Bosch rexroth ctrlX SAFETY SafeMotion Applications Manual
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Bosch rexroth ctrlX SAFETY SafeMotion Applications Manual

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Application Manual
ctrlX SAFETY
"SafeMotion"
ctrlX DRIVEplus
– Original version –
R911404905, Edition 02

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Summary of Contents for Bosch rexroth ctrlX SAFETY SafeMotion

  • Page 1 Application Manual ctrlX SAFETY "SafeMotion" ctrlX DRIVEplus – Original version – R911404905, Edition 02...
  • Page 2 Copyright © Bosch Rexroth AG 2022 All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract.

  • Page 3: Table Of Contents

    Encoder evaluation..........R911404905, Edition 02 Bosch Rexroth AG...
  • Page 4 Overview..........7.6.2 SafeMotion profile "Bosch Rexroth" ......Safety functions Global safety functions.
  • Page 5 11.3 Decommissioning drive components....... . . 249 12 Declaration of conformity R911404905, Edition 02 Bosch Rexroth AG...
  • Page 6 14.2 Application examples of ctrlX DRIVE with SafeMotion....287 15 Reference documentations 16 Service and support 17 Glossary 18 Index Bosch Rexroth AG R911404905, Edition 02...

  • Page 7: About This Documentation

    – ⮫ Chapter 11.2.1 Replacing the motor on page 243 – ⮫ Chapter 11.2.3 Replacing the optional encoder on page 244 – ⮫ Chapter 11.2.5 Replacing the cables on page 245 R911404905, Edition 02 Bosch Rexroth AG...
  • Page 8 In case of any errors or if you want to suggest changes to this documentation, please do not hesitate to contact us. Please send your feedback to: Bosch Rexroth AG Dept. DC-AE/EPI5 Buergermeister-Dr.-Nebel-Str. 2 97816 Lohr a.Main Germany E-mail: ⮫...

  • Page 9: Trademark Information

    GmbH, Germany HIPERFACE® is a registered trademark of SICK-STEGMANN GmbH EnDat® is a registered trademark of Dr. Johannes Heidenhain GmbH ACURO®link is registered trademark of Hengstler GmbH BiSS is registered trademark of iC-Haus GmbH R911404905, Edition 02 Bosch Rexroth AG...
  • Page 10 SAFETY "SafeMotion" 10 / 302 Bosch Rexroth AG R911404905, Edition 02...

  • Page 11: Important Directions On Use

    Device types with different drive power and interfaces are available for using the Antriebsregelgeräte in specific applications. Typical applications include, for example: ● Handling and assembly systems ● Packaging and food machines ● Printing and paper converting machines ● Machine tools R911404905, Edition 02 Bosch Rexroth AG...

  • Page 12: Unintended Use

    These components are not intended for use in a public low voltage system for residential areas. If these components are operating in such a network, high frequency interferences are to be expected. Additional measures for interfer- ence suppression can be required. Bosch Rexroth AG R911404905, Edition 02...

  • Page 13: Safety Instructions For Electric Drive And Control Systems

    ● The specifications contained in the application documentation regarding the use of the provided components are only application examples and recom- mendations. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 14: Hazards Due To Incorrect Use

    ● 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. Bosch Rexroth AG R911404905, Edition 02...
  • Page 15 2 × 6 mm2 (AWG 10) 10 mm2 (AWG 8) 16 mm2 (AWG 6) 16 mm2 (AWG 6) 25 mm2 (AWG 4) 35 mm2 (AWG 2) 50 mm2 (AWG 1/0) 25 mm2 (AWG 4) R911404905, Edition 02 Bosch Rexroth AG...

  • Page 16: Protective Extra-Low Voltage As Protection Against Electric Shock

    The safety regulations applicable to the system or machine have to be included. Unin- tended machine movements or other malfunctions are possible if safety devices are disabled, bypassed or not activated. Bosch Rexroth AG R911404905, Edition 02...

  • Page 17: Protection Against Electromagnetic And Magnetic Fields During Opera

    They should seek advice from their attending doctor. ● If overcome by possible effects on above-mentioned persons during opera- tion of drive controllers and accessories, remove the exposed persons from the vicinity of conductors and devices. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 18: Protection Against Contact With Hot Parts

    (risk of explosion) in the sense of the legal regulations. Dispose of used batteries sepa- rately from other waste. Comply with the national regulations of your country. Bosch Rexroth AG R911404905, Edition 02...

  • Page 19: Protection Against Pressurized Systems

    Non-compliance with this safety instruction can result in WARNING death or serious personal injury. Non-compliance with this safety instruction can result in CAUTION moderate or minor personal injury. Non-compliance with this safety instruction can result in NOTICE property damage. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 20 SAFETY "SafeMotion" 20 / 302 Instructions with regard to specific dangers Bosch Rexroth AG R911404905, Edition 02...

  • Page 21: System Presentation

    The following options are available to select and acknowledge the safety tech- nology functions provided with the firmware and the optional safety technology module “M5”: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 22 ● Selection und die acknowledgement via discrete wiring on the basis of 24-V- signal. The wiring layout has to be redundant or via a safe wiring with fault exclusion. The wiring type essentially depends on the safety level to be achieved. Bosch Rexroth AG R911404905, Edition 02...

  • Page 23: Product Presentation

    Characteristics of ctrlX DRIVE The type code shows the different characteristics of ctrlX DRIVE. The position 10 of the type code show whether your device has been equipped with a safety technology optional module. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 24 02 = ctrlX DRIVE plus … … ⑩ Hardware option 1 - Safety: T0 = Safe Torque Off (STO) M5 = SafeMotion (M5) ⑪ Hardware option 2: EC = Multi-encoder interface NN = Not equipped … … Bosch Rexroth AG R911404905, Edition 02...
  • Page 25 DA = Digital/analog I/O extension NN = Not equipped ⑬ Runtime type: S = Standard ⑭ Runtime version: 02 = Version 02 (XCS1) 03 = Version 03 (XCS2) ⑮ Runtime release: RS = Current release … … R911404905, Edition 02 Bosch Rexroth AG...
  • Page 26 Hardware option 3: NN = Not equipped ⑬ Runtime type: S = Standard ⑭ Runtime version: 02 = Version 02 (XMD1) 03 = Version 03 (XMD2) ⑮ Runtime release: RS = Standard (current release) … … Bosch Rexroth AG R911404905, Edition 02...

  • Page 27: Performance

    Time response and reaction times The time response of "SafeMotion" is represented in the following figure. The figure can be used to determine the hardware-dependent and configuration- dependent total reaction time for individual applications. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 28 “M5” See chapter ⮫ Error reaction and escalation strategy (in case of encoder errors with EnDat–2.2 encoders or ACUROⓇlink encoder, the error reaction time is increased by 2 ms) Bosch Rexroth AG R911404905, Edition 02...

  • Page 29: Reaction Time Of "Safe Zone Error" (Sze)

    ● Category 4, PL e according to EN ISO 13849-1 – for all safety functions working independently of the measuring system ● Category 3, PL d according to EN ISO 13849-1 – for all safety functions R911404905, Edition 02 Bosch Rexroth AG...

  • Page 30: Calculating The Pfh Component Of An Axis

    PFH value from the component manufacturer). Table 6: SafeMotion: Formula to calculate PFH for an axis = PFH + PFH + PFH + PFH + PFH axis M5 option EC option encoder SBC function, brake 1 brake 1 Bosch Rexroth AG R911404905, Edition 02...

  • Page 31: Calculating The Total Pfh Value Of A Safety Zone

    Table 8: SafeMotion: Formula to calculate PFH for a safety zone = PFH + PFH + PFH +…+ PFH Safety zone Discrete_selection Axis_1 Axis_2 Axis_n The following conditions/restrictions apply to the general use of the formula for PFH calculation for a safety zone: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 32 ⮫ Calculating the PFH This value depends on the parameterized safety axis_x component of an axis functions and has to be calculated for each axis of the safety zone. Legend: PFH=(1-DC)/MTTFD ® Bosch Rexroth AG R911404905, Edition 02...

  • Page 33: Functional Principle

    The maximum length of the dynamization pulse can be configured (refer to ⮫ Signal control of inputs). The figure below schematically illustrates the interconnection of an active safety unit and multiple drives with an optional safety technology module: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 34 The figure below schematically illustrates the interconnection of a passive safety unit and multiple drives with an optional safety technology module: Bosch Rexroth AG R911404905, Edition 02...

  • Page 35: Encoder Evaluation

    ● In the "configuration mode" (CM), the encoder evaluation is not active and does not signal any errors. The parameter P-0-3256 displays the current status of the encoder evaluation, encoder errors, encoder warning, ..R911404905, Edition 02 Bosch Rexroth AG...
  • Page 36 The wrong parameterization of the mounting position and of the encoder gearbox causes incorrect position and velocity values. Make sure the physical mounting position of the encoder has been parameterized correctly. The figure below illustrates the possible mounting positions of the safe encoder: Bosch Rexroth AG R911404905, Edition 02...
  • Page 37 Via the command "C8400 SMO: Apply encoder configuration command", the settings of the encoder of interface XG20 / XG21 (or XG20.1 / XG21.1, XG20.2 / XG21.2) can be applied from the standard firmware to "SafeMotion". R911404905, Edition 02 Bosch Rexroth AG...

  • Page 38: Scaling System

    ● Parameter scaling: Settings to be defined by the user for "unit", "time unit" and "exponent". "Unit" and "time unit" are physical values. The "exponent" defines the number of decimal places of the scaled values. Bosch Rexroth AG R911404905, Edition 02...
  • Page 39 With the "ramp time" scaling type, the scaling can be defined by means of “P-0-3224.0.3, SMO: Ramp reference velocity for acceleration data“. The data reference can be at the motor shaft or at the load. The incremental scaling, as in the standard firmware, is not supported. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 40 Example: P‑0‑3221.0.7="36000°" (default value) ⇒ the limit velocity is 4,800,000 rpm ● "modulo format" (P‑0‑3222.0.1, bit 7="1") Overflow limit = "P‑0‑3221.0.6, SMO: Modulo value" Example: P-0-3221.0.6=360° (default value) ⇒ the limit velocity is 24,000 rpm Bosch Rexroth AG R911404905, Edition 02...
  • Page 41 The scaling defines in which format (unit) the data are displayed. Not all setting variants for scaling and data reference are supported. The setting of the data reference is restricted by the encoder used and its mounting position, as well as the desired data representation: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 42 Depending on P‑0‑3221.0.7, the internal resolution is set in "SafeMotion", which influences the monitoring precision. To achieve the highest possible precision, P‑0‑3221.0.7 should be set to the smallest possible value for the application. Bosch Rexroth AG R911404905, Edition 02...

  • Page 43: Notes On Commissioning

    Each of them has its own identifier in the form of a parameter. Identifiers useful for the purpose of diagnostics and service are stored in the following parameters: ● S‑0‑0140, Device name ● S‑0‑0141, Motor type ● S‑0‑0142, Application type ● P‑0‑1520, Control section type R911404905, Edition 02 Bosch Rexroth AG...

  • Page 44: Firmware Identifiers

    "SafeMotion" main branch and the "Diagnostics" child node. The following dialogs are available: ● ""SafeMotion"" shows information on the status and diagnostic messages of Safe Motion Bosch Rexroth AG R911404905, Edition 02...
  • Page 45 45 / 302 Diagnostic system Fig. 8: "SafeMotion" status dialog ● "Safety bus communication“ shows information on the status and diagnostic messages of the Safety bus communication Fig. 9: "Safety bus communication" status dialog R911404905, Edition 02 Bosch Rexroth AG...
  • Page 46 ● "Safe brake control" shows information on the status of the safe brake con- trol Fig. 12: "Safe brake control“ status dialog ● "IO mapper inputs" shows information on the status of the IO mapper inputs Bosch Rexroth AG R911404905, Edition 02...

  • Page 47: Error Reaction And Escalation Strategy

    Fig. 14: "Safety zone“ status dialog 7.4.4 Error reaction and escalation strategy "SafeMotion“ has two operating states, normal operation and special mode. In both operating states, an error or a warning is generated if a monitoring function is triggered. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 48 "Safe Torque Off" (STO) is active. If it has been configured, the safety function SBC becomes active with STO; i.e. the connected brakes have been safely switched off. Bosch Rexroth AG R911404905, Edition 02...
  • Page 49 (see “P-0-0117, Activation of control unit reaction on error and "P-0-0119, Best possible deceleration"). Differing configurations are detected by the tran- sition command error "C8814 SMO: Configuration faulty. The following error reactions can be configured: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 50 "SMD". In case of an inactive SMO encoder evaluation (P‑0‑3242.x.1), "SafeMotion“ monitors that the reac- tion is completed within the parameterized toler- ance time for the error reaction (P-0-3263.0.6 or P‑0‑3263.0.7). Bosch Rexroth AG R911404905, Edition 02...
  • Page 51 (emergency Velocity command value reset stop) with ramp and filter (emergency stop) Velocity command value reset (emergency stop) Velocity command value reset Velocity command value reset (emergency stop) (emergency stop) R911404905, Edition 02 Bosch Rexroth AG...
  • Page 52 F3 reaction mand value reaction, the axis is F7 reaction reset with inac- not yet torque-free. tive SMO ⇒ F7 error encoder evalua- For the F7 reaction, tion the axis needs the entire parameterized time. Bosch Rexroth AG R911404905, Edition 02...
  • Page 53 F3 ≙ the axis needs the x *1) P‑0‑3263.0.5 reset (emer- reset (emer- F7 reaction entire parameterized (maximum t P‑0‑3263.0.6 gency stop) gency stop) time and ramp until standstill. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 54 / the parameterized distance. The error reaction is taken to the next higher escalation level until the axis has been decelerated. The figure below shows the escalation strategy on its individual levels: Bosch Rexroth AG R911404905, Edition 02...
  • Page 55 7-4. The deceleration process is monitored with the transition function "Safely-monitored deceleration" (SMD-E). If deceleration is not successful, i.e. the SMD-E monitoring triggers, the error F8351 is generated and the drive is switched to level 3 of the escalation strategy. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 56: Safemotion State Machine

    ● the "Subdevice state machine" (defines the device-specific states which determine the behavior of the device) and ● the "SafeMotion state machine" (defines the safety technology-specific states which determine the behavior of safety technology) Bosch Rexroth AG R911404905, Edition 02...

  • Page 57: Function

    – All local safe outputs have been set to "0". – The brake output has been deactivated, i.e. an electrically releasing brake is applied. – The input signals (local input, Safety bus, ctrlX SAFETYlink) are not evalu- ated R911404905, Edition 02 Bosch Rexroth AG...
  • Page 58 The SafeMotion state machine is coupled to the subdevice state machine; i.e. the SafeMotion state machine changes its state, if the subdevice state machine changes its state. To change between the states of the state machine, use the following commands: Bosch Rexroth AG R911404905, Edition 02...

  • Page 59: Safemotion Profiles

    Thus, the safety functions can be independently selected and deselected in some profiles, but in other profiles they cannot. This chapter describes the supported profiles with their profile-specific properties. Only the “Bosch Rexroth“ Safe Motion profile is available. It is automatically activated with “Safe Motion“. R911404905, Edition 02...

  • Page 60: Safemotion Profile "Bosch Rexroth

    SafeMotion profile "Bosch Rexroth" Brief description The “Bosch Rexroth“ profile Safe Motion profile is a Bosch Rexroth-specific profile. With this profile, the safety functions cannot be individually selected, it is only possible to select different safety technology operating states. Within the safety technology operating states the safety functions configured in these states become active.
  • Page 61 The figure below shows the parameters involved and the basic function in conjunction with the "Bosch Rexroth" SafeMotion profile: Fig. 17: Control and status parameters with active SafeMotion profile "Bosch Rexroth" Safety technology operating states In the "Bosch Rexroth" Safe Motion profile, the individual safety functions cannot be directly selected.
  • Page 62 1) In certain cases, safety cannot be acknowledged In the Engineering software, the safety status of the axis is displayed in the "SafeMotion" status dialog (see also ⮫ Status dialogs in ctrlX DRIVE Engi- neering). Bosch Rexroth AG R911404905, Edition 02...
  • Page 63 (P-0-3262), only one safety technology operating status is activated at a time (P-0-3231). The table below shows the prioritization for the different selection combinations of the activation devices: Table 12: Prioritization of the selection of safety technology operating states in Bosch Rexroth SafeMotion profile Activation signals...
  • Page 64 Typically, the special mode "EMERGENCY STOP" is used to implement the EMERGENCY STOP function of a machine. Safety functions In the special mode "EMERGENCY STOP" (SMES), the following safety func- tions are active: Bosch Rexroth AG R911404905, Edition 02...
  • Page 65 Special mode “Safe standstill” (SMST) In the “Bosch Rexroth“ SafeMotion profile, the safety technology operating status special mode Safe standstill (SMST) is available in two characteris- tics: "SMST1" and "SMST2". When “SafeMotion“ is commissioned, the stand- still safety function to become active in special mode can be configured in P‑0‑3285.0.1.
  • Page 66 Special mode "Safe motion" (SMM) In the "Bosch Rexroth" SafeMotion profile, the special mode SafeMotion (SMM) consists of 16 individual safety technology operating states (SMM1 to SMM16). They can be independently configured and parameterized. During the commis- sioning of "SafeMotion", it is possible to configure in P-0-3290.x.1 for the...
  • Page 67 Using the parameter P-0-3262, it is possible to read out whether a selection for the special mode "Safe motion" exists. Using the status bits of P-0-3231, the safety technology signals whether a spe- cial mode "Safe motion" is presently active or not. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 68 (EC) or the mode selection signal (MS) were not reset. If the moni- toring time then is greater than the threshold parameterized in P‑0‑3290.x.6, the error “F3142 Activation time of enabling control exceeded” is generated. Bosch Rexroth AG R911404905, Edition 02...

  • Page 69: Safety Functions

    With the auxiliary function “limitation of the positioning velocity“, it is possible to monitor and, if necessary, limit the velocity command value effective in the drive to the active velocity threshold (P‑0‑3238). R911404905, Edition 02 Bosch Rexroth AG...

  • Page 70: Safe Speed Monitor (Ssm)

    Both velocity thresholds are bipolar, i.e. the parameterized threshold values are active in both directions (positive and negative velocity). ● Status displays: The status parameters (P‑0‑3264.0.1, bit 5) indicates if the safety function is activated. Bosch Rexroth AG R911404905, Edition 02...

  • Page 71: Safety Functions In Normal Operation

    A tolerated motion in a non-released direction of motion can be specified by the standstill window (P‑0‑3270.0.3). The safety function Safe direction is active in normal operation, if it has been parameterized for this mode (P‑0‑3277.0.1). R911404905, Edition 02 Bosch Rexroth AG...
  • Page 72 For example, the 16 different Safe motions (SMM) with the corresponding directions can be selected via the SMMx signals 1 to 16 (A_SMMx, x=1..16) in the SafeMotion profile Bosch Rexroth. ● Status display: The status parameter (P‑0‑3264.0.1, bit 6: safe direction of motion positive/bit 7: safe direction of motion negative) indicates if the safety function is activated.

  • Page 73: Safety Functions In Special Mode "Safe Standstill

    ● A0321 Special mode Safe standstill active with STO ● F2025 Drive not ready for control ● F8354 Error when checking interrupting circuits With the safety function "Safe torque off" activated, the display of the drive controller panel shows "SMST1". R911404905, Edition 02 Bosch Rexroth AG...
  • Page 74 The function "Safe torque off" can only be terminated by deselecting the safety function. After the safety function was terminated, the working motion of the drive can only be continued after drive enable has been set. Bosch Rexroth AG R911404905, Edition 02...

  • Page 75: Safe Operating Stop (Sos)

    For such axes, Bosch Rexroth recommends using the Safe braking and holding system. Injury and/or property damage caused by deviation from...
  • Page 76 (S‑0‑0124), preset for the drive (P‑0‑0048). If larger velocity command values are speci- fied, an error reaction is triggered (F6200), setting the drive system to standstill. Bosch Rexroth AG R911404905, Edition 02...
  • Page 77 "Safe operating stop", e.g. in case of a vertical axis, this motion must be safely prevented by additional measures, e.g. a mechanical brake or counter- weight. For such axes, Bosch Rexroth recommends using the Safe braking and holding system. R911404905, Edition 02...

  • Page 78: Safe Brake Control (Sbc)

    In the time between the occurrence of the error and the triggering of the "additional holding device", axis motion can occur. This has to be taken into account for the risk assessment of the installation. For such axes, Bosch Rexroth recommends using the safe braking and holding system. Make sure...
  • Page 79 ● The functionality was enabled in (P-0-3265.0.1). ● With safety technology encoder evaluation activated, axis standstill is safely detected (P-0-3256). ● The drive acknowledges safety (P‑0‑3237). R911404905, Edition 02 Bosch Rexroth AG...
  • Page 80 (see Divi- sion Information Sheet No. 005 of the German Social Accident Insurance (DGUV) "Gravity-loaded axes - Vertical axes” and C-standards). Bosch Rexroth AG R911404905, Edition 02...

  • Page 81: Safety Functions In Special Mode "Safe Motion Smmx

    ● Maximum safety level: The safety function is intended for safety-relevant applications up to Category 3, PL d according to EN ISO 13849-1 or up to SIL 2 according to EN 62061. ● Notes on parameterization: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 82 For example, the 16 different Safe motions (SMM) with the corresponding directions can be selected via the SMMx signals 1 to 16 (A_SMMx, x=1..16) in the SafeMotion profile Bosch Rexroth. ● Status display: The status parameter (P‑0‑3264.0.1, bit 4) indicates if the safety function is activated.
  • Page 83 "additional holding device", axis motion can occur. This has to be taken into account for the risk assessment of the installation. For such axes, Bosch Rexroth recommends using the safe braking and holding system. Values for "Safely-limited speed" In accordance with the Machinery Directive 2006/42/EC, the manufacturer of the machine must carry out a risk assessment.

  • Page 84: Safely-Monitored Transient Oscillation (Sls-Lt)

    For example, the 16 different Safe motions (SMM) with the corresponding directions can be selected via the SMMx signals 1 to 16 (A_SMMx, x=1..16) in the SafeMotion profile Bosch Rexroth. ● Status display: The status parameter (P‑0‑3264.0.1, bit 6) indicates if the safety function is activated.
  • Page 85 P‑0‑3290.x.8: Safely-reduced speed If the drive exceeds the velocity limit value [P‑0‑3290.x.8 (x=1..16)] for longer than a specified time [P‑0‑3290.x.7 (x=1..16), the drive switches off with the error message “F7014 Timeout safely-monitored transient oscillation“. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 86: Safe Direction (Sdi)

    (P‑0‑3270.0.3). The safety function Safe direction is active in normal operation, if it has been parameterized for this mode (P‑0‑3277.0.1). and / or Bosch Rexroth AG R911404905, Edition 02...

  • Page 87: Safely-Limited Increment (Sli)

    For example, the 16 different Safe motions (SMM) with the corresponding directions can be selected via the SMMx signals 1 to 16 (A_SMMx, x=1..16) in the SafeMotion profile Bosch Rexroth. ● Status display: The status parameter (P‑0‑3264.0.1, bit 6: safe direction of motion positive/bit 7: safe direction of motion negative) indicates if the safety function is activated.
  • Page 88 (SMM1 - SMM16). More- over, via parameter "P‑0‑3290.x.3, SMO: Safely-limited increment" (x=1..16), the effective increment has to be parameterized. safety function "Safely-limited increment" selected active "SafeMotion" profile using parameter “P-0-3264, SMO: Safety function selection". Bosch Rexroth AG R911404905, Edition 02...

  • Page 89: Transition Functions

    16 different Safe motions (SMM) with the corresponding increments can be selected via the SMMx signals 1 to 16 (A_SMMx, x=1..16) in the Safe Motion profile "Bosch Rexroth". Monitoring function In the case of the safety function Safely-limited increment, dual-channel moni- toring prevents the drive from moving by more than one maximum increment [P‑0‑3290.x.3 (x=1..16)].
  • Page 90 ● The deceleration can be optionally monitored during the transition using the safety function "Safely-monitored deceleration (SMD)". When the monitoring function is triggered, this causes an error reaction (F7051 / F8351) which decelerates the drive system. Bosch Rexroth AG R911404905, Edition 02...
  • Page 91 1", configured parameter "P‑0‑3280.0.1, SMO: Configuration of operation mode transitions“ during the commissioning of safety technology. The transition function "Safe stop 1" can be executed in 8 variants, as the table below shows: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 92 (SS1–t toring NC-controlled and SS1–r) transition (with trend monitoring) SS1, time- and Based on (+2b standstill-pri- actual oritized with velocity NC-controlled transition (based on actual velocity) Legend: *1) monitoring function of higher priority Bosch Rexroth AG R911404905, Edition 02...
  • Page 93 F8 error reaction (F3 reaction=F7 reaction in P‑0‑3263.0.1), the time is not prolonged. If the SMD acknowledges the transition process without error, the transition by the transition function SS1 is completed with the selection of the safety function STO. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 94 "F7050 Maximum transition time exceeded" is signaled. The drive keeps being deceler- ated in accordance with the parameterized error reaction (P-0-3263.0.1) (see ⮫ Error reaction and escalation strategy). Bosch Rexroth AG R911404905, Edition 02...
  • Page 95 "Safe stop 1 (SS1)“. If the SMD detects an exceeded velocity, the error "F7051 Safely-monitored deceleration " is reported and the drive is set to standstill according to the parameterized error reaction (P‑0‑3263.0.1) (see ⮫ Error reaction and escalation strategy). R911404905, Edition 02 Bosch Rexroth AG...
  • Page 96 SMD executed on the basis of the actual velocity P‑0‑3255 SMO: Velocity threshold for Safe standstill P‑0‑3280.0.2 SMO: Max. Transition time normal oper. to safe standstill P‑0‑3280.0.3 SMO: Max. Transition time between safe operating states Bosch Rexroth AG R911404905, Edition 02...
  • Page 97 SS1 is selected. That is to say the drive makes itself independent of the command value input of the control unit and is decel- R911404905, Edition 02 Bosch Rexroth AG...
  • Page 98 If the drive has been decelerated without error within the parameterized transition time (P-0-3280.0.2 or P-0-3280.0.3), the transition by the transi- tion function SS1 is completed with the selection of the safety function "Safe torque off (STO)". Bosch Rexroth AG R911404905, Edition 02...
  • Page 99 If the drive has been decelerated without error within the parameterized transition time (P-0-3280.0.2 or P-0-3280.0.3), the transition by the transi- tion function SS1 is completed with the selection of the safety function "Safe torque off (STO)". R911404905, Edition 02 Bosch Rexroth AG...
  • Page 100 ⇒ The maximum time between the selection of the transition function "Safe stop 1 (SS1)" and activating of the safety function Safe torque off (STO) does not depend on the transition progress! The maximum time span does is not extended by an error. Bosch Rexroth AG R911404905, Edition 02...
  • Page 101 (P-0-3280.0.2 or P-0-3280.0.3). If the transition is not completed within the parameterized tran- sition time, the error "F8350 Maximum transition time exceeded" is signaled and the safety function "Safe torque off” is activated. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 102 SMD executed on the basis of the actual velocity P‑0‑3255 SMO: Velocity threshold for Safe standstill P‑0‑3280.0.2 SMO: Max. transition time normal oper. to safe standstill P‑0‑3280.0.3 SMO: Max. transition time between safe operating states Bosch Rexroth AG R911404905, Edition 02...

  • Page 103: Safe Stop 2 (Ss2)

    ● The transition can be performed in a "drive-controlled" way or in an "NC-con- trolled" way. ● The safety function "Safe operating stop (SOS)" is automatically activated at the end of the transition function Safe stop 2 (SS2). R911404905, Edition 02 Bosch Rexroth AG...
  • Page 104 SMO: Configuration of operation mode transitions“ during the commissioning of safety technology. Selecting the transition function transition function "Safe stop (SS2)" activated active "SafeMotion" profile using parameter “P-0-3264, SMO: Safety function selection", when the following conditions have been ful- filled: Bosch Rexroth AG R911404905, Edition 02...
  • Page 105 P‑0‑3263.0.1), the time is not prolonged. If the SMD acknowledges the transition process without error, the transition by the transition function "Safe stop 2 (SS2)" is completed with the selection of the safety function "Safe operating stop (SOS)". R911404905, Edition 02 Bosch Rexroth AG...
  • Page 106 "F7050 Maximum transition time exceeded" is signaled. The drive keeps being deceler- ated in accordance with the parameterized error reaction (P-0-3263.0.1) (see ⮫ Error reaction and escalation strategy). Bosch Rexroth AG R911404905, Edition 02...
  • Page 107 If the transition process is terminated ahead of time via the "NC-Ready" signal, although the target velocity of the selected safety function has not yet been reached, the error “F7052 Selected target velocity exceeded" is generated and the drive is decelerated. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 108 "F7050 Maximum transition time exceeded" is signaled. The drive keeps being deceler- ated in accordance with the parameterized error reaction (P-0-3263.0.1) (see ⮫ Error reaction and escalation strategy). Bosch Rexroth AG R911404905, Edition 02...
  • Page 109 P‑0‑3280.0.2 SMO: Max. Transition time normal oper. to safe standstill P‑0‑3280.0.3 SMO: Max. Transition time between safe operating states Deselecting the safety function An active transition function "Safe stop 2 (SS2)" becomes inactive under the following conditions: R911404905, Edition 02 Bosch Rexroth AG...

  • Page 110: Safely-Monitored Deceleration (Smd)

    (cf. P‑0‑3263.0.6 P‑0‑3263.0.7, P‑0‑3280.0.2, P‑0‑3280.0.3, P‑0‑3280.0.4). When monitoring function triggered, this causes error reaction which decelerates the drive system. The corresponding error mes- sage "F7050 Maximum transition time exceeded "F8350 Maximum transition time exceeded“. Bosch Rexroth AG R911404905, Edition 02...
  • Page 111 The active monitoring functions depend on the parameterization of the axis, as well as on the selected safety function. The tables below show when the different types of monitoring are active and which error is generated when the monitoring function triggers. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 112 SMD with time- SMMx based trend moni- (SS2), toring SMD based on actual F7050 F7051 / E3151 velocity SMD with ramp- based trend moni- toring SMMx SMMx F7051 SMD with time- based trend moni- toring Bosch Rexroth AG R911404905, Edition 02...
  • Page 113 STO (SS1), F8350 F8351 SMD with ramp-based SOS (SS2), trend monitoring 0 or 4 F7050 F7051 F8350 F8351 F8350 F8351 F8350 F8351 SMD with time-based 0 or 4 trend monitoring F7050 F7051 F8350 F8351 R911404905, Edition 02 Bosch Rexroth AG...
  • Page 114 F8351 / E3151 F8350 F8351 / E3151 0 or 4 F7050 F7051 / E3151 F8350 F8351 / E3151 F8350 F8351 F8350 F8351 SMD with ramp-based 0 or 4 trend monitoring F7050 F7051 F8350 F8351 Bosch Rexroth AG R911404905, Edition 02...
  • Page 115 When configuring P‑0‑3280.0.1, bit 7=0 or P‑0‑3238 > (2 × P‑0‑3255) → F7051 after exceeding P‑0‑3238; when config- uring P‑0‑3280.0.1, bit 7=1 and P‑0‑3238 ≤ (2 × P‑0‑3255) → Warning E3151 after exceeding P‑0‑3238 with monitoring of incorrect distance R911404905, Edition 02 Bosch Rexroth AG...
  • Page 116 (P-0-3280.0.1). In the case of NC-controlled transition, the higher-level control unit adjusts the command value system for the drive in accordance with the monitoring thresholds of the selected safety function. Bosch Rexroth AG R911404905, Edition 02...
  • Page 117 Maximum transition time exceeded" [only for F3 equal to F7 reaction (P‑0‑3263.0.1)] is reported and the drive is set to standstill according to the parameterized error reaction (P‑0‑3263.0.1) (see ⮫ Error reaction and escala- tion strategy). R911404905, Edition 02 Bosch Rexroth AG...
  • Page 118 “P-0-3280.0.1, SMO: Configuration of operation mode transitions" and this is possible due to the system properties (selected velocity window and selected direction of motion are complied with) (see ⮫ "Immediate switching" option). Bosch Rexroth AG R911404905, Edition 02...
  • Page 119 Maximum transition time exceeded" [only for F3 equal to F7 reaction (P‑0‑3263.0.1)] is reported and the drive is set to standstill according to the parameterized error reaction (P‑0‑3263.0.1) (see ⮫ Error reaction and escala- tion strategy). R911404905, Edition 02 Bosch Rexroth AG...
  • Page 120 – takes effect during transition between two special modes "P‑0‑3280.0.12, SMO: Reaction time, SMD trend time, between safe operation" – takes effect during transition from normal operation to Safe motion "P‑0‑3280.0.13, SMO: Delay time SMD trend time, NO to SMM operation" Bosch Rexroth AG R911404905, Edition 02...
  • Page 121 Transition function "Safely-monitored deceleration based on actual velocity" When the transition function "Safely-monitored deceleration based on actual velocity" (SMD ) is selected, the drive-controlled or NC-controlled transition ActVel of the axis is performed in accordance with the configuration (P-0-3280.0.1). R911404905, Edition 02 Bosch Rexroth AG...
  • Page 122 Maximum transition time exceeded" [only for F3 equal to F7 reaction (P‑0‑3263.0.1)] is reported and the drive is set to standstill according to the parameterized error reaction (P‑0‑3263.0.1) (see ⮫ Error reaction and escala- tion strategy). Bosch Rexroth AG R911404905, Edition 02...
  • Page 123 In step 2, monitoring via two channels takes place to find out whether the actual velocity is within the velocity envelope curve (P-0-3238). The velocity envelope curve is generated by the drive by means of the deceleration ramp (P‑0‑3280.0.9, SMO: SMD deceleration) and the jerk limit (P‑0‑3280.0.10, R911404905, Edition 02 Bosch Rexroth AG...
  • Page 124 “P-0-3280.0.1, SMO: Configuration of operation mode transitions" and this is possible due to the system properties (selected velocity window and selected direction of motion are complied with) (see ⮫ "Immediate switching" option). Bosch Rexroth AG R911404905, Edition 02...
  • Page 125 “F8350 Maximum transition time exceeded“ [only in case of F3 equal to F7 reaction (P‑0‑3263.0.1)] ● "SMD‑E" in case of F7 error: “F8350 Maximum transition time exceeded“ For F3/F7 errors, the transition is monitored as follows: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 126 – Section 2: "Monitoring of the transition to the "Safe standstill error"" using the deceleration ramp (P‑0‑3263.0.5 and P‑0‑3263.0.8) until the "velocity window of Safe standstill” (P-0-3255) has been reached: Bosch Rexroth AG R911404905, Edition 02...
  • Page 127 (2 × “P-0-3255, SMO: Velocity threshold for safe standstill") ● The actual velocity is greater than the velocity envelope curve of decelera- tion monitoring (P-0-3238) The incorrect distance is determined by adding the actual velocity values. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 128 Fig. 46: Immediate switching within the motion modes P‑0‑3290.x.2 SMO: Safely-limited speed for SMMx P‑0‑3290.y.2 SMO: Safely-limited speed for SMMx Bosch Rexroth AG R911404905, Edition 02...

  • Page 129: Additional And Auxiliary Functions

    ● The function can be used in drive systems equipped with the optional safety technology module "M5". ● The following operation modes / axis functions are supported: – Drive-internal interpolation – Drive-controlled positioning – Positioning block mode – Establishing position data reference (relative measuring systems) R911404905, Edition 02 Bosch Rexroth AG...
  • Page 130 (P-0-3255) compared to the active velocity threshold. In addition, the limitation to the bipolar velocity limit value (S-0-0091) or S‑0‑0038/S‑0‑0039 is carried out. With active limitation of the positioning velocity, the warning "E2049 Positioning velocity >= limit value" is output. Bosch Rexroth AG R911404905, Edition 02...

  • Page 131: Selection And Acknowledgment

    "single-channel wiring" (with fault exclusion for the discrete wiring) or as a "dual-channel wiring". The two figures below illustrate the wiring types in schematic form. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 132: Ctrlx Safetylink

    Single-channel wiring is only allowed for diagnostic purposes (no safe acknowledgment). The safe local output is suited for safety-relevant applications up to Category 4, PL e according to EN ISO 13849-1 or up to SIL 3 according to EN 62061. ctrlX SAFETYlink Bosch Rexroth AG R911404905, Edition 02...
  • Page 133 (zone master, e.g. ctrlX SAFEX-C.1*). All devices connected via ctrlX SAFETYlink are automatically summarized to a safety zone. The safety zone starts and ends at the zone master; i.e. it is a ring structure. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 134 ● "How-to" on the subject "⮫ ctrlX SAFETY to control the SafeMotion function of ctrlX DRIVE" ⮫ collection of blogs and videos about ctrlX DRIVE which is continuously updated is also available in the ctrlX AUTOMATION Community. Bosch Rexroth AG R911404905, Edition 02...

  • Page 135: Safety Bus Communication

    The active predefined configuration defines which data are transmitted via these connections. The content and use of the configurations are independent of the master communication and the safety protocol via and with which the data are transmitted. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 136: Configuring The Consumer And Producer Connection

    Safety bus communication and their default connec- tion via target and/or source parameters with the SafeMotion profile. The pos- sible predefined configurations are made available to the control unit via the device data sheet. Bosch Rexroth AG R911404905, Edition 02...
  • Page 137 P‑0‑3261, bit 6 SMM4 signal (A_SMM4) SMM5Signal P‑0‑3261, bit 7 SMM5 signal (A_SMM5) SMM6Signal P‑0‑3261, bit 8 SMM6 signal (A_SMM6) SMM7Signal P‑0‑3261, bit 9 SMM7 signal (A_SMM7) SMM8Signal P‑0‑3261, bit 10 SMM8 signal (A_SMM8) R911404905, Edition 02 Bosch Rexroth AG...
  • Page 138 IO mapper block Safe connector, the binary-coded selection bits are decoded using the IO mapper block binary-to-bit decoder. Freely configurable assemblies for consumer connections The consumer connection configuration has to be specified in P‑0‑3342.0.1 with the type number. Bosch Rexroth AG R911404905, Edition 02...
  • Page 139 The producer connection configuration has to be specified by entering the type number (P‑0‑3342.0.1). Only the following bits are used in the “parameterization mode” (PM): − SafetyError (P‑0‑3231, bit 25) − EncoderStandstill (P‑0‑3256, bit 6) − SafetyStatus (P‑0‑3237, bit 0) R911404905, Edition 02 Bosch Rexroth AG...
  • Page 140 Special mode Safe motion 7 (SMM7) SMM8Status P‑0‑3231, bit 10 Special mode Safe motion 8 (SMM8) SMM9Status P‑0‑3231, bit 11 Special mode Safe motion 9 (SMM9) SMM10Status P‑0‑3231, bit 12 Special mode Safe motion 10 (SMM10) Bosch Rexroth AG R911404905, Edition 02...
  • Page 141 SafetyStatus, SafetyError and SMESStatus have to be evaluated. That is to say SMM1 is only active, if: SMM bits=0000 and SafetyStatus=1 and SafetyError=1 and SMESStatus=0. Freely configurable assemblies for producer connections he producer connection configuration has to be specified in P‑0‑3343.0.1 with the type number. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 142 Safety status Profiles The configurations of the producer connection and the consumer connection can be summarized in a so-called profile. For FailSafe over EtherCat, only combinations of configurations defined in a profile can be used: Bosch Rexroth AG R911404905, Edition 02...

  • Page 143: Failsafe Over Ethercat (Fsoe)

    FSoE slave address To unequivocally identify all bus nodes via FSoE, each node has to have an unequivocal “FSoE slave address” (P‑0‑3350). R911404905, Edition 02 Bosch Rexroth AG...
  • Page 144 The connection IDs and the slave addresses are exchanged in the system state “Connection“. ● The content “0” is supplied to the safety bus in accordance with the data width. ● Protocols from the SoE connection layer are processed. Bosch Rexroth AG R911404905, Edition 02...

  • Page 145: Io Mapper Inputs

    Safe Motion profile (see ⮫ Safety bus communication). With "P‑0‑3340.0.1, SMO: Mask of control word, safety bus" can be used to mask R911404905, Edition 02 Bosch Rexroth AG...
  • Page 146 The IO mapper blocks are called and configured via dialogs in ctrlX DRIVE Engineering (see Commissioning). ⮫ Depending on the selected IO mapper block type, a circuit diagram of the IO mapper block is displayed in the corresponding dialog of the network. Bosch Rexroth AG R911404905, Edition 02...
  • Page 147 It is not necessary to apply a signal at optional inputs. If no signal has been applied to an optional input (the input is not used), S-0-0000 has to be configured as the source signal at the optional input. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 148: I/O Mapper Block Types

    Fig. 54: IO mapper block “Safe connector” (type 1) Variables of the IO mapper block Table 20: Input variable of the IO mapper block Safe connector Input variable Type of input SAFE-In Safe input Bosch Rexroth AG R911404905, Edition 02...
  • Page 149 With the IO mapper block “Safe OR“, the safe input signals of multiple enabling control devices can be processed in parallel. At least 2 inputs have to be used; a maximum of 4 input signals is allowed. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 150 "1". If the optional safe input "SAFE_In" is used, it is ANDed with the result of the restart lockout block and the result is applied to the "SAFE-Out" output. Bosch Rexroth AG R911404905, Edition 02...
  • Page 151 When the value falls below the minimum pulse duration, “F3010 SMO: Error IO mapper inputs” is generated. When the maximum pulse duration of 30 seconds is exceeded, F3010 is also generated. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 152 Logic AND operation of the inputs SAFE-In 1, In 2, In 3 and In 4. At least 2 inputs have to be used; apart from that, two optional inputs are available. The status TRUE is internally pre-assigned to optional inputs that are not used. Bosch Rexroth AG R911404905, Edition 02...
  • Page 153 If the AND operation of the inputs provides logic "0", the output of the restart lockout block is set to logic "0”. To set this output to logic "1” again, a 0-1-0 change (with trigger to the falling edge) has to be detected at the In_Start input. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 154 Table 29: Input variable of the IO mapper block Safe AND with ES bypass and protection against restart Input variable Type of input SAFE-In_W1 Safe input SAFE-In_Bypass_W1 Safe input In_W2 Functional input In_Bypass_W2 Functional input In_W3 Functional input In_Bypass_W3 Functional input In_W4 Functional input Bosch Rexroth AG R911404905, Edition 02...
  • Page 155 “F3010 SMO: Error IO mapper inputs is generated. When the maximum pulse duration of 30 seconds is exceeded, F3010 is also generated. Fig. 62: Pulse duration complied with (in addition, the selection of "SAFE-In_W1" is masked via the "SAFE-In_Bypass_W1" signal) R911404905, Edition 02 Bosch Rexroth AG...

  • Page 156: Signal Control Of Outputs

    The safety of the entire safety zone is monitored by the safety control (zone master). The zone master collects the "safety" status from all nodes and gener- ates the sum signal "safety of the safety zone". This sum signal is provided to all zone nodes. Bosch Rexroth AG R911404905, Edition 02...

  • Page 157: Safety Function

    Axes within the safety zone with inactive safety technology or axes which have not been configured as zone node, generate the error message F7035 when receiving telegrams via the ctrlX SAFETYlink. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 158 (safe or not safe) via the ctrlX SAFETYlink. The zone master generates the zone status (safe or not safe) from the status of the zone nodes of the safety zone. The zone master acknowledges the safety of the Bosch Rexroth AG R911404905, Edition 02...

  • Page 159: Notes On Commissioning

    Performance). ⮫ A requirement to use the "Safe zone error" (SZE) function is a safety zone generated via a ctrlX SAFETYlink with a zone master [e.g. ctrlX SAFETY (SAFEX- C.1*)] and configured drives. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 160: Safety Function

    ● Zone node does not signal any zone error and does not react to zone error either (type 4) Monitoring function According to the configuration, the zone nodes react differently to their own errors and zone errors: ● Type 1 Bosch Rexroth AG R911404905, Edition 02...
  • Page 161 SAFETYlink. When the zone node gets signaled a zone error via the zone bus, it does not react to the zone error. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 162 SAFETYlink. A zone error is transferred via the ctrlX SAFETYlink to the zone master and is available as condensed status via the error state for zone nodes for further processing. Bosch Rexroth AG R911404905, Edition 02...

  • Page 163: Commissioning

    / the conformity of the components in accordance with the Machi- nery Directive 2006/42/EC is ensured. Perform- Average probability of a dangerous Safety integ- Risk ance failure [1/h] (PFH) rity level Level (PL) (SIL) ≥10 …<10 ≥3×10 …<10 ≥10 …<3×10 ≥10 …<10 ≥10 …<10 R911404905, Edition 02 Bosch Rexroth AG...

  • Page 164: First Use

    − Check the danger zone and secure it against access by individuals (e.g., put up warning signs, install bar- riers or the like). Observe the applicable laws and local regulations. Bosch Rexroth AG R911404905, Edition 02...

  • Page 165: Introduction

    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. In case of error, personal injury and material damages...
  • Page 166 XG20 / XG21 or XG20.n / XG21.n (e.g. for measuring) is not allowed. Rexroth motors In conjunction with the optional safety technology modules "SafeMotion" (M5), the following motors by Rexroth can be used: IndraDyn S: MS2N, MS2E Bosch Rexroth AG R911404905, Edition 02...
  • Page 167 : "B" is a placeholder for the type code position at which the brake type is encrypted Encoder type encrypted in type code encoder type , CM : ACUROⓇlink encoder with an encoder resolution for the safe position of 9 bits R911404905, Edition 02 Bosch Rexroth AG...
  • Page 168 Third-party motors/optional measuring systems Third-party motors and optional measuring systems are only supported from AXS–V–0308.01 in the integrated safety technology in ctrlX DRIVEplus. Bosch Rexroth AG R911404905, Edition 02...
  • Page 169 [XG20 (or XG20.1 and XG20.2 for double-axis devices]; mere plug-in connectors are allowed. Branches to other evaluation devices, a third-party supply, interconnecting active units or switching between encoders are not allowed. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 170 When the "Proof Test interval" is over, a "Proof Test" has to be carried out with the encoder or the encoder has to be decommissioned. Note: The drive system ctrlX DRIVE does not monitor or log the "Mission Time". Bosch Rexroth AG R911404905, Edition 02...
  • Page 171 – Brake has to be connected to XZ03 or – brake has to be connected to XG03 When the Safe brake control is used, the brake connected to the controller has to comply with the following requirements: R911404905, Edition 02 Bosch Rexroth AG...

  • Page 172: Commissioning Steps

    The following commissioning steps describe the commissioning using the safety technology wizard on the basis of ctrlX DRIVE Engineering 01V16. The commissioning is only possible with corresponding hardware; offline simu- lation is not possible. Bosch Rexroth AG R911404905, Edition 02...
  • Page 173 Via the menu item “Load SMO default values” the context menu of the SafeMo- tion node, the following dialog can be called. This dialog assists you with the loading of the SMO default values: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 174 The functional commissioning is activated via the “Functional ena- “SafeMotion bling” dialog. The dialog can be called via ctrlX DRIVE Engineering Commissioning �� Functional enabling” . It is only displayed as long as Safe- �� Motion has not been activated yet. Bosch Rexroth AG R911404905, Edition 02...
  • Page 175 Step 2: Activating SafeMotion Starting the commissioning wizard Before the wizard is called, the functional commissioning of the axis should have been completed to the point that the axis can be operated under control. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 176 SMO axis identifier (P–0–3235.0.1) is an unequivocal identifier in the entire safety-related installation. It is used to unequivocally relate parameterization actions to the corresponding machine axis. Therefore, an SMO axis identifier may only be assigned once in each machine. Bosch Rexroth AG R911404905, Edition 02...
  • Page 177 If more parameters need to be verified than can be displayed, the “Apply” button is grayed out. The button only becomes active again when the user has compared all parameter values by using the scrollbar. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 178 “Cancel” button, the assignment of the axis identifier can be aborted. For devices without panel, the axis identifier can only be confirmed using the “Apply axis identifier” button in the corresponding dialog. Bosch Rexroth AG R911404905, Edition 02...
  • Page 179 ...” button. Not all encoders are approved for "safe encoder evaluation". Therefore, only the data of approved encoder types are applied. If the encoder configuration cannot be applied, a command error (C8401, C8402) is gener- ated. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 180 Afterwards, go to the next commissioning dialog using the “Next >>” button. Basic encoder evaluation Fig. 75: Basic settings of the SMO encoder Bosch Rexroth AG R911404905, Edition 02...
  • Page 181 The parameter verification is carried out in ctrlX DRIVE Engineeringvia the bottom sections of the SafeMotion dialogs (“verification display”). Go to the next commissioning dialog by using the “Next >>” button. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 182 The parameter verification is carried out in ctrlX DRIVE Engineeringvia the bottom sections of the SafeMotion dialogs (“verification display”). Go to the next commissioning dialog by using the “Next >>” button. Bosch Rexroth AG R911404905, Edition 02...
  • Page 183 The "Scaling / units in the standard firmware" link opens a dialog in which you can have a look at the scaling / units of the standard firmware and, if necessary, change them before applying them: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 184 After they were applied from the standard firmware, the SMO scaling parame- ters have to be verified in the following dialogs. Afterwards, go to the next commissioning dialog using the “Next >>” button. Setting the scaling and units Fig. 79: Scaling / units Bosch Rexroth AG R911404905, Edition 02...
  • Page 185 The parameter verification is carried out in ctrlX DRIVE Engineeringvia the bottom sections of the SafeMotion dialogs (“verification display”). Go to the next commissioning dialog by using the “Next >>” button. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 186 (with view to the motor output shaft) causes positive velocity feedback value (positive polarity). – This applies to linear motors: Motion of primary part in the direction of the cable connection side causes positive velocity feedback value (posi- tive polarity). Bosch Rexroth AG R911404905, Edition 02...
  • Page 187 The parameter verification is carried out in ctrlX DRIVE Engineeringvia the bottom sections of the SafeMotion dialogs (“verification display”). Go to the next commissioning dialog by using the “Next >>” button. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 188 Configuring the brake The link "Brake configuration links to the functional dialog for configuring brake control (for a description of the dialog, refer to the firmware description "Con- trolling the brake”). Bosch Rexroth AG R911404905, Edition 02...
  • Page 189 Go to the next commissioning dialog by using the “Next >>” button. Safety zone In the “Safety zone“ dialog, configure the properties and the behavior of the axis in conjunction with a ctrlX SAFETYlink safety zone. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 190 Go to the next commissioning dialog by using the “Next >>” button. Signal control of inputs In the “Signal control of inputs“ dialog, the local inputs of the interface XG44 can be configured as safe inputs. Bosch Rexroth AG R911404905, Edition 02...
  • Page 191 The parameter verification is carried out in ctrlX DRIVE Engineeringvia the bottom sections of the SafeMotion dialogs (“verification display”). Go to the next commissioning dialog by using the “Next >>” button. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 192 The input signals output signals are set via the drop down lists at the inputs/ outputs of the function block circuit diagram. The input types available in P– 0–3331.x.1 limit the selection of possible input signals for each input of a function block. Bosch Rexroth AG R911404905, Edition 02...
  • Page 193 Using the dynamization source is optional, i.e. the dynamization of the input signals may also take place from a different source. Fig. 89: Selecting the status signal of the safe local output with dynamization option R911404905, Edition 02 Bosch Rexroth AG...
  • Page 194 Safe speed monitor In the dialog section "Safe speed monitor (SSM)", the Safe speed monitor can be enabled and the corresponding monitoring thresholds of the velocity window can be parameterized. Bosch Rexroth AG R911404905, Edition 02...
  • Page 195 Pertinent parameters ● P–0–3277.0.1, SMO: Configuration of normal operation (bit 0, bit 1) ● P–0–3270.0.3, SMO: Standstill window for safe direction Afterwards, the settings that were made have to be verified. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 196 The parameter verification is carried out in ctrlX DRIVE Engineeringvia the bottom sections of the SafeMotion dialogs (“verification display”). Go to the next commissioning dialog by using the “Next >>” button. Bosch Rexroth AG R911404905, Edition 02...
  • Page 197 After the selection was made, a preview of the values is displayed at first. By clicking the “Copy” button, the values are applied to the configuration of the motion mode and can be edited there. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 198 "Safely-limited speed" is always active in the special mode "Safe motion". If the safety function "Safely-monitored transient oscillation (SLS-LT)" is to be used, it has to be activated via the check box "Safely-monitored transient oscillation (SLS-LT) active". Afterwards, the maximum time of the occurring Bosch Rexroth AG R911404905, Edition 02...
  • Page 199 The parameter verification is carried out in ctrlX DRIVE Engineeringvia the bottom sections of the SafeMotion dialogs (“verification display”). Go to the next commissioning dialog by using the “Next >>” button. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 200 ● SS1 time-prioritized: When the transition time is over, STO always becomes active; this is independent of whether the axis standstill was reached or not; deceleration can be achieved up to SIL3. Bosch Rexroth AG R911404905, Edition 02...
  • Page 201 In the section Reaction times for trend monitoring on time basis, parameterize times by which the R911404905, Edition 02 Bosch Rexroth AG...
  • Page 202 In the Max. transition times for transition ... section, configure the times with which SafeMotion monitors the transitions between the operating states. Within the times set here, the command value system of the drive must have been adjusted to the new operating status. Bosch Rexroth AG R911404905, Edition 02...
  • Page 203 SafeMotion dialogs (“verification display”). Go to the next commissioning dialog by using the “Next >>” button. Error reaction Via the "Error reaction" dialog, parameterize the reaction of SafeMotion to F3 errors, F7 errors and E83 warnings. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 204 In the SMD during the error reaction section, configure the SMD safety function for the error reaction. The SMD monitoring of the error reaction always takes place "based on the actual velocity". Thus, the following parameters have to be configured: Bosch Rexroth AG R911404905, Edition 02...
  • Page 205 SafeMotion dialogs (“verification display”). Go to the next commissioning dialog by using the “Next >>” button. Support functions Via the "Support functions" dialog, the following support functions of SafeMo- tion can be activated and parameterized: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 206 ● P‑0‑3218, SMO: Scaling factor for velocity limit value ● P‑0‑3219, SMO: Configuration of support functions ● P‑0‑3238, SMO: Active velocity threshold Scaling setting validation check For SafeMotion, the polarity for position, velocity, acceleration, force/torque is set to an identical value. Bosch Rexroth AG R911404905, Edition 02...
  • Page 207 ● P‑0‑3219, SMO: Configuration of support functions Go to the next commissioning dialog by using the “Next >>” button. Completing the commissioning After all SafeMotion dialogs relevant to the axis have been configured, the SafeMotion report is generated and displayed: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 208 The SafeMotion report has to be signed by the person in charge of the commis- sioning and included in the machine documentation. NOTE: If not all parameters have been verified, the SafeMotion report cannot be generated: Bosch Rexroth AG R911404905, Edition 02...
  • Page 209 − Do not access the danger zone before the axis is vali- dated successfully! When closing the commissioning wizard, the user is reminded that the axis has not yet been validated: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 210 To satisfy all applications, there are three options of axis validation: ● Easy startup mode ● External command value input and external drive enable ● Manual motion Bosch Rexroth AG R911404905, Edition 02...
  • Page 211 When the start position has been reached, it has to be marked at the axis mechanics so that the travel distance can be measured later on. The position feedback value is displayed for information purposes in the dialog. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 212 After the start position has been set, the axis measurement can be started in step 3. Start the "measure position difference" command (C8600) via the “Start measurement” button. Fig. 104: Axis validation: Measuring the position difference Bosch Rexroth AG R911404905, Edition 02...
  • Page 213 "SafeMotion" with regard to the distance and polarity. By clicking the “Confirm axis validation” button, the commissioning engineer bindingly confirms the successful execution of the R911404905, Edition 02 Bosch Rexroth AG...
  • Page 214 The axis validation has to be recorded and added to the safety-relevant docu- mentation of the machine. The axis validation record can be generated via the “Report” button. Fig. 107: Axis validation report Bosch Rexroth AG R911404905, Edition 02...

  • Page 215: Serial Commissioning

    That is to say both the SMO axis identifier, addressing of the Safety bus communication and the parameterization of the pattern axis are applied. This procedure is suited for the following cases: R911404905, Edition 02 Bosch Rexroth AG...
  • Page 216 At first, the communication between the control unit and the series axis has to be established. Afterwards, the following steps have to be carried out: Switch axis to the parameterization mode (PM or P2). Select parameter backup and load it to the axis via the control unit. Bosch Rexroth AG R911404905, Edition 02...
  • Page 217 ● Serial number of control section (see type plate at device) ● Serial number of power section (see type plate at device) ● (date), (name), (signature) NOTE: The parameter values required for the log can only be read via the control. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 218 (e.g., axis-specific monitoring thresholds). The prerequisite for using option 3 is a completely commissioned and validated pattern axis, as well as an axis with identical axis mechanics that is to be commissioned. Bosch Rexroth AG R911404905, Edition 02...
  • Page 219 ● P‑0‑3235.0.6, SMO: Proposed axis identifier, auto commissioning ● P-0-4090, Configuration for loading default values ● S‑0‑0262, C07_x Load defaults procedure command The parameters of the automated commissioning are accessed via a higher-level control unit. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 220 (P-0-3234.0.1, P-0-3234.0.4), it is possible to prove after the automated serial commissioning that the correct SMO image has been loaded to the axis. Parameter "P‑0‑3235.0.2, SMO: Proposed axis identifier" still contains the value from the pattern axis. Bosch Rexroth AG R911404905, Edition 02...
  • Page 221 The machine manufacturer has to define the scope of the machine acceptance test for series machines, depending on the type and complexity of the machine. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 222: Axis Acceptance

    In ctrlX DRIVE Engineering, the “Selection“ dialog can be opened via the Machine acceptance test �� Selection” node. �� The dialog is not provided if the default settings of the IO mapper inputs are active. Bosch Rexroth AG R911404905, Edition 02...
  • Page 223 The default directory for memos is the "My Documents" directory of the logged-on user. This directory is also used for further memos. The active axis R911404905, Edition 02 Bosch Rexroth AG...
  • Page 224 ● P‑0‑3330.x.1, SMO: IO mapper inputs, type ● P‑0‑3330.x.2, SMO: IO mapper inputs, IDN source ● P‑0‑3330.x.3, SMO: IO mapper inputs, bit source ● P‑0‑3330.x.4, SMO: I/O mapper inputs, IDN target ● P‑0‑3330.x.5, SMO: I/O mapper inputs, bit target Bosch Rexroth AG R911404905, Edition 02...

  • Page 225: Global Monitoring Functions

    Safe maximum speed. In all other operating states, moving the axis is completely prevented (SMES and SMSTx operating states) or other velocity monitoring functions are active in parallel and already trigger at lower velocities (SMMx operating states). R911404905, Edition 02 Bosch Rexroth AG...

  • Page 226: Monitoring Functions In Normal Operation

    Monitoring functions in normal operation In ctrlX DRIVE Engineering, the dialog “Monitoring in normal operation“ can be “... �� Machine acceptance test �� Monitoring functions opened in via the node in normal operation” . Bosch Rexroth AG R911404905, Edition 02...

  • Page 227: Special Mode "Emergency Stop" And Special Mode "Safe Stand

    10.5.5 Special mode "EMERGENCY STOP" and special mode "Safe stand- still" "Special mode Safe standstill" dialog opened “... �� Machine acceptance test �� Special inctrlX DRIVE Engineering via the mode Safe standstill” node. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 228 ● Checking the monitoring windows for Safe operating stop Checking the SMST1 and SMES transitions The operating states SMST and SMES cannot be deactivated in the Bosch Rexroth Safe Motion profile; it is possible, however, to mask them via safe constant selection in the "IO mapper inputs".
  • Page 229 “P-0-3238, SMO: Active velocity threshold. Checking the SMST2 transition The SMST operating status cannot be deactivated in the Bosch Rexroth Safe Motion profile; it is possible, however, to mask it via safe constant selection in the "IO mapper inputs". In this case, it is impossible to check the transition to the operating status.
  • Page 230 “P-0-3238, SMO: Active velocity threshold. Checking the monitoring windows for Safe operating stop The SMST operating status cannot be deactivated in the Bosch Rexroth Safe Motion profile; it is possible, however, to mask it via safe constant selection in the "IO mapper inputs".

  • Page 231: Special Mode "Safe Motion

    “... �� Machine acceptance test �� Special inctrlX DRIVE Engineering via the mode Safe motion” node. The dialog is not provided if no special mode "Safe motion" (SMM1…16) has been configured. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 232 The following checks have to be run: ● Transition to the special mode "Safe motion" ● Monitoring the activation time of enabling control ● "Safely-limited speed" ● "Safely-monitored transient oscillation" Bosch Rexroth AG R911404905, Edition 02...
  • Page 233 "OK" column in the corresponding transi- tions. Via the “Screenshot” button, a screenshot of the tab page can be copied to the clipboard for the purpose of documentation. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 234 "F7013 Velocity threshold exceeded" is generated. With the corresponding oscilloscope measurement, the check can be accordingly documented. In normal operation, the threshold of the "Safely-limited speed" is displayed in the recorded parameter “P-0-3238, SMO: Active velocity threshold". Bosch Rexroth AG R911404905, Edition 02...
  • Page 235 ● Trigger: S-0-0390, Diagnostic message number to F7031 ● Measuring signals: – S-0-0390, Diagnostic message number – P‑0‑3231, SMO: Operating state – P‑0‑3257, SMO: Actual position value – P‑0‑3258, SMO: Actual velocity value R911404905, Edition 02 Bosch Rexroth AG...

  • Page 236: Error Reaction

    Via the “Screenshot” button, a screenshot of the tab page can be copied to the clipboard for the purpose of documentation. 10.5.7 Error reaction In ctrlX DRIVE Engineering, the “Error reaction“ dialog can be opened via the “... �� Machine acceptance test �� Error reaction” node. Bosch Rexroth AG R911404905, Edition 02...
  • Page 237 – S-0-0390, Diagnostic message number – P‑0‑3231, SMO: Operating state – P‑0‑3238, SMO: Active velocity threshold – P‑0‑3258, SMO: Actual velocity value After the configuration, the oscilloscope has to be activated via the “Start” button. R911404905, Edition 02 Bosch Rexroth AG...

  • Page 238: Safety Zone

    No zone errors are generated or no reaction to zone errors takes place (see P-0-3266.0.2) In this dialog, it is possible to check whether the axis, as configured, generates a zone error or reacts to zone errors. Bosch Rexroth AG R911404905, Edition 02...
  • Page 239 ● Measuring signals: – S-0-0390, Diagnostic message number – P‑0‑3266.0.0, SMO: Status word safety zone – P‑0‑3266.0.1, SMO: Control word safety zone After the configuration, the oscilloscope has to be activated via the “Start” button. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 240 Document the axis reaction to zone errors by saving the oscilloscope measurement via the "Save oscillosc. measurement" link or by copying it to the clipboard via the "Screenshot of oscilloscope measurement" link. Bosch Rexroth AG R911404905, Edition 02...

  • Page 241: Signal Control Of Outputs

    Fig. 116: Machine acceptance test: Signal control of outputs Parameters involved: ● P‑0‑3335.0.1, SMO: Signal control of outputs discrete, IDN assignment ● P‑0‑3335.0.2, SMO: Signal control of outputs discrete, bit number R911404905, Edition 02 Bosch Rexroth AG...
  • Page 242 SAFETY "SafeMotion" 242 / 302 Machine acceptance test Bosch Rexroth AG R911404905, Edition 02...

  • Page 243: Maintenance

    Log the replacement in the safety-related documentation of the machine (serial number, type, …). 11.2.2 Replacing the optional brake When replacing optional brakes, comply with the safety instructions in the chapter “Safety instructions for electric drives and controls”! R911404905, Edition 02 Bosch Rexroth AG...

  • Page 244: Replacing The Optional Encoder

    If the optional encoder is used as safety technology encoder, it has to be ensured that the replacement encoder complies with the requirements of safety technology! (see ⮫ Required motors and measuring systems). Bosch Rexroth AG R911404905, Edition 02...

  • Page 245: Replacing The Controller

    (admis- sible pollution degree according to EN50178: 2). ● Replace cables Material damage due to faulty power connectors! NOTICE Only connect or disconnect power connectors in clean and dry state. ● Reconnect the connections R911404905, Edition 02 Bosch Rexroth AG...

  • Page 246: Firmware Replacement

    For the descriptions of the variant “Device with ctrlX DRIVE Panel“, refer to “ctrlX DRIVE Panel“. Commissioning Preparations and conditions of firmware replacement General information on how to proceed Comply with the following points when replacing the firmware: Bosch Rexroth AG R911404905, Edition 02...
  • Page 247 SMO. To update a firmware release or to downgrade a firmware release, proceed as follows: Firmware replacement with ctrlX DRIVE Engineering Connect the device to the computer. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 248 Fig. 117: "Firmware update" dialog in ctrlX DRIVE Engineering Additional information and details Firmware replacement with a TFTP client To replace the firmware using a TFTP client, proceed as follows: Connect the device to the computer. Bosch Rexroth AG R911404905, Edition 02...

  • Page 249: 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). R911404905, Edition 02 Bosch Rexroth AG...
  • Page 250 SAFETY "SafeMotion" 250 / 302 Decommissioning drive components Bosch Rexroth AG R911404905, Edition 02...

  • Page 251: Declaration Of Conformity

    All converters and inverters of the ctrlX DRIVE product line comply with the protection goals of the Low-Voltage Directive 2014/35/EU. We declare con- formity with the Machinery Directive for the optional safety technology module "M5" (SafeMotion). Fig. 118: DCTC-30136-004, D0 (2022-01-13) page 1 of 2 R911404905, Edition 02 Bosch Rexroth AG...
  • Page 252 SAFETY "SafeMotion" 252 / 302 Fig. 119: DCTC-30136-004, D0 (2022-01-13) page 2 of 2 Bosch Rexroth AG R911404905, Edition 02...

  • Page 253: Project Planning

    SAFETY "SafeMotion" 253 / 302 Project planning R911404905, Edition 02 Bosch Rexroth AG...

  • Page 254: Safemotion M5

    Minimum bending radius in the case of permanent installation: 4xD (= 4x6.3 mm = 25.2 mm) Minimum bending radius in the case of flexible routing: 8xD (= 8x6.3 mm = 50.4 mm) Order designation for a cable with a length of 5 m: RKB0062/005,0 Bosch Rexroth AG R911404905, Edition 02...

  • Page 255: Xg44, Safemotion M5 Safety Technology

    Connectors included in scope of delivery. Technical data of inputs and outputs: ⮫ Chapter 13.5.2 Digital inputs (safety technology SafeMotion) on page 276 ⮫ Chapter 13.5.4 Digital outputs (safety technology SafeMotion) on page 278 R911404905, Edition 02 Bosch Rexroth AG...

  • Page 256: Xf21 P1, Xf22 P2, Communication (Rj-45)

    Receive, Differential Input - n. c. n. c. Receive, Differential Input + XF22 P2 Transmit, Differential Output - Transmit, Differential Output + Housing Shield connection XF21 P1 Properties ● Ethernet Standard ● Type: RJ-45, 8-pin Bosch Rexroth AG R911404905, Edition 02...

  • Page 257: Motor Connections

    0.19 m; 0.25 m; 0.35 m; 0.55 m; 1 m; 1.25 m; 2 m; 3 m; 5 m; Order code for a cable with a length of 0.55 m: RKB0013/00,55 Minimum bending radius: 30.75 mm 13.3 Motor connections R911404905, Edition 02 Bosch Rexroth AG...

  • Page 258: Xz03, Hybrid Connection

    Only the allowed control voltage for the device is allowed at the motor temperature evaluation input. Excess voltage at the input may damage the device. Connectors not included in scope of delivery. Function The connection point contains the connections for Bosch Rexroth AG R911404905, Edition 02...
  • Page 259 Occurring voltage load See technical data of device used (U Includes short circuit protection A1, A2, A3 against each other and each of them against ground Table 36: Shield connection Motor cable shield connection R911404905, Edition 02 Bosch Rexroth AG...
  • Page 260 Make sure to comply with the required minimum current consumption of 100 mA when using an external contact element. Otherwise the brake current monitor will signal an error. Bosch Rexroth AG R911404905, Edition 02...

  • Page 261: Xd03, Motor Connection

    Size the required cross section of the connection lines according to the occurring current load. − Provide for optimum shield contact of the motor power cable. − For the connection between drive controller and motor, use our ready-made motor power cables, where possible. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 262 PE + XD03: Screw connection at device XD03: Screw connection at connector XZ03: Spring terminal at connector 1) See ⮫ Chapter 13.3.1 XZ03, hybrid connection (motor, motor temperature monitoring and motor holding brake) on page 258 Bosch Rexroth AG R911404905, Edition 02...
  • Page 263 Includes short circuit protection A1, A2, A3 against each other and each of them against ground Shield connection accessories: ● XCS*-*0054/70: XAS2-006-003-NN; ● XMS*-*0054/70: XAS2-005-003-NN; Typical motor cable cross section: 1 × 6 mm R911404905, Edition 02 Bosch Rexroth AG...
  • Page 264 A1, A2, A3 against each other and each of them against ground 1) Ferrule only allowed without plastic sleeve. Shield connection accessories: ● XMS*-W0090: XAS2-005-003-NN; Typical motor cable cross section: 1 × 10 mm Bosch Rexroth AG R911404905, Edition 02...
  • Page 265 Cable feedthrough at the device: Shield connection accessories: ● XCS*-W0100/120: XAS2-002-003-NN; Typical motor cable cross section: 1 × 16 mm Double wiring with 2 × 10 mm is possible using twin ferrule R911404905, Edition 02 Bosch Rexroth AG...
  • Page 266 Shield connection accessories: ● XCS*-W0150/180: – XAS2-007-001-NN; – XAS2-007-002-NN; ● XMS*-W0150/180: – XAS2-008-001-NN; – XAS2-008-002-NN; Typical motor cable cross section: 1 × 16 mm Double wiring with 2 × 10 mm is possible using twin ferrule Bosch Rexroth AG R911404905, Edition 02...
  • Page 267 1) Insulate ring cable lugs with heat shrink sleeves Shield connection accessories: ● XCS*/XMS*-W0210/250/280: – XAS2-004-001-NN; – XAS2-004-002-NN; Typical motor cable cross section: ● 1 × 50 mm ● Double wiring with 2 × 25 mm is possible using twin ferrule R911404905, Edition 02 Bosch Rexroth AG...

  • Page 268: Xg03, Motor Temperature Monitoring And Motor Holding Brake

    100 mA when using an external contact element. Otherwise, the brake current monitoring function will signal an error. Function The connection point contains the connections for ● monitoring the motor temperature ● controlling the motor holding brake Bosch Rexroth AG R911404905, Edition 02...
  • Page 269 0100…0375 0054…0070 0023 2323 0100…0280 0054…0090 0006…0036 5454…7070 0606…3636 1) Hybrid connection (motor, temperature monitoring and motor holding brake) 2) Connectors included in scope of delivery 3) Connectors not included in scope of delivery R911404905, Edition 02 Bosch Rexroth AG...
  • Page 270 Time constant of load Number of switching actions at Wear-free electronic contact maximum time constant of load Switching frequency Short circuit protection XG03.7 against XG03.8 (output for controlling the motor holding brake) Overload protection Bosch Rexroth AG R911404905, Edition 02...
  • Page 271 Time constant of load Number of switching actions at Wear-free electronic contact maximum time constant of load Switching frequency Short circuit protection XG03.7 against XG03.8 (output for controlling the motor holding brake) Overload protection R911404905, Edition 02 Bosch Rexroth AG...

  • Page 272: Encoder Connections

    272 / 302 Encoder connections XZ03 (1.5 mm See description of connection point XZ03. ⮫ Chapter 13.3.1 XZ03, hybrid connection (motor, motor temperature moni- toring and motor holding brake) on page 258. 13.4 Encoder connections Bosch Rexroth AG R911404905, Edition 02...

  • Page 273: Xg20, Digital Motor Encoder Connection

    Form a loop to lead the encoder cable to the connection point XG20 so that no force is applied to the encoder connector: Fig. 120: Encoder cable forming a loop to be led to connection point XG20 R911404905, Edition 02 Bosch Rexroth AG...

  • Page 274: Xg21, Multi-Encoder

    Encoder systems with a supply voltage of 12 volt: ● Motors MS2N AS/AM, BS/BM ● Motors MSK S1/M1, S3/M3 ● HIPERFACE® ● Resolvers without encoder data memory ● EnDat 2.2 Encoder systems with a supply voltage of 5 volt: ● EnDat 2.2 Bosch Rexroth AG R911404905, Edition 02...

  • Page 275: Specifying The Digital/Analog Inputs/Outputs

    The digital inputs type A correspond to IEC 61131–2 (type 1). Table 51: Digital inputs type A Data Unit min. max. Allowed input voltage High Input current (at high state) Delay time μs 100 + position controller cycle R911404905, Edition 02 Bosch Rexroth AG...

  • Page 276: Digital Inputs (Safety Technology Safemotion)

    SAFETY "SafeMotion" 276 / 302 Specifying the digital/analog inputs/outputs 13.5.2 Digital inputs (safety technology SafeMotion) Table 52: Data Data Unit min. max. Allowed input voltage High Input current (at high state) Delay time µs Bosch Rexroth AG R911404905, Edition 02...

  • Page 277: Digital Outputs (Standard)

    2) In the case of inductive loads with a greater energy content, an external free-wheeling arm has to be installed. The active clamping voltage has to be < 25 V. 3) The maximum energy content depends on the switching frequency f of the outputs R911404905, Edition 02 Bosch Rexroth AG...

  • Page 278: Digital Outputs (Safety Technology Safemotion)

    The active clamping voltage has to be < 25 V. Table 55: Time response Designation Unit min. max. Test pulse width (t μs Cycle duration (T 1000 Time between two test pulses (t High Bosch Rexroth AG R911404905, Edition 02...

  • Page 279: Diagnostic Display

    Description of colors and flashing patterns: See firmware documentation (ctrlX DRIVE Diagnostic Messages of Runtime AXS-V-02VRS (R911383776) or Diag- nostic Messages of Runtime AXS-V-03VRS (R911409808)). R911404905, Edition 02 Bosch Rexroth AG...

  • Page 280: Sercos/Ethercat/Profinet Io

    Connection to the network available with telegram exchange (EtherCat bus active) Flashing green Sercos Table 58: Port LED LED: Color / flashing Significance pattern No connection No data transfer Data transfer is active Permanently lit yellow Connection to network available Permanently lit green Bosch Rexroth AG R911404905, Edition 02...
  • Page 281 281 / 302 Diagnostic display PROFINET IO Table 59: Port LED LED: Color / flashing Significance pattern No connection No data transfer Data transfer is active Permanently lit yellow Connection to network available Permanently lit green R911404905, Edition 02 Bosch Rexroth AG...
  • Page 282 1) Flashing pattern: One square corresponds to a duration of 200 ms; the arrow marks the end of a cycle GN = LED permanently lit green RD = LED permanently lit red -- = LED is off Bosch Rexroth AG R911404905, Edition 02...
  • Page 283 RD = LED permanently lit red, -- = LED is off 2) Display priority; the state of the highest priority is displayed 3) NRT = Non Real Time 4) MST = Master Synchronization Telegram R911404905, Edition 02 Bosch Rexroth AG...

  • Page 284: Diagnostic Display Of Optional Safety Technology Modules "M5

    FSoE status Initializa- tion/reset Session / ⮫ FSoE status, detailed diag- Connection / nostics Flashing red-green Parameter Data ⮫ FSoE status, detailed diag- nostics Green Identifying the safety technology Flashing red-green critical safety technology error Bosch Rexroth AG R911404905, Edition 02...
  • Page 285 Jittering, alternately with 7 Sequential number error the exact cause of error by pulses means of detailed diagnostics. Jittering, alternately with 8 Communication error pulses R911404905, Edition 02 Bosch Rexroth AG...
  • Page 286 SAFETY "SafeMotion" 286 / 302 Diagnostic display Bosch Rexroth AG R911404905, Edition 02...

  • Page 287: Ctrlx Automation Community

    ● Receive direct help and interact with Bosch Rexroth expert in the Forum. ⮫ ● Get access to Bosch Rexroth apps or third party apps by ctrlX World via the ctrlX Store. Information, instructions and notes on the ctrlX AUTOMATION Community can be found in the ⮫...

  • Page 288: Reference Documentations

    AXS-V-03RS ctrlX DRIVE Reference Book DOK-XDRV**-GEN3-PARA**- R911409808 RERS-EN-P Parameters of Runtime AXS- V-03RS ctrlX DRIVE Application Manual DOK-XDRV**-TECHFUNC***- R911409771 APRS-EN-P Technology Function ctrlX DRIVE Quick Start Guide DOK-XDRV**-TECHFUNC***- R911409766 QURS-EN-P Technology Function First Steps Bosch Rexroth AG R911404905, Edition 02...
  • Page 289 Error list and diagnostic messages ctrlX SAFETY Installation manual DOK-XSAFE*-SAFEX-C.1XC- ⮫ R911405649 CORS-EN-P Compact safety controller Devices SAFEX-C.12 / SAFEX-C.15 ctrlX SAFETY Programming Manual DOK-XSAFE*-SAFEX-C.1XC- ⮫ R911405647 PRRS-EN-P Compact safety controller Devices SAFEX-C.12 / SAFEX-C.15 R911404905, Edition 02 Bosch Rexroth AG...
  • Page 290 Document typecode Material number ctrlX WORKS First Steps Quick Start Guide DOK-XWORKS-F*STEP*****- R911403760 QURS-EN-P ctrlX WORKS Basic System Application Manual DOK-XWORKS-***********- R911403761 APRS-EN-P ctrlX PLC Engineering Application Manual DOK-XPLC**-ENGINEERING- R911403764 APRS-EN-P PLC programming system Bosch Rexroth AG R911404905, Edition 02...

  • Page 291: 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) R911404905, Edition 02 Bosch Rexroth AG...
  • Page 292 SAFETY "SafeMotion" 292 / 302 Bosch Rexroth AG R911404905, Edition 02...

  • Page 293: Glossary

    SENSEmotor is the encoder interface/protocol for the motor encoders coded with IS / IM / JS / JM in the type code of the motor. "I" stands for BASIC, "J" for STANDARD. "S" stands for single-turn, "M" for multi-turn. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 294 However, the manufacturer is obliged to supervise manufacturing of the product and has to be authorized to assume responsibility for the product. Bosch Rexroth AG R911404905, Edition 02...
  • Page 295 TwinCAT TwinCAT® is registered and licensed trademark of Beckhoff Automation GmbH, Germany. User A user is a person installing, commissioning or using a product which has been placed on the market. R911404905, Edition 02 Bosch Rexroth AG...
  • Page 296 SAFETY "SafeMotion" 296 / 302 Bosch Rexroth AG R911404905, Edition 02...

  • Page 297: Index

    Input signals..... . . 145 PF01 LED......279 R911404905, Edition 02 Bosch Rexroth AG...
  • Page 298 Handling......18 Connection, motor temperature monitoring (XG03)......268 Bosch Rexroth AG R911404905, Edition 02...
  • Page 299 Setting-up mode..... . . 21 XG44......255 R911404905, Edition 02 Bosch Rexroth AG...
  • Page 300 ....... . . 189 Safe stop 2......103 Bosch Rexroth AG R911404905, Edition 02...
  • Page 301 SAFETY "SafeMotion" 301 / 302 R911404905, Edition 02 Bosch Rexroth AG...
  • Page 302 Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 97816 Lohr a.Main Germany Tel. +49 9352 18 0 Fax +49 9352 18 8400 www.boschrexroth.com/electrics R911404905 R911404905...

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