Related Manuals for Bosch Rexroth ctrlX SAFETY
Summary of Contents for Bosch Rexroth ctrlX SAFETY
- Page 1 ctrlX SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE Application Manual Edition 03 R911383774...
- Page 2 Record of revisions see ""Editions of this documentation" on page 1" Copyright © Bosch Rexroth AG 2020 All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
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Page 3: Table Of Contents
Standards relevant to components....................19 4.3.3 Standards relevant to machinery....................... 19 4.3.4 EC/EU directives..........................20 Overview of functions and characteristics.................... 20 4.4.1 Characteristics of integrated safety technology................. 20 4.4.2 Performance............................20 Safety characteristics of the safety system................... 21 R911383774_Edition 03 Bosch Rexroth AG... - Page 4 Diagnostic system..........................45 9.2.1 General information........................... 45 Diagnostic messages of integrated safety technology................46 9.3.1 Overview............................46 9.3.2 Status information of integrated safety technology................46 9.3.3 Behavior in the case of non-fatal safety technology errors (F3xxx)........... 47 Bosch Rexroth AG R911383774_Edition 03...
- Page 5 Interfaces relevant to safety technology....................55 12.1.1 XG41, safety technology Safe Torque Off..................55 12.2 Technical data of inputs and outputs....................55 12.2.1 Digital inputs (safety technology)....................... 55 12.2.2 Digital outputs (safety technology)....................56 Service and support..................... 59 Index..........................61 R911383774_Edition 03 Bosch Rexroth AG...
- Page 6 SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE Bosch Rexroth AG R911383774_Edition 03...
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Page 7: Introduction
"Safe Torque Off" safety option of ctrlX DRIVE. – is addressed to individuals who mount, operate and maintain ctrlX DRIVE with the "Safe Torque Off" safety option. R911383774_Edition 03 Bosch Rexroth AG... - Page 8 If you discover mistakes in this documentation or suggest changes, you can send your feedback to the following e-mail address: [email protected] We need the following information to handle your feedback: ● The number indicated under "Internal File Reference". ● The page number. Bosch Rexroth AG R911383774_Edition 03...
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Page 9: Important Directions For Use
Drive controllers have to be programmed before commissioning to ensure that the motor executes the functions specific to the application. Drive controllers of the ctrlX DRIVE series have been developed for use in single- and multi-axis drive and control tasks. R911383774_Edition 03 Bosch Rexroth AG... -
Page 10: Unintended Use
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 interference suppression. Bosch Rexroth AG R911383774_Edition 03... -
Page 11: Safety Instructions For Electric Drives And Controls
R911383774_Edition 03 Bosch Rexroth AG... -
Page 12: General Information
● 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 Rexroth. Bosch Rexroth AG R911383774_Edition 03... - Page 13 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) R911383774_Edition 03 Bosch Rexroth AG...
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Page 14: Hazards By Improper Use
Always wait 30 minutes after switching off power to allow live capacitors to discharge before accessing an electric component. Measure the electrical voltage of live parts before beginning to work to make sure that the equipment is safe to touch. Bosch Rexroth AG R911383774_Edition 03... - Page 15 (4 AWG) 16 mm (6 AWG) 35 mm (2 AWG) 50 mm (1/0 AWG) 25 mm (4 AWG) 70 mm (2/0 AWG) 35 mm (2 AWG) Tab. 3-1: Minimum cross section of the equipment grounding connection R911383774_Edition 03 Bosch Rexroth AG...
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Page 16: Protective Extra-Low Voltage As Protection Against Electric Shock
The safety regulations applicable to the installation or machine must be taken into consideration. Unintended machine movements or other malfunctions are possible if safety devices are disabled, bypassed or not activated. To avoid accidents, injury and/or property damage: Bosch Rexroth AG R911383774_Edition 03... -
Page 17: Protection Against Electromagnetic And Magnetic Fields During Operation And Mounting
Health hazard for persons with active implantable medical devices (AIMD) such as pacemakers or passive metallic implants. ● Hazards for the above-mentioned groups of persons by electromagnetic and magnetic fields in the immediate vicinity of drive controllers and the associated current-carrying conductors. R911383774_Edition 03 Bosch Rexroth AG... -
Page 18: Protection Against Contact With Hot Parts
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! Bosch Rexroth AG R911383774_Edition 03... -
Page 19: Protection Against Pressurized Systems
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. R911383774_Edition 03 Bosch Rexroth AG... -
Page 20: Explanation Of Signal Words And The Safety Alert Symbol
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. NOTICE In case of non-compliance with this safety instruction, property damage could occur. Bosch Rexroth AG R911383774_Edition 03... -
Page 21: System Overview
The safety signals are transmitted with conventional wiring. R911383774_Edition 03 Bosch Rexroth AG... -
Page 22: Conceptual Overview
For more detailed information on the required Safety Integrity Levels (SIL) and Performance Levels (PL), please refer to the applied component- and machine-relevant standards in "Safety- relevant standards and regulations". Bosch Rexroth AG R911383774_Edition 03... -
Page 23: Product Presentation
The safety functions are selected via 24 V inputs at the drive controller. Certification The safety technology was certified by TÜV Rheinland ®. The NRTL listing by TÜV Rheinland of North America is available for HCS01. The other series are in preparation. R911383774_Edition 03 Bosch Rexroth AG... -
Page 24: Integrated Safety Technology In Ctrlx Drive
4.3.1 General information Standard documents and sheets are subject to copyright protection and Bosch Rexroth cannot pass them on. If required, contact the authorized sales agencies; in Germany directly contact Beuth Verlag GmbH (http://www.beuth.de). Below the user will find a short overview of the relevant standards for the use of safety-related control units. -
Page 25: Standards Relevant To Components
Safety of machine tools ‑ Small numerically controlled turning machines and turning centres EN 12417 Machine tools ‑ Safety ‑ Machining centres EN 13218 Machine tools ‑ Safety ‑ Stationary grinding machines Tab. 4-4: Standards relevant to machinery R911383774_Edition 03 Bosch Rexroth AG... -
Page 26: Ec/Eu Directives
1 ms exists ● When deselecting the safety functions – Time until an error-free dual-channel deselection exists – Reaction time of the drive system to drive enable having been set (putting motor under current, releasing the brake) Bosch Rexroth AG R911383774_Edition 03... -
Page 27: Safety Characteristics Of The Safety System
The specified safety characteristics refer to an average ambi‐ ent temperature of 40 °C (see also "Ambient and operating conditions" in the Project Planning Manuals). Tab. 4-7: Safety characteristics of the ctrlX DRIVE system with the optional safety technology module "T0" R911383774_Edition 03 Bosch Rexroth AG... -
Page 28: Calculating The Total Pfh Value Of A Safety Zone
DRIVE This value is independent of the safety level to be attained. axis_x system with the optional safety technology module T0" on page 21" Tab. 4-8: Variable description to calculate PFH for a safety zone Bosch Rexroth AG R911383774_Edition 03... -
Page 29: Functional Principle Of Integrated Safety Technology
I of the Directive 2006/42/EC. The schematic diagram of a ctrlX DRIVE device below illustrates the basic functions and functional principles explained in this section: Fig. 5-1: Schematic diagram of ctrlX DRIVE with integrated safety technology R911383774_Edition 03 Bosch Rexroth AG... -
Page 30: Dynamization
Maximum bounce time for a selection or 400 ms bounce deselection Phase shift of the test pulses on both φ channels: no requirement Tab. 5-1: Limit values of the dynamization pulses of the OSSD outputs Bosch Rexroth AG R911383774_Edition 03... - Page 31 When the safety functions are selected via a passive safety unit, the drive generates the dynamization pulses and makes them available via the "STO_DynOut_CH1" and "STO_DynOut_CH2" outputs at the XG41 R911383774_Edition 03 Bosch Rexroth AG...
- Page 32 A safety zone cannot contain more than 25 drives with an optional safety technology module "T0". If more than 25 drives are to be operated at a safety unit, multiple safety zones have to be set up. Bosch Rexroth AG R911383774_Edition 03...
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Page 33: Integrated Safety Function
"Safe torque off", e.g. in the case of a vertical axis, this motion has to be safely prevented by additional measures, e.g. a mechanical brake or a counterweight. For such axes, Bosch Rexroth recommends using the Safe braking and holding system. - Page 34 The dynamization function is explained in the chapter on "Dynamization". The dynamization pulses are monitored for the following aspects: ● Time interval ● Pulse width ● Sampling ratio Bosch Rexroth AG R911383774_Edition 03...
- Page 35 The selection of the safety function is detected when a "0"-signal is detected on both selection inputs. The selection can alternatively be made via active or passive safety units. See also "Examples of application" R911383774_Edition 03 Bosch Rexroth AG...
- Page 36 "Safe Torque Off", e.g. in the case of a vertical axis, this motion has to be safely prevented by additional measures, e.g. a mechanical brake or a counterweight. For such axes, Bosch Rexroth recommends using the Safe braking and holding system.
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Page 37: Examples Of Application
STO function in the case of selection via passive safety units Dual-channel wiring Fig. 7-1: STO function with dual-channel wiring for single-axis devices and passive safety unit The assignment of the dynamization signals can be selected as desired. R911383774_Edition 03 Bosch Rexroth AG... - Page 38 In the case of dual-channel wiring for multi-axis devices (e.g., "XMD") and passive safety units, the wiring (as illustrated above) has to be implemented as a "safe wiring". This is necessary to exclude short circuit between lines supplied by the same dynamization output. Bosch Rexroth AG R911383774_Edition 03...
- Page 39 In the case of single-channel wiring between the passive safety unit and connector XG41 of the "T0 option", the internal structure of the passive safety unit, too, has to meet the requirements of the "safe wiring". Application engineers are free to choose any dynamization signal. R911383774_Edition 03 Bosch Rexroth AG...
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Page 40: Sto Function In The Case Of Selection Via Active Safety Units
Fig. 7-4: STO function with active safety unit (plus-plus-switching outputs) Single-channel wiring When the safety function is selected via a safety unit, the short circuit with 24 V has to be detected by the OSSD output. Bosch Rexroth AG R911383774_Edition 03... - Page 41 See also EN ISO 13849-2:2012, table D.4 In the case of single-channel wiring between the active safety unit and connector XG41 of the "T0 option", the OSSD output has to be designed with "serial redundancy" according to SIL3. R911383774_Edition 03 Bosch Rexroth AG...
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Page 42: Safe Stop 1 (Emergency Stop)" Function With "T0" Option
STO function after a fixed time that has been set is over. The selection always has to take place after the time that has been set, independent of the axis state. Fig. 7-6: SS1 function with dual-channel wiring and passive safety unit Bosch Rexroth AG R911383774_Edition 03... -
Page 43: Zone Setup
SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE 37/65 Examples of application 7.1.4 Zone setup Fig. 7-7: Example of zone setup (in this case: 2 ctrlX DRIVE in a safety zone with dual-channel wiring and passive safety unit) R911383774_Edition 03 Bosch Rexroth AG... - Page 44 38/65 ctrlX SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE Bosch Rexroth AG R911383774_Edition 03...
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Page 45: Commissioning The Safety Technology
For the maximum gearbox input torque, too, a safety factor in relation to the maximum motor torque has to be taken into account. This also applies to motor-gearbox combinations by Bosch Rexroth. (See also documentation of the respective gearbox.) In the case of error, injury and property... -
Page 46: Required Controller Configuration
Single-axis converter: XCS1-W0***A****-***T0) ● Single-axis inverter: XMS1-W0***A****-***T0) ● Double-axis inverter: XMD1-W****A****-***T0) For pin assignments and technical data of the optional safety technology module "T0", please refer to the Appendix: "XG41, safety technology Safe Torque Off". Bosch Rexroth AG R911383774_Edition 03... -
Page 47: Required Motors And Measuring Systems
⇒ In this case, all cases of operation occurring in the application must be taken into account, including mains failure and tripped fuses. R911383774_Edition 03 Bosch Rexroth AG... -
Page 48: Commissioning Steps
(active or passive) and the wiring type (single-channel or dual-channel): ● the STO_DynOut_CH1 (XG41:1) and STO_DynOut_CH2 (XG41:5) dynamization outputs in the case of selection via a passive safety unit ● the STO_CH1 (XG41:3) and STO_CH2 (XG41:7) selection inputs always Bosch Rexroth AG R911383774_Edition 03... - Page 49 Step 4: Activating / deactivating the safety function Before selecting the safety function "Safe Torque Off", decelerate the drive system using the command value input and reset drive enable. Drive-controlled deceleration is not carried out! R911383774_Edition 03 Bosch Rexroth AG...
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Page 50: Requirements For The Control Unit
"Dynamization" are not inhibited. ‑ or ‑ The control unit features OSSD outputs (active safety unit) and has to monitor the wiring between the control unit and the safety option, as well as detect errors in the wiring. Bosch Rexroth AG R911383774_Edition 03... -
Page 51: Troubleshooting Information
(see also firmware Application Manual "Device configuration"). Identifiers useful for the purpose of diagnostics and service are stored in the following parameters: ● S‑0‑0140, Controller type ● S‑0‑0141, Motor type ● S‑0‑0142, Application type ● P‑0‑1516.0.x, Component type data, carrier unit R911383774_Edition 03 Bosch Rexroth AG... -
Page 52: Diagnostic Messages Of Integrated Safety Technology
"Limited diagnostic message" is active (green), unless the axis has been in control (AF) after the initialization. In this state, selection errors are not output so that external components for selection have enough time for initialization. Bosch Rexroth AG R911383774_Edition 03... -
Page 53: Behavior In The Case Of Non-Fatal Safety Technology Errors (F3Xxx)
Generally, there are 4 types of fatal errors (F8 errors): ● fatal errors during initialization (F81xx) ● fatal axis errors during operation (F80xx) ● fatal safety technology errors (F83xx) ● fatal axis and supply unit errors during operation (F88xx) R911383774_Edition 03 Bosch Rexroth AG... -
Page 54: Removing Malfunctions, Maintenance Measures, Deactivating The Motors
"Safety instructions for electric drives and controls"! In the case of malfunctions, maintenance measures or to deactivate the motors, proceed as follows: ● Observe the instructions contained in the machine documentation. Bosch Rexroth AG R911383774_Edition 03... -
Page 55: Replacing Drive Components
(allowed pollution degree according to EN50178: 2). 5. Replace motor To mechanically replace the AC servo motor, observe the instructions of the machine manufacturer. R911383774_Edition 03 Bosch Rexroth AG... -
Page 56: Replacing The Brake
While the brake is replaced, secure the axis by a blocking device or by moving the axis to a safe end position. The same type of brake must be used after replacement. Bosch Rexroth AG R911383774_Edition 03... -
Page 57: Decommissioning Drive Components
Furthermore, the impact and hazard analysis must contain a risk assessment of the process of decommissioning. On the basis of this impact and hazard analysis, decommission the drive or component (see also IEC 61508-1:2010, 7.17). R911383774_Edition 03 Bosch Rexroth AG... - Page 58 52/65 ctrlX SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE Bosch Rexroth AG R911383774_Edition 03...
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Page 59: Declaration Of Conformity
"T0" [STO (Safe Torque Off)]. The declaration of conformity is also available with signatures in the English language. If you have access to the Bosch Rexroth Intranet, please download the declaration of conformity here. Otherwise, please contact our sales representative. - Page 60 54/65 ctrlX SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE Bosch Rexroth AG R911383774_Edition 03...
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Page 61: Project Planning
12.2 Technical data of inputs and outputs 12.2.1 Digital inputs (safety technology) The digital inputs correspond to IEC 61131-2. Data Unit min. max. Allowed input voltage High Current consumption Tab. 12-2: Digital inputs (safety technology) R911383774_Edition 03 Bosch Rexroth AG... -
Page 62: Digital Outputs (Safety Technology)
3000 Periodic time 3600 Phase shift between two test not specified pulses on both channels (φ) Tab. 12-3: Time behavior 12.2.2 Digital outputs (safety technology) The digital outputs are compatible with digital inputs IEC 61131-2. Bosch Rexroth AG R911383774_Edition 03... - Page 63 The effective termi‐ nal voltage has to be < 25 V. : Number of digital inputs that are used for a digital output Tab. 12-4: Digital outputs R911383774_Edition 03 Bosch Rexroth AG...
- Page 64 SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE Project planning Time behavior Description Unit typ. Test pulse width (t μs Periodic time (T Phase shift between two test ° pulses on both channels (φ) Tab. 12-5: Time behavior Bosch Rexroth AG R911383774_Edition 03...
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Page 65: Service And Support
Detailed description of malfunction and circumstances ● Type plate specifications of the affected products, in particular type codes and serial numbers ● Your contact data (phone and fax number as well as your e-mail address) R911383774_Edition 03 Bosch Rexroth AG... - Page 66 60/65 ctrlX SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE Bosch Rexroth AG R911383774_Edition 03...
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Page 67: Index
ctrlX SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE 61/65 Index Index Replacing............49 Automatic operation..........15 Normal operation..........15 Commissioning the safety technology Safety instruction........... 39 Connection Overview of the safety function......27 Safety technology Safe Torque Off (XG41)... 55 Control section RoHS............... - Page 68 62/65 ctrlX SAFETY "Safe Torque Off" Safety Option in ctrlX DRIVE Index Safe Torque Off..........27 State-of-the-art............3 STO..............27 Safe Torque Off (XG41)......... 55 Support............... 59 T0..............20, 27 Commissioning, ctrlX DRIVE......41 Controller configuration........40 Technical data Digital inputs..........55 Digital outputs (safety technology)....
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- Page 72 Bosch Rexroth AG P.O. Box 13 57 97803 Lohr a.Main, Germany Bgm.-Dr.-Nebel-Str. 2 97816 Lohr a.Main, Germany Phone +49 9352 18 0 Fax +49 9352 18 8400 www.boschrexroth.com/electrics *R911383774* R911383774 DOK-XDRV**-SI-TX******-AP03-EN-P...