 Loss of optional encoder reference F2176 Loss of measuring encoder reference F2177 Modulo limitation error of motor encoder F2178 Modulo limitation error of optional encoder F2190 Incorrect Ethernet configuration F2270 Analog input 1 or 2, wire break F2802 PLL is not synchronized F2814 Undervoltage in mains F2815 Overvoltage in mains F2816 Softstart fault power supply unit F2817 Overvoltage in power section F2818 Phase failure F2819 Mains failure F2820 Braking resistor overload F2821 Error in control of braking resistor F2833 Ground fault in motor line Page

8 VI/229 Bosch Rexroth AG RE30159-WA Table of Contents F2834 Contactor control error F2835 Mains contactor wiring error F2836 DC bus balancing monitor error F2837 Contactor monitoring error F2840 Error supply shutdown F2860 Overcurrent in mains-side power section F2890 Invalid device code F2891 Incorrect interrupt timing F2892 Hardware variant not supported Page 6 Warnings (Exxxx) Fatal Warnings (E8xxx) E8025 Overvoltage in power section E8026 Undervoltage in power section E8029 Positive position limit exceeded E8030 Negative position limit exceeded E8034 Emergency-Stop activated E8035 Quick stop with probe detection is active E8040 Torque/force actual value limit active E8042 Both travel range limit switches activated E8043 Positive travel range limit switch activated E8044 Negative travel range limit switch activated E8055 Motor overload, current limit active E8057 Device overload, current limit active E8260 Torque/force command value limit active E8802 PLL is not synchronized E8814 Undervoltage in mains E8815 Overvoltage in mains E8818 Phase failure E8819 Mains failure Warnings of Category (E4xxx) E4001 Double MST failure shutdown E4002 Double MDT failure shutdown E4005 No command value input via master communication E4007 SERCOS III: Consumer connection failed E4008 Invalid addressing command value data container A E4009 Invalid addressing actual value data container A E4010 Slave not scanned or address E4011 Communication watchdog: Overload of cyclic communication Non-fatal Warnings (E2xxx) E2010 Position control with encoder 2 not possible E2021 Motor temperature outside of measuring range E2026 Undervoltage in power section E2047 Interpolation velocity = E2048 Interpolation acceleration = E2049 Positioning velocity >= limit value

9 RE30159-WA Bosch Rexroth AG VII/229 Table of Contents E2050 Device overtemp. prewarning E2051 Motor overtemp. prewarning E2053 Target position out of travel range E2054 Not homed E2055 Feedrate override S = E2056 Torque limit = E2058 Selected positioning block has not been programmed E2059 Velocity command value limit active E2061 Device overload prewarning E2063 Velocity command value > limit value E2064 Target position out of num. range E2070 Acceleration limit active E2074 Encoder 1: Encoder signals disturbed E2075 Encoder 2: Encoder signals disturbed E2077 Absolute encoder monitoring, motor encoder (encoder alarm) E2078 Absolute encoder monitoring, opt. encoder (encoder alarm) E2092 Internal synchronization defective E2100 Positioning velocity of master axis generator too high E2101 Acceleration of master axis generator is zero E2270 Analog input 1 or 2, wire break E2810 Drive system not ready for operation E2818 Phase failure E2819 Mains failure E2820 Braking resistor overload prewarning Page 7 Command Diagnosis Commands C0100 Communication phase 3 transition check C0200 Exit parameterization level procedure command C0300 Set absolute position procedure command C0400 Activate parameterization level 1 procedure command C0500 Reset class 1 diagnostics, error reset C0600 Drive-controlled homing procedure command C0700 Load defaults proced. command (motor-spec. controller val.) C0720 Load defaults procedure command (safety technology) C0730 Load defaults procedure command (MLD) C0740 Command Activate field bus profile settings C0750 Load defaults procedure command (factory settings) C0800 Load basic parameters command C0900 Position spindle command C1300 Positive stop drive procedure command C1400 Command Get marker position C1500 Cancel reference point procedure command C1600 Parking axis command C1800 Command Drive optimization / command value box C2200 Backup working memory procedure command

10 VIII/229 Bosch Rexroth AG RE30159-WA Table of Contents C2300 Load working memory procedure command C2400 Selectively backup working memory procedure command C2800 Analog input adjustment command C2900 Command Firmware update from MMC C3100 Recalculate actual value cycle C3300 Set coordinate system procedure command C3400 Shift coordinate system procedure command C3500 Command Determine encoder correction values C4100 Switch parameter set command C4200 Drive-controlled oscillation command C4300 NC-controlled homing procedure command C4400 Calculate displacement procedure command C4500 Displacement to referenced system procedure command C4700 Command Activate easy startup mode C4800 Command Determine cogging torque compensation table C5200 Communication phase 4 transition check C5300 SERCOS III: Command SYNC delay measurement C6000 Set absolute position procedure command C6100 Command Activate IP settings Command Errors C0101 Invalid parameters (-> S ) C0102 Limit error in parameter (-> S ) C0103 Parameter conversion error (->S ) C0104 Config. IDN for MDT not configurable C0105 Maximum length for MDT exceeded C0106 Config. IDNs for AT not configurable C0107 Maximum length for AT exceeded C0108 Time slot parameter > Sercos cycle time C0109 Position of data record in MDT (S ) even C0110 Length of MDT (S ) odd C0111 ID9 + Record length - 1 > length MDT (S ) C0112 TNcyc (S ) or TScyc (S ) error C0113 Relation TNcyc (S ) to TScyc (S ) error C0114 T4 > TScyc (S ) - T4min (S ) C0115 T2 too small C0118 Order of cyclic command value configuration incorrect C0132 Invalid settings for controller cycle times C0139 T2 (S )+length MDT (S )>TScyc (S ) C0151 IDN for command value data container not allowed C0152 IDN for actual value data container not allowed C0172 Delay measurement (S ) not carried out C0173 Connections (number) not configurable C0174 Connection configuration not allowed C0175 Producer cycle time of a connection not correct C0201 Invalid parameters (->S ) C0202 Parameter limit error (->S ) Page

11 RE30159-WA Bosch Rexroth AG IX/229 Table of Contents C0203 Parameter conversion error (->S ) C0210 Feedback 2 required (->S ) C0212 Invalid control section data (->S ) C0219 Max. travel range too large C0220 Error when initializing position of encoder C0221 Initialization velocity encoder 1 too high C0223 Invalid settings for controller cycle times C0224 Error when initializing position of encoder C0225 Initialization velocity encoder 2 too high C0227 Error when initializing position of measuring encoder C0228 Initialization velocity measuring encoder too high C0229 Field bus: IDN for cycl. command val. not configurable C0230 Field bus: Max. length for cycl. command val. exceeded C0231 Field bus: IDN for cycl. actual val. not configurable C0232 Field bus: Length for cycl. actual values exceeded C0233 Field bus: Tcyc (P ) incorrect C0234 Field bus: P missing for cycl. command values C0238 Order of cyclic command value configuration incorrect C0239 IDN for command value data container not allowed C0240 IDN for actual value data container not allowed C0242 Multiple configuration of a parameter (->S ) C0243 Brake check function not possible C0244 Act. modulo value cycle greater than max. travel range C0245 Operation mode configuration (->S ) not allowed C0246 Trav. range lim. switch not ass. to dig. input C0247 Dig. output already assigned to other axis C0248 Dig. input assigned differently to axes C0249 Dig. I/Os: Bit number too large C0250 Probe inputs incorrectly configured C0251 Error during synchronization to master communication C0253 Error in combination operation mode - encoder (->S ) C0254 Configuration error PROFIsafe C0255 Safety command for system init. incorrect C0256 Safety technology configuration error C0257 Error in safety technology encoder initialization C0258 Error in relation TNcyc (S ) to fine interpol C0259 MLD configuration error (->S ) C0260 Incremental enc. emulator resol. cannot be displayed C0270 Error when reading encoder data => motor encoder C0271 Incorrect parameterization of motor encoder (hardware) C0272 Incorr. parameteriz. of motor enc. (mechanical system) C0273 Modulo value for motor encoder cannot be displayed C0274 Motor encoder unknown C0275 Error when reading encoder data => optional encoder C0276 Incorrect parameterization of optional enc. (hardware) C0277 Incorr. parameteriz. of opt. enc. (mechanical system) Page

12 X/229 Bosch Rexroth AG RE30159-WA Table of Contents C0278 Modulo value for optional encoder cannot be displayed C0279 Optional encoder unknown C0280 Maximum travel range cannot be displayed internally C0281 Commutation via encoder-2 impossible C0282 Sensorless posit. of synchr. motors, invalid ctrl parameters C0283 Error during initialization of motor control (->S ) C0284 Invalid motor data in encoder memory (->S ) C0285 Type of construction of motor P incorrect C0286 Several motor encoders connected C0287 Error during initialization of motor data (->S ) C0288 Rotary scaling not allowed C0289 Error at init. of synchr. motor with reluctance torque C0290 Error when reading encoder data => measuring encoder C0291 Incorr. parameterization of measuring enc. (hardware) C0292 Measuring encoder unknown C0293 Modulo value for measuring encoder cannot be displayed C0294 Incorrect measuring encoder configuration C0298 Impossible to exit parameterization level C0299 Functional package selection changed. Restart C0301 Measuring system unavailable C0302 Absolute evaluation of measuring system impossible C0303 Absolute encoder offset cannot be saved C0401 Switching not allowed C0501 Error clearing only in parameter mode C0601 Homing only possible with drive enable C0602 Distance home switch - reference mark erroneous C0603 Homing impossible with optional encoder C0604 Homing impossible with absolute encoder C0606 Reference mark not detected C0607 Reference cam input not assigned C0608 Pos. stop a. HW lim. switch not allowed f. modulo axes C0609 Different travel directions parameterized C0610 Absolute encoder offset could not be saved C0702 Default parameters not available C0703 Default parameters invalid C0704 Parameters not copyable C0706 Error when reading the controller parameters C0751 Parameter default value incorrect (-> S ) C0752 Locked with password C0799 An invalid index was set C0851 Parameter default value incorrect (-> S ) C0852 Locked with password C0902 Spindle positioning requires drive enable C0903 Error during initialization C0906 Error during search for zero pulse C1301 Class 1 diagnostics error at command start Page

13 RE30159-WA Bosch Rexroth AG XI/229 Table of Contents C1402 Faulty reference mark signal C1801 Start requires drive enable C1802 Motor feedback data not valid C1803 Inertia detection failed C1804 Automatic controller setting failed C1805 Travel range invalid C1806 Travel range exceeded C1807 Determining travel range only via travel distance C1808 Drive not homed C2202 Error when writing data to non-volatile memory C2301 Error when reading non-volatile memory C2302 Error when converting parameters C2402 Error when saving parameters C2502 Error when accessing the MMC C2504 Error when writing data to internal memory C2602 Error when accessing the MMC C2604 Error when reading the internal memory C2801 Analog input not configured C2802 Oscillations of input signal outside tolerance range C2803 Measured values at zero point and max. value identical C2804 Automatic adjustment failed C2903 Error when accessing the MMC C2904 Error when accessing the flash C2905 Programmed firmware defective C3101 Act. modulo value cycle greater than max. travel range C3102 Drive is still in drive enable C3501 Acquisition velocity not allowed C3502 Motor encoder not available C3503 Optional encoder not available C3504 Measuring encoder not available C3505 No encoder selected C3506 Correction value table cannot be stored C4101 Switching only possible without AF C4102 Switching only possible in parameter mode C4103 Preselect parameter set forbidden value C4104 Error during parameter set switching (->S ) C4105 Error during gear change C4201 Oscillation requires drive enable C4202 Oscillation command speed cannot be reached C4302 Distance home switch - reference mark erroneous C4304 Homing impossible with absolute encoder C4306 Reference mark not detected C4307 Reference cam input not assigned C4308 Pos. stop a. HW lim. switch not allowed f. modulo axes C4701 Drive active, activation of easy startup impossible C4801 Cogging torque compensation: Measuring vel. too high Page

14 XII/229 Bosch Rexroth AG RE30159-WA Table of Contents C4802 Cogging torque compensation: Measuring vel. too low C4803 Cogging torque compensation: Inadmissible acceleration C4804 Cogging torque comp.: Err. when storing corr. val table C4805 Cogging torque comp.: Motor measuring system not homed C5301 SERCOS III: Delay measurement failed C6001 Measuring system unavailable C6002 Absolute evaluation of measuring system impossible C6003 Absolute encoder offset cannot be saved C6004 Command cannot be executed under drive enable C6101 Incorrect IP settings Page Index

15 RE30159-WA Bosch Rexroth AG 13/229 General Information 1 General Information 1.1 About this Documentation Edition of this documentation Edition Status Note RE30159-WA First edition Fig.1-1: Record of revisions 1.2 Documentation for HNC100-3X Documentation marked with the book symbol must be available to you before handling the product and must be observed: Title Document number Document type Digital drive controller for hydraulic axes with sercos interface Type VT-HNC100.../S Digital drive controller for hydraulic axes with sercos interface Type VT-HNC X/S... Digital drive controller for hydraulic drives with sercos interface Type VT-HNC100.-3X Digital drive controller for hydraulic drives with sercos interface Type VT-HNC100.-3X Declaration on environmental compatibility for the areas EMC, climate and mechanical load Fig.1-2: RE RE B RE PA RE WA RE U Additional documentation Technical data sheet Available on the Internet at Operating instructions Available on the Internet at Parameter description Available on the Internet at Description of diagnostic message Available on the Internet at Environmental declaration Available on the Internet at

16 14/229 Bosch Rexroth AG RE30159-WA

17 RE30159-WA Bosch Rexroth AG 15/229 2 Important Directions for Use 2.1 Appropriate Use Introduction Rexroth products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability. WARNING Important Directions for Use Personal injury and property damage caused by incorrect use of the products! The products have been designed for use in the industrial environment and may only be used in the appropriate way. If they are not used in the appropriate way, situations resulting in property damage and personal injury can occur Areas of Use and Application Rexroth as manufacturer is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks. Before using Rexroth products, make sure that all the pre-requisites for an appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use. If the products take the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the manner described in the relevant documentation. drive controllers made by Rexroth are designed to control electrical motors and monitor their operation. Control and monitoring of the drive controllers may require additional sensors and actors. The drive controllers may only be used with the accessories and parts specified in this documentation. If a component has not been specifically named, then it may neither be mounted nor connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant Functional Descriptions. drive controllers have to be programmed before commissioning, making it possible for the motor to execute the specific functions of an application. drive controllers of the HNC line have been developed for use in single- and multi-axis drive and control tasks.

18 16/229 Bosch Rexroth AG RE30159-WA Important Directions for Use 2.2 Inappropriate Use To ensure application-specific use of drive controllers, device types of different drive power and different interfaces are available. Typical applications include, for example: Handling and mounting systems, Packaging and food machines, Printing and paper processing machines and Machine tools. drive controllers may only be operated under the assembly and installation conditions described in this documentation, in the specified position of normal use and under the ambient conditions as described (temperature, degree of protection, humidity, EMC, etc.). Using the drive controllers outside of the operating conditions described in this documentation and outside of the indicated technical data and specifications is defined as "inappropriate use". drive controllers must not be used, if... they are subject to operating conditions that do not meet the specified ambient conditions. This includes, for example, operation under water, under extreme temperature fluctuations or extremely high maximum temperatures. Furthermore, drive controllers must not be used in applications which have not been expressly authorized by Rexroth. Please carefully follow the specifications outlined in the general Safety Instructions! Components of the drive system HNC are products of category C3 (with restricted distribution) according to IEC These components are not provided for use in a public low-voltage mains supplying residential areas. If these components are used in such a mains, high-frequency interference is to be expected. This can require additional measures of radio interference suppression.

19 RE30159-WA Bosch Rexroth AG 17/229 3 Safety Instructions for Electric and Hydraulic Drives and Controls 3.1 Definition of terms System Electric drive system Hydraulic drive system User Application manual Electrical equipment Device Manufacturer Component Machine Product Project planning manual Safety Instructions for Electric and Hydraulic Drives and Controls A systems consists of several devices or systems that are connected for a specific purpose or at a certain location, but which are not to be introduced as a single functional unit. An electric drive system comprises all components, starting with the power supply up to the motor shaft; such as electric motor(s), motor encoder, supply and drive control devices as well as auxiliary and additional components, such as power filter, power choke, lines and cables. A hydraulic drive system comprises all components, starting with the pressure supply up to the actual drive. Such as: Hydraulic cylinder, hydraulic motors, hydraulic valves, hydraulic pumps, transducers as well as lines and cables. A user is the person installing, commissioning or using the introduced product. An application manual comprises the entire documentation. The documentation provides information about the use and safety-relevant content for configuration, assembly, installation, mounting, commissioning, operation, maintenance and repair as well as the shutting-down of the product. The following terms are also used: Operation manual, instructions, commissioning manual, instruction manual, project planning manual, etc. An electric resource is an object used to generate, convert, transmit, distribute or use electric energy, such as e.g. electric motors, transformers, control units, cables, lines, electric power consumption devices, assembled printed circuit board, plug-ins, equipment cabinets. The device is an end product with an individual function, intended for the user. It is distributed as individual commodity. A manufacturer is a natural person or a corporate body, responsible for construction and manufacturing of a product which is distributed in his name. The manufacturer can use end products, finished parts or components or he can subcontract work. However, the manufacturer has to be authorized to supervise the manufacturing process of the products at all times and to assume product responsibility. A component is a combination of component parts with a defined function. The product elements are part of a resource, device or system. Components of the electric or hydraulic drive and control system: Supply and control units, controls, valves, motors, cables, etc. A machine is comprised of interconnected parts or components out of which at least one has to be movable. Thus, a machine consists of machine drive elements as well as control and energy circuits that have been assembled to form a system. A machine can, for example, be intended for processing, handling, transport or packaging of material. The term "machine" also covers an assembly of machines that are positioned and open-loop controlled to function as a uniform entity. Product examples: Device, component, component part, system, software, firmware, etc. A project planning manual is part of the application documentation to support the user during designing and planning of systems or machines.

20 18/229 Bosch Rexroth AG RE30159-WA Safety Instructions for Electric and Hydraulic Drives and Controls Qualified personnel Control system 3.2 Basic Information Knowledge of electric installation, control technology, programming, hydraulics and the respective technical terms are required to use this manual. To ensure the safe use, activities can only be carried out by a skilled person or a trained person, under supervision of a skilled person. A skilled person is defined as a person who can analyze the tasks assigned, detect potential sources of danger and who can take adequate safety precautions, due to the technical training he received, his knowledge and experiences as well as his knowledge of relevant regulations. A skilled person has to comply with relevant technical regulations. A control system comprises several control components that are interconnected and which are not to be distributed as a single functional unit Using the Safety Instructions and Passing Them on to Third Parties Do not install or operate the product unless you have thoroughly read all enclosed documents. These safety instructions and all other information for the user are to be read prior to working with these components. If no user information about the components is available, please contact your Bosch Rexroth distribution partner. Please ask your distribution partner to immediately provide these documents to the person in charge of safe operation of the components. In case of sale, rental and/or other ways of passing on the component, these safety instructions have to be provided in the national language of the user. Unintended use of these components and non-compliance with the specified safety instructions as well as tampering with the safety device can result in material damage, bodily injury, electric shock or, in the extreme case, in death Requirements for Safe Use Please read the following information before the initial commissioning of the product components to avoid bodily injuries and/or material damage. The safety instructions have to be complied with. Bosch Rexroth does not assume any liability in case of damages due to a non-compliance with the safety instructions. Before commissioning, the operating, maintenance and safety instructions have to be read. If the user documentation is ambiguous in the available language, please contact your supplier. The correct and safe operation of the component requires appropriate and professional transport, storage, mounting, installation as well as operation and maintenance. Only qualified personnel is authorized to work on the product component or in proximity to the product component. Only use accessories and spare parts approved by Bosch Rexroth. Please comply with the safety instructions and regulations of the country in which the components of the electric drive and control system are operated. Only operate the product in the intended use. See chapter "Intended Use". The ambient conditions as well as the conditions of use specified in this application manual have to be complied with.

21 RE30159-WA Bosch Rexroth AG 19/229 Safety Instructions for Electric and Hydraulic Drives and Controls Applications for functional safety are only permitted if they are explicitly and unambiguously specified in the user documentation "Integrated Safety Engineering". If this is the case, the applications are excluded. Functional safety contains part of the overall safety in which measures to minimize the risks for operator protection depend on electric, electronic or programmable controls. The specifications listed in the user documentations regarding the use of supplied components are only use cases and recommendations. The machine manufacturer and the system installer have to verify the compatibility of the supplied components and the specification about the use of the components made in this application manual himself; he has to adapt the safety instructions and standards applicable to his application and he has to execute the required measures, changes and extensions. The commissioning of the supplied components is not permitted unless it has been verified that the machine or the system, in which the components are installed, complies with the country-specific regulations, safety instructions and standards of the application. Operation of the components is only permitted in case of compliance with the national EMC regulations for the application. Please refer to the relevant application manual for information about an EMC-compliant installation, contained in the EMC section. The manufacturer of the system or the machine is obliged to ensure the compliance with limit values, specified by national statutory provisions. The technical data and the connection and installation conditions of the components can be taken from the relevant application manual and have to be complied with. Before commissioning the control with a hydraulic system, please refer to and comply with the safety-relevant information and risk specifications in the instructions of the manufacturer of the hydraulic system. Country-specific regulations the user has to comply with European countries: according to Eurocodes EN United States of America (USA): National Electric Code (NEC) National Electrical Manufacturers Association (NEMA) as well as local building specifications Regulations of the National Fire Protection Association (NFPA) Canada: Canadian Standards Association (CSA) Other countries: International Organization for Standardization (ISO) International Electrotechnical Commission (IEC) Hazards due to Improper Use High voltage and high operating current! Danger to life or serious injury by electric shock! High voltage due to incorrect connection! Danger to life or injury by electric shock!

22 20/229 Bosch Rexroth AG RE30159-WA Safety Instructions for Electric and Hydraulic Drives and Controls Dangerous movements! Danger to life, serious injury or material damage due to unintended drive motions because of misuse or incorrect actuation! Health hazard for persons with cardiac pacemakers, metallic implants and hearing aids in close proximity of electric drive systems! Risk of burns by hot housing surfaces! 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 and components!

23 RE30159-WA Bosch Rexroth AG 21/ Hazard-related Instructions Safety Instructions for Electric and Hydraulic Drives and Controls Protection Against Contact with Electrical Parts and Housings This section is related to components of the electric drive and control system with voltages exceeding 50 volt. Contact with parts conducting voltages above 50 volt 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 electric voltage! Danger to life, risk of injury by electric shock or serious injury! Only qualified personnel is allowed to operate, maintain and/or repair the electric components of the drive and control system. Follow the general installation and safety regulations when working at high voltage units. Before switching the machine on, the grounding conductor must be securely 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. Before accessing electric parts with voltage potentials higher than 50 V, disconnect electric components from the mains or from the power supply unit. Secure the electric component against reconnection. For electric components, note the following: Always wait for 30 minutes after switching off power to allow live capacitors to discharge before accessing an electric component. Measure the electric voltage of live parts before operation to ensure that the equipment is safe to touch. Install the covers and guards provided before switching on. Never touch electric connection points of the components while the machine is switched on. Do not remove or plug in connectors when the machine is connected. Electric drive systems can be operated at power supply systems under certain conditions, if protected by sensitive residual-current devices (RCD/RCM). 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 drive and control system to the grounding conductor at the grounding points. Connect the grounding conductor of the components of the drive and control system permanently to the main power supply at all times. The leakage current is greater than 3.5 ma.

24 22/229 Bosch Rexroth AG RE30159-WA Safety Instructions for Electric and Hydraulic Drives and Controls Establish a quipment grounding conductor connection with a minimum cross section according to the following table. For an external conductor connection shorter than 10 mm 2, a connection of two quipment grounding conductors is optional. Both connections have the same cross section as the external conductors. Cross section of the external conductor 1.5 mm 2 (AWG 16) Minimum cross section of the grounding conductor Leakage current 3.5 ma 1 protective earth conductor 2 protective earth conductors mm 2 (AWG 16) 2.5 mm 2 (AWG 14) mm 2 (AWG 14) 4 mm 2 (AWG 12) 10 mm 2 (AWG 8) 2 4 mm 2 (AWG 12) 6 mm 2 (AWG 10) 2 6 mm 2 (AWG 10) 10 mm 2 (AWG 8) - 16 mm 2 (AWG 6) - 25 mm 2 (AWG 4) 16 mm 2 (AWG 6) - 35 mm 2 (AWG 2) - 50 mm 2 (AWG 1/0) 25 mm 2 (AWG 4) - 70 mm 2 (AWG 2/0) 35 mm 2 (AWG 2) Fig.3-1: Minimum cross section of a grounding conductor connection Protective Extra-Low Voltage as Protection Against Electric Shock The safety extra-low voltage is used to connect devices with basic insulation to extra-low voltage circuits. All connections and terminals with voltages from 5 to 50 Volt are designed as protective extra low voltage ("Protective Extra Low Voltage - PELV") at the components of Bosch Rexroth drive and control systems. Devices equipped with basic insulation such as programming devices, PCs, notebooks and indicator units can be connected to these contacts. Danger to life, risk of injury by electric shock! High voltage due to incorrect connection! If extra low voltage circuits of devices that also contain voltages and electric circuits (e.g. the power supply) are connected to Bosch Rexroth products, the connected low voltage circuits have to comply with the requirements for ("Protective Extra Low Voltage - PELV") Protection Against Dangerous Movements Dangerous movements can be caused by incorrect actuation of connected drives. The reasons can vary: Improper or incorrect wiring or cabling Operator error

25 RE30159-WA Bosch Rexroth AG 23/229 Safety Instructions for Electric and Hydraulic Drives and Controls Incorrectly entered parameters prior to commissioning Errors in transducers and signal generators Defective components Errors in software or firmware These errors can occur immediately after switch on or after an indefinite time during the operation. Monitorings in the components of the electric drive and control system rule a malfunction in the connected drives out, to the greatest possible extend. With regard to operator protection and especially with regard to danger to life and/or material damage, it is critical to only rely on the monitoring functions. Incorrect drive movements can occur until the installed monitoring system becomes active. The incorrect axis movement depends on the control type and the operating state. Dangerous movements! Life-threatening danger, risk of injury, severe bodily harm or material damage! A risk assessment is required for the system or the machine and their specific features, in which the components of electric drive and control systems are to be installed. The user has to provide monitoring and measures for operator protection, depending on the result of the risk assessment. The safety instructions of the system or the machine also have to be taken into consideration. By disabling, avoiding or not enabling the safety devices, random machine motions or malfunctions can occur. In case of malfunctions impairing the safety, immediately stop the product and inform the responsible personnel about the malfunction. Avoiding accidents, danger to life and/or material damage. The controls as such do not contain any safety function for personal safety and do not constitute safety-relevant components Keep away from the motion range of a machine and machine parts. Prevent accidental access of persons, e.g. by a safety fence a guard a protective cover a photoelectric barrier Ensure a sufficient stability of safety fences and protective covers against the maximum possible kinetic energy. Install an EMERGENCY STOP switch. The switch has to be within quick and easy reach. Check, if the EMERGENCY STOP is working, before commissioning the system or the machine. Do not operate the machine in case of a malfunction of the EMERGENCY STOP switch. Ensure that the machine cannot be switched on accidentally. Disconnect the drives using the contact breaker, disconnect the hydraulic system.make sure that there is no more pressure on the system or use a safe interlock. Stop the drives before accessing the hazard area. Vertical axes have to be additionally protected against drawdown after the motor has been switched off, e.g. by mechanic locking by the vertical axis,