REXROTH IndraControl L25 CML...3N Series Project Planning Manual
જાહેરાત
જાહેરાત
Electric Drives and Controls Hydraulics
Linear Motion and
Assembly Technologies Pneumatics Service
Rexroth IndraControl
L25
Project Planning Manual
R911328474
Edition 03
Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Title
Type of Documentation
Document Typecode
Internal File Reference
Purpose of Documentation
Record of Revision
Rexroth IndraControl
L25
Project Planning Manual
DOK-CONTRL-IC*L25*****-PR03-EN-P
RS-7395430658d72e230a6846a00141db89-3-en-US-4
This documentation describes the IndraControl L25 controls.
Edition
120-0401-B356/EN-01
120-0401-B356/EN-02
120-0401-B356/EN-03
Release Date Notes
08.2009
10.2010
04.2011
First edition
Second edition
Third edition
Copyright
Validity
Published by
Note
© Bosch Rexroth AG 2009
Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1).
The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availa‐ bility of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ 97816 Lohr am Main, Germany
Phone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85 http://www.boschrexroth.com/
Development Control Platform TL (CS)
This document has been printed on chlorine-free bleached paper.
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG I/69
Table of Contents
Table of Contents
Page
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Rexroth IndraControl L25
Table of Contents
Page
24 V Voltage Supply of the Main Circuit U
................................................................................... 34
+24 V Supply of the Segment Circuit U
....................................................................................... 34
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG III/69
Table of Contents
Page
IV/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
1
1.1
1.2
1.3
Bosch Rexroth AG 5/69
System Presentation
System Presentation
Brief Description IndraControl L25
The IndraControl L25 is a modular and scalable control. The control combines the benefits of a compact small control with a standardized I/O system based on terminal technology. The control is a universal hardware platform that can be used for motion-logic and PLC applications. The control provides commu‐ nication interfaces such as Ethernet, EtherNet/IP as well as a SERCOS III interface. Up to two function modules extend the IndraControl L25 via integra‐ ted PCI bus and additional fieldbus interfaces and technology interfaces. The locally available I/O units can be extended by the Rexroth Inline I/O system, just by simply mounting the components side by side. The complete application programs, including runtime, are stored on an easily accessible Compact Flash card.
Device Variants
The IndraControl L25 control is available in several device variants. The devi‐ ces differ mainly in the availability of SERCOS III and PROFIBUS DP interfaces
(see also
fig. 1-1 "Device variants" on page 5
and
chapter 7.1 "Connections on the Front Panel – Overview" on page 29
).
Connection
X7E1 and X7E2
X7E3 and X7E4
X7P
Connection type
Ethernet (SERCOS III)
Ethernet (TCP/IP, RT Ethernet)
RS485 (PROFIBUS DP)
Device variant
CML...3N...
CML...PN...
CML...PN...
Fig.1-1: Device variants
Further characteristic features are listed in the type designation code in chapter
10.1 "Type Designation Code" on page 59
.
View
Operating elements and interfaces are arranged on the front panel:
In the left part is a display with eight characters and four operating keys, the reset button, a LED, the Ethernet interface, the ready contact and a receptacle for a Compact Flash card. The interfaces for SERCOS III are located in the center. The voltage supply is located in the right part.
Fig.1-2: View of a typical IndraControl L25
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Rexroth IndraControl L25
System Presentation
1.4 Further Documentation
Title Identification
PLC Programming with Rexroth
IndraLogic 1.0;
Operating and Programming
Guide
RECO-Inline PROFIBUS DP;
Application Manual
DOK-CONTRL-IL**PRO*V01-
AW02-EN-P
DOK-CONTRL-R-IL-PBSSYS-
AW02-EN-P
RECO Inline PROFIBUS DP Ter‐ minal and Module Supply;
Application Manual
DOK-CONTRL-R-IL-PB*-BK-
FK02-EN-P
DOK-IWORKS-ENGINEE*V10-
AW01-EN-P
Rexroth IndraWorks 10VRS En‐ gineering;
Application Manual
Rexroth WinStudio;
Application Manual
Automation Terminals of the
Rexroth Inline Range;
Application Manual
Rexroth IndraControl L Function
Modules
Project Planning Manual
DOK-CONTRL-WIS*PC**V06-
KB01-DE-P
DOK-CONTRL-ILSYSINS***-
AW01-EN-P
DOK-CONTRL-IC*L*FM****-
PR01-EN-P
Fig.1-3: Further documentation
Parts number
R911305036
R911289597
R911289587
R911327718
R911307630
R911317021
R911326408
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 7/69
Important Instructions on Use
2 Important Instructions on Use
2.1 Intended Use
2.1.1 Introduction
Rexroth products represent state-of-the-art developments and manufacturing.
They are tested prior to delivery to ensure operational safety and reliability.
Therefore the products may only be used for the intended purpose. If they are not used as intended, situations causing personal injury as well as material damage can occur.
Bosch Rexroth disclaims as manufacturer any warranty, liability or damages occurring due to inappropriate use of the products. Fur‐ thermore, Rexroth is not paying any compensation; the user is responsible for any risks resulting from inappropriate use of the products.
Before using Bosch Rexroth products, the following requirements must be met to ensure intended use of the products:
● Anyone handling one of the Rexroth products in any way has to read and understand the respective safety-related guidelines as well as the instruc‐ tions on intended use.
● Hardware products have to remain in their original state, in other words, no modification regarding the design are allowed. Software products must not be decompiled and their source codes must not be modified.
● Damaged or faulty products must not be implemented or put into opera‐ tion.
● It must be ensured that the products are installed as specified in the doc‐ umentation.
2.1.2 Areas of Use and Application
The Bosch Rexroth IndraControl L25 is suitable for logic and motion applica‐ tions.
The IndraControl L25 may only be used with the accessories and mounting parts which are listed in this documentation. Components not named expressly mentioned must neither be mounted nor con‐ nected. The same applies to cables and conduits.
The products may only be operated with the expressly stated con‐ figurations and component combinations as well as with the soft‐ ware and firmware which is given and specified in the respective functional description.
In case of non-compliance, the guarantee and warranty claims shall automatically expire.
Typical fields of use of the IndraControl L25 are:
● Handling systems and assembly systems
● Packaging and food processing machines
● Printing machines and paper converting machines
● Machine tools
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Rexroth IndraControl L25
Important Instructions on Use
2.2
The IndraControl L25 may only be operated under the assembly and installation conditions, in the position of application and under the ambient conditions (tem‐ perature, degree of protection, humidity, EMC, etc.) specified in this documen‐ tation.
Inappropriate Use
Any use of IndraControl L25 in applications other than those specified above or under operating conditions other than those described in the documentation and the technical specifications is considered to be "non-intended use".
IndraControl L25 must not be used if
● it is exposed to operating conditions that do not fulfill the ambient condi‐ tions specified. For instance, operation under water, in case of extreme variations of temperature or in extreme maximum temperatures is not al‐ lowed.
● they are used in household devices or devices belonging to categories 1 to 7 and 10 specified in Appendix IA of the Directive 2002/96/EC
("WEEE").
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 9/69
Safety Instructions for Electric Drives and Controls
3 Safety Instructions for Electric Drives and Controls
3.1 Definitions of Terms
Application Documentation
Component
Control System
Device
Electrical Equipment
Electric Drive System
Installation
Machine
Manufacturer
Product
Project Planning Manual
Qualified Persons
Application documentation comprises the entire documentation used to inform the user of the product about the use and safety-relevant features for config‐ uring, integrating, installing, mounting, commissioning, operating, maintaining, repairing and decommissioning the product. The following terms are also used for this kind of documentation: User Guide, Operation Manual, Commissioning
Manual, Instruction Manual, Project Planning Manual, Application Manual, etc.
A component is a combination of elements with a specified function, which are part of a piece of equipment, device or system. Components of the electric drive and control system are, for example, supply units, drive controllers, mains choke, mains filter, motors, cables, etc.
A control system comprises several interconnected control components placed on the market as a single functional unit.
A device is a finished product with a defined function, intended for users and placed on the market as an individual piece of merchandise.
Electrical equipment encompasses all devices used to generate, convert, trans‐ mit, distribute or apply electrical energy, such as electric motors, transformers, switching devices, cables, lines, power-consuming devices, circuit board as‐ semblies, plug-in units, control cabinets, etc.
An electric drive system comprises all components from mains supply to motor shaft; this includes, for example, electric motor(s), motor encoder(s), supply units and drive controllers, as well as auxiliary and additional components, such as mains filter, mains choke and the corresponding lines and cables.
An installation consists of several devices or systems interconnected for a de‐ fined purpose and on a defined site which, however, are not intended to be placed on the market as a single functional unit.
A machine is the entirety of interconnected parts or units at least one of which is movable. Thus, a machine consists of the appropriate machine drive ele‐ ments, as well as control and power circuits, which have been assembled for a specific application. A machine is, for example, intended for processing, treatment, movement or packaging of a material. The term "machine" also cov‐ ers a combination of machines which are arranged and controlled in such a way that they function as a unified whole.
The manufacturer is an individual or legal entity bearing responsibility for the design and manufacture of a product which is placed on the market in the in‐ dividual's or legal entity's name. The manufacturer can use finished products, finished parts or finished elements, or contract out work to subcontractors.
However, the manufacturer must always have overall control and possess the required authority to take responsibility for the product.
Examples of a product: Device, component, part, system, software, firmware, among other things.
A project planning manual is part of the application documentation used to support the sizing and planning of systems, machines or installations.
In terms of this application documentation, qualified persons are those persons who are familiar with the installation, mounting, commissioning and operation of the components of the electric drive and control system, as well as with the hazards this implies, and who possess the qualifications their work requires. To comply with these qualifications, it is necessary, among other things,
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Rexroth IndraControl L25
Safety Instructions for Electric Drives and Controls
User
1) to be trained, instructed or authorized to switch electric circuits and devices safely on and off, to ground them and to mark them
2) to be trained or instructed to maintain and use adequate safety equipment
3) to attend a course of instruction in first aid
A user is a person installing, commissioning or using a product which has been placed on the market.
3.2 General Information
3.2.1 Using the Safety Instructions and Passing Them on to Others
Do not attempt to install and operate the components of the electric drive and control system without first reading all documentation provided with the product.
Read and understand these safety instructions and all user documentation prior to working with these components. If you do not have the user documentation for the components, contact your responsible Bosch Rexroth sales partner. Ask for these documents to be sent immediately to the person or persons respon‐ sible for the safe operation of the components.
If the component is resold, rented and/or passed on to others in any other form, these safety instructions must be delivered with the component in the official language of the user's country.
Improper use of these components, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety de‐ vices, could result in property damage, injury, electric shock or even death.
3.2.2 Requirements for Safe Use
Read the following instructions before initial commissioning of the components of the electric drive and control system in order to eliminate the risk of injury and/or property damage. You must follow these safety instructions.
● Bosch Rexroth is not liable for damages resulting from failure to observe the safety instructions.
● Read the operating, maintenance and safety instructions in your language before commissioning. If you find that you cannot completely understand the application documentation in the available language, please ask your supplier to clarify.
● Proper and correct transport, storage, mounting and installation, as well as care in operation and maintenance, are prerequisites for optimal and safe operation of the component.
● Only qualified persons may work with components of the electric drive and control system or within its proximity.
● Only use accessories and spare parts approved by Bosch Rexroth.
● Follow the safety regulations and requirements of the country in which the components of the electric drive and control system are operated.
● Only use the components of the electric drive and control system in the manner that is defined as appropriate. See chapter "Appropriate Use".
● The ambient and operating conditions given in the available application documentation must be observed.
● Applications for functional safety are only allowed if clearly and explicitly specified in the application documentation "Integrated Safety Technolo‐ gy". If this is not the case, they are excluded. Functional safety is a safety
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 11/69
Safety Instructions for Electric Drives and Controls concept in which measures of risk reduction for personal safety depend on electrical, electronic or programmable control systems.
● The information given in the application documentation with regard to the use of the delivered components contains only examples of applications and suggestions.
The machine and installation manufacturers must
– make sure that the delivered components are suited for their individ‐ ual application and check the information given in this application documentation with regard to the use of the components,
– make sure that their individual application complies with the appli‐ cable safety regulations and standards and carry out the required measures, modifications and complements.
● Commissioning of the delivered components is only allowed once it is sure that the machine or installation in which the components are installed complies with the national regulations, safety specifications and standards of the application.
● Operation is only allowed if the national EMC regulations for the applica‐ tion are met.
● The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective application documenta‐ tion.
The machine or installation manufacturer is responsible for compliance with the limit values as prescribed in the national regulations.
● The technical data, connection and installation conditions of the compo‐ nents are specified in the respective application documentations and must be followed at all times.
National regulations which the user must take into account
● European countries: In accordance with European EN standards
● United States of America (USA):
– National Electrical Code (NEC)
– National Electrical Manufacturers Association (NEMA), as well as local engineering regulations
– Regulations of the National Fire Protection Association (NFPA)
● Canada: Canadian Standards Association (CSA)
● Other countries:
– International Organization for Standardization (ISO)
– International Electrotechnical Commission (IEC)
3.2.3 Hazards by Improper Use
● High electrical voltage and high working current! Danger to life or serious injury by electric shock!
● High electrical voltage by incorrect connection! Danger to life or injury by electric shock!
● Dangerous movements! Danger to life, serious injury or property damage by unintended motor movements!
● Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electric drive systems!
● Risk of burns by hot housing surfaces!
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Rexroth IndraControl L25
Safety Instructions for Electric Drives and Controls
● Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!
● Risk of injury by improper handling of batteries!
● Risk of injury by improper handling of pressurized lines!
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 13/69
Safety Instructions for Electric Drives and Controls
3.3 Instructions with Regard to Specific Dangers
3.3.1 Protection Against Contact With Electrical Parts and Housings
This section concerns components of the electric drive and control system with voltages of more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal danger and electric shock. When operating components of the electric drive and control system, it is unavoidable that some parts of these components conduct dangerous voltage.
High electrical voltage! Danger to life, risk of injury by electric shock or serious injury!
● Only qualified persons are allowed to operate, maintain and/or repair the components of the electric drive and control system.
● Follow the general installation and safety regulations when working on power installations.
● Before switching on, the equipment grounding conductor must have been permanently connected to all electric components in accordance with the connection diagram.
● Even for brief measurements or tests, operation is only allowed if the equipment grounding conductor has been permanently connected to the points of the components provided for this purpose.
● Before accessing electrical parts with voltage potentials higher than 50 V, you must disconnect electric components from the mains or from the pow‐ er supply unit. Secure the electric component from reconnection.
● With electric components, observe the following aspects:
Always wait 30 minutes after switching off power to allow live capacitors to discharge before accessing an electric component. Measure the elec‐ trical voltage of live parts before beginning to work to make sure that the equipment is safe to touch.
● Install the covers and guards provided for this purpose before switching on.
● Never touch electrical connection points of the components while power is turned on.
● Do not remove or plug in connectors when the component has been pow‐ ered.
● Under specific conditions, electric drive systems can be operated at mains protected by residual-current-operated circuit-breakers sensitive to uni‐ versal current (RCDs/RCMs).
● Secure built-in devices from penetrating foreign objects and water, as well as from direct contact, by providing an external housing, for example a control cabinet.
High housing voltage and high leakage current! Danger to life, risk of injury by electric shock!
● Before switching on and before commissioning, ground or connect the components of the electric drive and control system to the equipment grounding conductor at the grounding points.
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Rexroth IndraControl L25
Safety Instructions for Electric Drives and Controls
● Connect the equipment grounding conductor of the components of the electric drive and control system permanently to the main power supply at all times. The leakage current is greater than 3.5 mA.
● Establish an equipment grounding connection with a minimum cross sec‐ tion according to the table below. With an outer conductor cross section smaller than 10 mm 2 (8 AWG), the alternative connection of two equip‐ ment grounding conductors is allowed, each having the same cross section as the outer conductors.
Cross section outer con‐ ductor
1.5 mm 2 (16 AWG)
2.5 mm 2 (14 AWG)
4 mm 2 (12 AWG)
6 mm 2 (10 AWG)
10 mm 2 (8 AWG)
16 mm 2 (6 AWG)
25 mm 2 (4 AWG)
35 mm 2 (2 AWG)
50 mm 2 (1/0 AWG)
70 mm 2 (2/0 AWG)
...
Minimum cross section equipment grounding conductor
Leakage current ≥ 3.5 mA
1 equipment grounding conductor
2 equipment grounding con‐ ductors
10 mm
16 mm
25 mm
35 mm
2
2
2
2
(8 AWG)
(6 AWG)
(4 AWG)
(2 AWG)
...
2 × 1.5 mm 2 (16 AWG)
2 × 2.5 mm 2 (14 AWG)
2 × 4 mm 2 (12 AWG)
2 × 6 mm 2 (10 AWG)
-
-
...
-
-
-
-
Fig.3-1: Minimum Cross Section of the Equipment Grounding Connection
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock
Protective extra-low voltage is used to allow connecting devices with basic in‐ sulation to extra-low voltage circuits.
On components of an electric drive and control system provided by Bosch
Rexroth, all connections and terminals with voltages between 5 and 50 volts are PELV ("Protective Extra-Low Voltage") systems. It is allowed to connect devices equipped with basic insulation (such as programming devices, PCs, notebooks, display units) to these connections.
Danger to life, risk of injury by electric shock! High electrical voltage by incorrect connection!
If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g., the mains connection) are connected to Bosch Rexroth products, the connected extra-low voltage circuits must comply with the re‐ quirements for PELV ("Protective Extra-Low Voltage").
3.3.3 Protection Against Dangerous Movements
Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 15/69
Safety Instructions for Electric Drives and Controls
● Improper or wrong wiring or cable connection
● Operator errors
● Wrong input of parameters before commissioning
● Malfunction of sensors and encoders
● Defective components
● Software or firmware errors
These errors can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation.
The monitoring functions in the components of the electric drive and control system will normally be sufficient to avoid malfunction in the connected drives.
Regarding personal safety, especially the danger of injury and/or property dam‐ age, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive move‐ ments depends upon the type of control and the state of operation.
Dangerous movements! Danger to life, risk of injury, serious injury or property damage!
A risk assessment must be prepared for the installation or machine, with its specific conditions, in which the components of the electric drive and control system are installed.
As a result of the risk assessment, the user must provide for monitoring func‐ tions and higher-level measures on the installation side for personal safety. The safety regulations applicable to the installation or machine must be taken into consideration. Unintended machine movements or other malfunctions are pos‐ sible if safety devices are disabled, bypassed or not activated.
To avoid accidents, injury and/or property damage:
● Keep free and clear of the machine’s range of motion and moving machine parts. Prevent personnel from accidentally entering the machine’s range of motion by using, for example:
– Safety fences
– Safety guards
– Protective coverings
– Light barriers
● Make sure the safety fences and protective coverings are strong enough to resist maximum possible kinetic energy.
● Mount emergency stopping switches in the immediate reach of the oper‐ ator. Before commissioning, verify that the emergency stopping equip‐ ment works. Do not operate the machine if the emergency stopping switch is not working.
● Prevent unintended start-up. Isolate the drive power connection by means of OFF switches/OFF buttons or use a safe starting lockout.
● Make sure that the drives are brought to safe standstill before accessing or entering the danger zone.
● Additionally secure vertical axes against falling or dropping after switching off the motor power by, for example,
– mechanically securing the vertical axes,
– adding an external braking/arrester/clamping mechanism or
– ensuring sufficient counterbalancing of the vertical axes.
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Rexroth IndraControl L25
Safety Instructions for Electric Drives and Controls
● The standard equipment motor holding brake or an external holding brake controlled by the drive controller is not sufficient to guarantee personal safety!
● Disconnect electrical power to the components of the electric drive and control system using the master switch and secure them from reconnec‐ tion ("lock out") for:
– Maintenance and repair work
– Cleaning of equipment
– Long periods of discontinued equipment use
● Prevent the operation of high-frequency, remote control and radio equip‐ ment near components of the electric drive and control system and their supply leads. If the use of these devices cannot be avoided, check the machine or installation, at initial commissioning of the electric drive and control system, for possible malfunctions when operating such high-fre‐ quency, remote control and radio equipment in its possible positions of normal use. It might possibly be necessary to perform a special electro‐ magnetic compatibility (EMC) test.
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐ ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors or permanent magnets of electric motors represent a serious danger to persons with heart pacemakers, metal implants and hearing aids.
Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electric components!
● Persons with heart pacemakers and metal implants are not allowed to enter the following areas:
– Areas in which components of the electric drive and control systems are mounted, commissioned and operated.
– Areas in which parts of motors with permanent magnets are stored, repaired or mounted.
● If it is necessary for somebody with a heart pacemaker to enter such an area, a doctor must be consulted prior to doing so. The noise immunity of implanted heart pacemakers differs so greatly that no general rules can be given.
● Those with metal implants or metal pieces, as well as with hearing aids, must consult a doctor before they enter the areas described above.
3.3.5 Protection Against Contact With Hot Parts
Hot surfaces of components of the electric drive and control system. Risk of burns!
● Do not touch hot surfaces of, for example, braking resistors, heat sinks, supply units and drive controllers, motors, windings and laminated cores!
● According to the operating conditions, temperatures of the surfaces can be higher than 60 °C (140 °F) during or after operation.
● Before touching motors after having switched them off, let them cool down for a sufficient period of time. Cooling down can require up to 140 mi‐ nutes! The time required for cooling down is approximately five times the thermal time constant specified in the technical data.
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 17/69
Safety Instructions for Electric Drives and Controls
● After switching chokes, supply units and drive controllers off, wait 15 mi‐ nutes to allow them to cool down before touching them.
● Wear safety gloves or do not work at hot surfaces.
● For certain applications, and in accordance with the respective safety reg‐ ulations, the manufacturer of the machine or installation must take meas‐ ures to avoid injuries caused by burns in the final application. These measures can be, for example: Warnings at the machine or installation, guards (shieldings or barriers) or safety instructions in the application documentation.
3.3.6 Protection During Handling and Mounting
Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!
● Observe the relevant statutory regulations of accident prevention.
● Use suitable equipment for mounting and transport.
● Avoid jamming and crushing by appropriate measures.
● Always use suitable tools. Use special tools if specified.
● Use lifting equipment and tools in the correct manner.
● Use suitable protective equipment (hard hat, safety goggles, safety shoes, safety gloves, for example).
● Do not stand under hanging loads.
● Immediately clean up any spilled liquids from the floor due to the risk of falling!
3.3.7 Battery Safety
Batteries consist of active chemicals in a solid housing. Therefore, improper handling can cause injury or property damage.
Risk of injury by improper handling!
● Do not attempt to reactivate low batteries by heating or other methods (risk of explosion and cauterization).
● Do not attempt to recharge the batteries as this may cause leakage or explosion.
● Do not throw batteries into open flames.
● Do not dismantle batteries.
● When replacing the battery/batteries, do not damage the electrical parts installed in the devices.
● Only use the battery types specified for the product.
Environmental protection and disposal! The batteries contained in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations.
Dispose of used batteries separately from other waste. Observe the national regulations of your country.
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Rexroth IndraControl L25
Safety Instructions for Electric Drives and Controls
3.3.8 Protection Against Pressurized Systems
According to the information given in the Project Planning Manuals, motors and components cooled with liquids and compressed air can be partially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids and cooling lubricants. Improper handling of the connected sup‐ ply systems, supply lines or connections can cause injuries or property damage.
Risk of injury by improper handling of pressurized lines!
● Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐ sion).
● Observe the respective manufacturer's operating instructions.
● Before dismounting lines, relieve pressure and empty medium.
● Use suitable protective equipment (safety goggles, safety shoes, safety gloves, for example).
● Immediately clean up any spilled liquids from the floor due to the risk of falling!
3.4
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.
Explanation of Signal Words and the Safety Alert Symbol
The Safety Instructions in the available application documentation contain spe‐ cific signal words (DANGER, WARNING, CAUTION or NOTICE) and, where required, a safety alert symbol (in accordance with ANSI Z535.6-2006).
The signal word is meant to draw the reader's attention to the safety instruction and identifies the hazard severity.
The safety alert symbol (a triangle with an exclamation point), which precedes the signal words DANGER, WARNING and CAUTION, is used to alert the reader to personal injury hazards.
DANGER
In case of non-compliance with this safety instruction, death or serious injury will occur.
WARNING
In case of non-compliance with this safety instruction, death or serious injury could occur.
CAUTION
In case of non-compliance with this safety instruction, minor or moderate injury could occur.
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 19/69
Safety Instructions for Electric Drives and Controls
NOTICE
In case of non-compliance with this safety instruction, property damage could occur.
20/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
4
4.1
4.2
Bosch Rexroth AG 21/69
Technical Data
Technical Data
Equipment
Processor
RAM
Clock frequency
Interfaces:
Interface to function modules
●
Interface to I/O terminals ●
Communication interfa‐ ces
Ready contact
●
●
●
Renesas SH 7785
Min. 128 MByte DRAM and min. 256 kByte RDS
576 MHz (CPU CLK)
Bosch Rexroth PC104 Plus
Rexroth Inline interface
1 × Ethernet connection (RJ 45, 10/100 base-T)
1 × SERCOS III Master/Slave interface
1 single-pin ready contact
Voltage Supply
The IndraControl L25 is supplied with 24 V. The following values of the oper‐ ating voltage comply with DIN EN 61131-2:
Nominal value
Tolerances
Residual ripple
U max
U min
DC 24 V
-15 %, +20 % (without residual ripple)
± 5 %
30 V
19.2 V
Fig.4-1: Operating voltage according to DIN EN 61131-2
Three operating voltages have to be applied on the IndraControl L25 (see
chapter 7.2.1 "Supply Voltages to be Connected Externally" on page 31
).
Taking the function modules and Inline terminals into consideration, the current consumption from these voltages is:
Current consumption from U
LS tension
and maximum ex‐
Current consumption from U
M
and U
S
Fig.4-2: Power consumption
Maximum 2 A
Max. of 8 A in total
The power consumption of IndraControl L25 (without connected I/
Os and function modules) is typically 8.7 watts.
RDS - Remanent Data Storage
Remanent data is automatically written to the Compact Flash card after voltage loss.
The data is restored after rebooting the control.
22/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Technical Data
4.3 Ambient Conditions
In operation
Max. surrounding air temperature
Relative humidity
+5 ... +55 °C
Air pressure
RH-2; 5 % to 95 % acc. to DIN EN 61131-2, non-condensing.
Up to 2,700 m above MSL according to
DIN 60204
Mechanical strength Max. vibration:
Frequency range: 10 to 150 Hz
Excursion: 0.075 mm for 10 ... 57 Hz
Acceleration: 1 g for 57 to 150 Hz acc. to EN 60068-2-6
Storage / Transport
-25 ℃ to +70 ℃
RH-2; 5 % to 95 % acc. to DIN EN 61131-2, non-condensing.
Up to 3,000 m above MSL according to
DIN 60204
Max. shock:
15 g according to EN 60 068-2-27, no disturbance of the function
Fig.4-3: Ambient Conditions
The surrounding air must be free from acids, alkaline solutions, corrosive agents, salts, metal vapors, and other electrically con‐ ductive contaminants in high concentrations.
The ambient air must be dust-free. Housings and installation com‐ partments must at least comply with degree of protection IP 54 according to DIN VDE 0470-1.
4.4
DANGER Danger of destruction by overheating
Operation is allowed up to 45 ℃ and if the air recirculates.
If the internal temperature reaches approx. 92 ℃, the control switches off au‐ tomatically.
If the internal temperature is 87 °C or higher, the display indicates the warning
"Temp !!!".
The internal temperature of IndraControl L25 can be read out with the "IH_Tem‐ perature" function in the "RIH_HWTestLib" library of the application program in order to trigger further reactions.
Used Standards
The IndraControl L25 complies with the following standards:
Standard
DIN EN 60 204-1
DIN EN 61 131-2
Meaning
Electrical equipment of machines
Programmable logic controllers
Equipment and tests requirements
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
4.5
Bosch Rexroth AG 23/69
Technical Data
Standard
DIN EN 60 529
UL 508
Fig.4-4: Used standards
Meaning
Degrees of protection (including housings and installa‐ tion compartments)
Industrial Control Equipment
The IndraControl L25 as well as the additionally available function modules and the Inline terminals correspond to the CE require‐ ments!
Systems with the IndraControl L25 that are used in residential areas
(housing, business and commercial areas as well as small-sized enterprises) require a single approval by an authority or a testing agency. In Germany, such single approvals are issued by the ”Reg‐ ulierungsbehörde für Telekommunikation und Post (RegTP)” (Ger‐ man Regulatory Authority for Telecommunications and Posts).
UL and CSA certified
4.6
The devices of the IndraControl L25 product family are certificated according to
● UL508 (Industrial Control Equipment) and
● C22.2 no. 142-M1987 (CSA)
UL file no. E210730
However, there can be combinations or stages of expansions with limited or missing certification. Therefore verify the certification by using the UL label on the device.
To guarantee an UL- and CSA-compliant operation, the following conditions have to be fulfilled:
● Use only insulated copper wire suitable for at least 60/75 °C.
NOTICE Loss of UL and CSA compliance due to changes on the device.
The UL- and CSA- marking is only valid for the device in its delivery status. After having modified the device the UL and CSA compliance must be verified.
Compatibility Test
All Rexroth controls and drives are developed and tested according to the latest state-of-the-art of technology.
As it is not possible to follow the continuing development of all materials (e. g.
lubricants in machine tools) which may interact with our controls and drives, it cannot be completely ruled out that any reactions with the materials used by
Bosch Rexroth might occur.
24/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Technical Data
4.7
For this reason, before using the respective material a compatibility test has to be carried out for new materials (e. g. lubricants and cleaning agents) and our housing or our housing materials.
Wear Parts
Display
This section describes the wear parts as well as their service life. Wear parts are not subject to any warranty.
The service life of the display is limited. A progressive deterioration of the dis‐ play takes place after the service life was exceeded.
The manufacturer specifies the following service life of the displays:
● 60,000 h for 23 ± 5°C and 60 ± 20% RH (relative air humidity)
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
5
5.1
5.2
Bosch Rexroth AG 25/69
Dimensions
Dimensions
General Information
All values in the illustrations are given in mm.
Housing Dimensions
The width of the IndraControl L25 is 175.4 mm, the height is 120 mm and the depth is 84.7 mm. Please refer to the following figures for detailed dimensions:
Fig.5-1: Bottom view
Fig.5-2: Front view
26/69
Dimensions
Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
5.3
Fig.5-3: Left view (the cut-out for the top-hat rail is located in the center)
Installation Notes
● Avoid installation locations that are exposed to direct sunlight because this causes additional heat.
● Keep as much distance as possible to noise sources
● Lay all connecting cables in loops and use strain reliefs for all cables.
● Keep as much distance as possible to noise sources.
● Provide the following minimum clearances for sufficient cooling:
100 mm
30 mm
30 mm
30 mm
100 mm
Fig.5-4: Minimum distances for the circulation of surrounding air
● Additionally, provide sufficient clearance for mounting, dismounting, con‐ nector and cable length.
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
6
6.1
6.2
Bosch Rexroth AG 27/69
Display and Operating Components
Display and Operating Components
General Information
On its front, the IndraControl L25 is provided with the following display and operating components: a single-line display with four operating keys as well as a LED and a Reset button.
Display and Operating Keys
Display The display is a LCD with eight characters (5 × 10 dot matrix).
6.3
Fig.6-1: Display with four operating keys
The keys below the display have the following functions:
Key
<Esc>
<Down>
(down arrow)
<Up>
(up arrow)
<Enter>
Fig.6-2:
Menu navigation
One level up
One menu entry down
One menu entry up
One level down
Functions of the operating keys
Input functions
Cancel input
Reduce parameter value
Increase parameter value
Confirm input
Reset Button and Stop LED
The reset button and a red LED are arranged in the section below the display.
Reset button
LED
Fig.6-3: Reset button and STOP LED
By activating the reset button, the whole device is reset and a restart is forced, without the need to switch off the supply voltages.
The reset button can only be actuated with a sharp tool (e. g. tip of a pencil).
The LED serves for diagnostics and status display.
The states indicated by the LED depend on the firmware used and are included in the description of the particular system.
28/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
7
7.1
Bosch Rexroth AG 29/69
Connections and Interfaces
Connections and Interfaces
Connections on the Front Panel – Overview
Designa‐ tion at the housing
X7E5
X7E1
X7E2
X2R
X7E3
X7E4
X7P
Connection type Connector type
(integrated)
Mating connec‐ tor and cable
(from outside)
Notes on de‐ vice variants
Ethernet
(TCP/IP, program‐ ming device)
Ethernet
(SERCOS III)
RJ45 female connector
8-pin
RJ45 connector
(twisted pair, 8wire)
-
RJ45 connector
8-pin female RJ45 connector
(twisted pair, 8wire)
Only available on CML...3N...
device variant
Ethernet
(SERCOS III)
Ready contact
RJ45 female connector
8-pin
Connector strip
3-pin, 3.5 mm
RJ45 connector
(twisted pair, 8wire)
3-pin female connector strip, spring force,
3.5 mm (inclu‐ ded in the scope of deliv‐ ery)
-
Only available on CML...3N...
device variant
Ethernet
(TCP/IP,
Ethernet)
Ethernet
(TCP/IP,
Ethernet)
RS485
(PROFIBUS DP)
RT
RJ45 female connector
8-pin
RT
RJ45
D-Sub female connector
9-pin female connector
8-pin
RJ45 connector
(twisted pair, 4-/
8-wire)
Only available on CML...PN...
device variant
RJ45 connector
(twisted pair, 4-/
8-wire)
D-Sub bus con‐ nector, IP 20,
9-pin
Only available on CML...PN...
device variant
Only available on CML...PN...
device variant
30/69 Bosch Rexroth AG
Connections and Interfaces
View IndraControl L25, CML...3N...
device variant
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
X7E1
L
S
X7E2
L
S
X7E5
X2R
1 2
①
②
Fig.7-1:
Slot for Compact Flash card
PWR IN voltage supply
IndraControl L25 connections, CML...3N... device variant
CAUTION Fitting or removing connectors when voltage is applied, may damage the IndraControl L25, a function module or an Inline terminal!
Turn off the supply voltage before establishing or breaking any connections!
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
View IndraControl L25, CML...PN...
device variant
X7E5
X2R
X7E3
L
S
X7E4
L
S
5
9
6
X7P
1
Bosch Rexroth AG 31/69
Connections and Interfaces
1 2
①
②
Fig.7-2:
Slot for Compact Flash card
PWR IN voltage supply
IndraControl L25 connections, CML...PN... device variant
CAUTION Fitting or removing connectors when voltage is applied, may damage the IndraControl L25, a function module or an Inline terminal!
Turn off the supply voltage before establishing or breaking any connections!
7.2 Voltage Supply
7.2.1 Supply Voltages to be Connected Externally
General Information
PWR IN The IndraControl L25 as well as any connected function modules and Inline terminals are supplied with power via the black connector to the right side of the IndraControl L25.
32/69 Bosch Rexroth AG
Connections and Interfaces
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Fig.7-3: Connector for supply voltages
Observe the color-coding of the connectors.
For connecting the operating voltages only the power connector (R-
IB IL SCN-PWR IN-PWR) may be used. The connector is contained in the scope of delivery. TheR-IB IL SCN-PWR IN-CP connector, which is available for other power terminals, is not allowed for the
IndraControl L25!
NOTICE Insufficient contact, loss of UL certification due to inadequate wire.
Use only copper wire (cross-section AWG 22 to 16; 0.34 mm 2 wiring the connection terminals.
to 1.5 mm 2 ) for
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 33/69
Connections and Interfaces
Connector con‐ tact
Signal
1.1
1.2
DC +24 V segment voltage (U
DC +24 V supply voltage (U
LS
)
S
)
1.3
1.4 and 2.4
2.1
LGND (ground, supply voltage)
FE (functional earth ground)
DC 24 V main voltage (U
M
)
2.2
2.3
DC 24 V main voltage (U
M
)
PGND (ground main and segment voltage)
Fig.7-4: Pin assignment on the voltage terminal
Five LEDs are arranged at the upper edge. The LEDs have the following mean‐ ing:
LED "U
M
"
Off
Green
Fig.7-5:
LED
"U
S
"
Off
Green
Meaning
Main circuit supply is missing.
24 V supply U
M
of the main circuit is present.
Diagnostic LED of the power terminal
Meaning
Fig.7-6:
LED "U
L
"
Off
Green
Segment circuit supply is missing
24 V supply U
LS
of the segment circuit is present
Diagnostic LED of the segment terminal
Meaning
Supply voltage U
LS
is missing
24 V supply voltage U
LS
is present
Fig.7-7: Diagnostic LED of the supply voltage
LED "FS" and
"FN"
Meaning
At the moment without function
Fig.7-8: LED FS and FN
The 7.5 V Inline voltage and the +24 V analog voltage U
ANA the external +24 V voltage U
LS
.
are derived from
24 V Voltage Supply U
LS
The 24 V supply voltage U
LS
(contact 1.2) generates the internally required voltages in the IndraControl L25.
34/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Connections and Interfaces
U
LS
is electrically isolated from the voltages U
M
and U
S
.
Requirement: A power supply unit that is electrically isolated from the power supply units for U
M
and U
S
is used for U
LS
.
U
M
and U
S
are not electrically isolated from each other.
24 V Voltage Supply of the Main Circuit U
M
Function
Current carrying capacity
The 24 V voltage for the main circuit supply U
M
IndraControl L25.
on terminal 2.2 is not used for
A main circuit U
M
begins at a power terminal at the IndraControl L25 and is lead to the next power terminal through all following terminals. At the next power terminal, a new circuit is started; its potential is isolated from the previous one.
Several power terminals can be used within one station.
Several segments, independent from each other, can be created within the main circuit. The main circuit provides the voltage potential, from which the segment voltages (U
S
) are derived. The splitting into segments permits to pro‐ tect or switch e. g. the supply of several actuators separately.
The maximum current carrying capacity is 8 A (total current with the segment circuit). If the limit value has been reached, a new power terminal must be used.
IndraControl
PWR IN PWR IN
Rexroth Inline
SEG/F
U
L
U
ANA
GNDL
U
LS
U
S
U
M
U
M
U
M
Generation of U
M
PWR IN
R-IL 24
PWR IN
R-IL 24
SEG/F
Fig.7-9:
Voltage terminal at IndraControl L25
Power terminal
Segment terminal with fuse
Main circuit
In the simplest case, the main voltage U
M trol L25.
can be supplied at the IndraCon‐
U
M
can also be supplied via a power terminal. A power terminal has to be used in the following cases:
1.
An electrical isolation has to be set up.
2.
The maximum current carrying capacity of a voltage jumper (
M total current of U
S
and U
M
) is reached.
, U
S
or GND,
+24 V Supply of the Segment Circuit U
S
Segment circuit supply U
S
has to be connected to contact 1.1 and is lead through the following series Rexroth Inline I/O terminals. It forms the segment circuit or auxiliary circuit (via voltage jumpers) of the Rexroth Inline terminals and the onboard I/Os.
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 35/69
Function
Voltage
Current carrying capacity
Generation U
S
Connections and Interfaces
The segment circuit with the segment voltage U
S
starts at the IndraCon‐ trol L25 or a supply terminal (power terminal or segment terminal) and is supplied through all following terminals up to the next supply terminal.
Several segment terminals can be used within a main circuit and thereby seg‐ ment the main circuit. The reference to ground is the same as that of the main circuit. Thus, different fused electric circuits can be implemented within the sta‐ tion without any external cross-wiring.
The voltage in the segment circuit is DC 24 V.
The maximum current carrying capacity is 8 A (total current with the main cir‐ cuit). If the limit value for a voltage jumper U
S and U
M
), a new power terminal must be used.
M
is reached (total current of U
The segment voltage U
S
can be provided in various ways:
1.
The segment voltage can be fed at the IndraControl L25 or at a power terminal.
2.
The segment voltage can be tapped from the main voltage, either at the
IndraControl L25 or at a power terminal using a jumper or a switch.
3.
A segment terminal with fuse can be used. In this terminal, the segment voltage is automatically tapped from the main voltage.
At the 120 V and 230 V voltage levels, it is not possible to set up segments. Only the manin circuit is used in this level. Special power terminals must be used.
IndraControl
PWR IN
Rexroth Inline
24 PWR IN 24 SEG/F
U
L
U
ANA
GNDL
U
LS
U
S
U
M
PWR IN
R-IL 24
PWR IN
R-IL 24
SEG/
Fig.7-10:
U
S
U
M
Voltage terminal at IndraControl L25
Power terminal
Segment terminal with fuse
Segment circuit
The voltages
M
and U
S
are electrically isolated from U
L
.
Requirement: Power supply units that are electrically isolated from the power supply unit for U
L
are used for voltages U
M
and U
S
.
When designing the station, do observe that the total current in the segment circuit U
S
and in the main circuit U
M
must not exceed 8 A.
U
M
is interrupted by the PWR IN terminal.
U
S
is interrupted by the PWR-IN and SEG/F terminals.
36/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Connections and Interfaces
7.2.2 Internally Generated Voltages
+7.5 V Inline Supply U
L
Function
Voltage
Generation of the Inline supply
Current carrying capacity
The +7.5-V Inline supply voltage is generated from the supply voltage U
LS
inside the IndraControl L25 and is supplied through all connected Rexroth Inline I/O terminals. It is the logic voltage supply (via voltage jumpers) of the Rexroth
Inline terminals.
This logic circuit starts at the IndraControl L25 and is supplied through all ter‐ minals of a station.
Logic voltage is supplied from the Inline supply to all terminals of the station.
The voltage in this circuit is 7.5 V.
The Inline supply is generated from the supply voltage U
LS trol L25.
of the IndraCon‐
The maximum current carrying capacity of the Inline supply is 2 A.
24 V Analog Supply (U
ANA
)
Function
Voltage
Provision
Current carrying capacity
The 24 V analog supply is also generated from the voltage U
LS
. It starts in the
IndraControl L25 and is supplied through all Rexroth Inline I/O terminals. It is the voltage supply (via voltage jumpers) U minals.
ANA
of the Rexroth Inline analog ter‐
The peripheral equipment of the terminals for analog signals is supplied from the analog circuit.
The voltage in this circuit is 24 V.
The analog voltage U voltage U
LS
ANA
is generated from the IndraControl L25 from the logic
The current carrying capacity of U
ANA
is max. 0.5 A.
IndraControl
PWR IN 24 PWR IN
Rexroth Inline
24 SEG/F
U
L
U
ANA
GNDL
U
LS
U
S
U
M
U
LS
PWR IN
R-IL 24
PWR IN
R-IL 24
SEG/F
Fig.7-11:
Voltage terminal at IndraControl L25
Power terminal
Segment terminal with fuse
Inline supply and analog circuit
For comments on the wiring, please refer to
chapter 8.3 "Electrical Installa‐ tion" on page 48 .
7.3 Interfaces
7.3.1 Ethernet Interfaces
X7E5 Ethernet network connection Connector X7E5 can be used to connect the IndraControl L25 to an Ethernet network.
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 37/69
Connections and Interfaces
The connection requirements defined for 100BaseT in IEEE 802.3 are appli‐ cable.
RJ45, female connector, 8-pin
Type:
Cable length:
Cable type:
Transmission rate:
Ethernet 100BaseT
100 m max.
CAT5e with S/STP
10 or 100 MBit/s
Ethernet RJ45
L
8
1
S
Ethernet
1
2
3
4
5
6
7
8 max. 100 m
Fig.7-12: Ethernet interface
Bosch Rexroth recommends to use a STP cable of category 5.
This port is intended for the programming device network!
LED
L (link)
S (send)
Status
On: Link to network is available
Off: No connection to network is available
On: Data packets are sent
Off: No data is sent
7.3.2 Ethernet Interface (only for Device Variant CML...PN ...)
X7E3, X7E4 Ethernet network con‐ nection
Connectors X7E3 and X7E4 can be used to connect the IndraControl L25 to an Ethernet network.
The connection requirements defined for 100BaseTX in IEEE 802.3 are appli‐ cable.
RJ45, female connector, 8-pin
Type
Cable length
Cable type
Transmission rate
Ethernet 100Base TX
100 m max.
CAT5e with S/STP
10 or 100 MBit/s
38/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Connections and Interfaces
Ethernet RJ45
L
8
1
S
Ethernet
6
7
8
4
5
1
2
3 max. 100 m
Fig.7-13: Ethernet interface
Bosch Rexroth recommends to use a STP cable of category 5.
According to the configuration in the application software, these connections can be used for another TCP/IP network or for an RT Ethernet network.
The two plugs correspond to a twofold switch in a TCP/IP network.
LED
L (link)
S (send)
Status
On: Link to network is available
Off: No connection to network is available
On: Data packets are sent
Off: No data is sent
7.3.3 PROFIBUS DP (only for Device Variant CML...PN...)
X7P PROFIBUS DP interface The IndraControl L25 provides a PROFIBUS interface according to DIN EN
50170, part 2.
D-Sub female connector, 9-pin
Type
Cable type
Transmission rate
RS485
Shielded, twisted pair
9.6 kBit/s to 12 kBit/ss
X7P
5
9 6
1 RxD/TxD-P
CNTR-T
DGND
VP 100 mA
RxD/TxD-N
CNTR-N
5
6
3
4
1
2
7
8
9
Shield above the metallic plug of the housing
Fig.7-14: PROFIBUS DP interface
The bus line is specified as cable type A according to EN 50170, Part 8-2. The bus line must comply with the following cable parameters:
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 39/69
Connections and Interfaces
Surge impedance at a frequency within a range from 3 to 20 MHz
Operating capacity
Loop resistance
Outer diameter
Core cross-section
135 to 156 ohm
<= 30 pF/m
<= 110 ohm/km
> 0.64 mm
> 0.34 mm 2
Fig.7-15: Parameters for PROFIBUS DP cable
The mentioned cable parameters in
of a standard cable of cable type A result in the following length extensions of a bus segment for the particular transmission rates:
Transmission rate in kbits/s
Max. segment length in m
9.6
19.2 45.45 93.75 187.5 500 1500 3000 6000 12000
1200 1200 1200 1200 1000 400 200 100 100 100
Fig.7-16: Maximum segment length with regard to the transmission rate
Two LEDS are located above the PROFIBUS interface that display the interface state:
LED designation
Stat.
Bus
Color
Green
Red
State
Lights permanently
Lights acyclically
Lights cyclically
Lights permanently
Flashes
Description
Communication
Not configured
Configured
No connection
Slave diagnostics
Fig.7-17: PROFIBUS state display per LED
7.3.4 SERCOS III (only for Device Variant CML...3N...)
X7E1 and X7E2 SERCOS interface Connect the SERCOS III devices to the optionally available X7E1 and X7E2 connectors.
RJ45, female connector, 8-pin
Type
Cable length
Cable type
Transmission rate
Ethernet 100BaseT
100 m max.
CAT5e with S/STP
10 or 100 MBit/s
40/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Connections and Interfaces
Ethernet RJ45
L
8
1
S
Ethernet
6
7
8
4
5
1
2
3 max. 100 m
Fig.7-18:
LED
L (link)
S (send)
Ethernet interface
Status
On: Link to network is available
Off: No connection to network is available
On: Data packets are sent
Off: No data is sent
7.3.5 Ready Contact
X2R ready contact Pin 1 and pin 2 of the 3-pin male connector strip X2R are the connections of the optionally available ready contact.
NOTICE Insufficient contact, loss of UL certification due to inadequate wire.
Use only copper wire (cross-section AWG 22 to 16; 0.34 mm 2 to 1.5 mm 2 ) for wiring the connection terminals.
The ready contact has a single-channel setup.
Characteristics of the relay (photo-MOS relay)
Switching capacity
UL rating
Dropout time
Bounce time
DC 60 V, 1 A
AC/DC 30 V,1 A, resistive
0.3 ms
None
Watchdog time (analog watchdog only) 50 ms ± 25 %
Fig.7-19: Characteristics of the ready contact
If it is in the release status, the ready contact is open. After powering up the device, the contact is closed. The contact is opened again, if one of the states listed below occurs:
● The DC 24 V supply voltage falls below the permissible limit.
● The internal 5 V and 3.3 V voltages fall below the permissible limit.
● The ready watchdog is elapsing.
● The reset button is actuated.
The LED arranged next to the ready contact is a red-green dual LED. This LED can assume the following states:
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 41/69
Connections and Interfaces
LED "Ready" Meaning
Off
Green
Watchdog has not been started yet or
Ready contact was opened by software (but the watchdog is still trig‐ gered internally)
Ready contact is closed; watchdogs are triggered.
Red Ready error; at least one watchdog has responded.
Fig.7-20: Ready LED
7.3.6 Interface for Compact Flash Card
Compact Flash card The IndraControl L25 features a slot for a Compact Flash card. This slot can be used to insert the memory card containing the firmware (this memory card has to be ordered separately). Additionally, data and programs are stored on this card. Operation without Compact Flash card is not possible.
DANGER Uncontrolled movements caused by operation without Compact Flash card!
Do not remove the Compact Flash card as long as the IndraControl L25 is in operation!
7.4
7.5
Inline Bus
To its right, the IndraControl L25 can be extended by additional Rexroth Inline terminals. The I/O unit can be extended up to 32-byte inputs and 32-byte out‐ puts by these terminals.
Max. 63 Rexroth Inline terminals can be connected.
For further information regarding Rexroth Inline terminals, please refer to the documentation "Automation Terminals Of The Rexroth
Inline Product Range" (parts number R911317021).
Function Module Connector
To its left, the IndraControl L25 is provided with a function module connector that can be used to connect extension modules.
This 120-pin connector is a Bosch Rexroth PC104Plus connector where the
PC104 signals as well as additional system-specific signals are applied. In other words, only the function modules especially developed for the IndraCon‐ trol L25 can be connected to this connector.
Max. two function modules can be connected. The both function modules must not exceed the following limit values in total:
● Current consumption from 5 V: Max. total current 1 A
● Current consumption from 3.3 V: Max. total current 2 A
● Total power consumption: Max. total of the total power consumption 10 W
For further information, please refer to the documentation "Rexroth IndraCon‐ trol L Function Modules" (parts number R911326408).
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Rexroth IndraControl L25
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Rexroth IndraControl L25
Bosch Rexroth AG 43/69
Installation and Maintenance
8 Installation and Maintenance
8.1 Mechanical Installation of IndraControl L25
8.1.1 General Information
Mount the IndraControl L25 to a mounting rail (standard top-hat rail) according to DIN EN 50022 (3.5 mm × 7.5 mm).
Ensure that the top-hat rail is attached such that it provides appro‐ priate rigidity.
In addition to its holding function, this top-hat rail also assumes the function of ground connection and heat removal. For that reason, the top-hat rail must be connected to a functional earth ground.
Furthermore, the top-hat rail is provided as heat sink in connection with the metal bottom frame of the IndraControl L25.
Ensure a well heat-dissipating connection to the rear panel of the control cabinet.
Install the IndraControl L25 horizontally in a control cabinet or in an appropriate housing.
If the ambient conditions are sufficient, the IndraControl L25 can be directly installed on the plant (see also
chapter 4.3 "Ambient Conditions" on page
CAUTION Do not mount controls, modules, inline termi‐ nals and connectors while the unit is provided with voltage!
Before mounting or dismounting components of the station, de-energize the entire station.
Connect the voltage only after the entire station has been set up. Any nonobservance of this requirement may damage the components.
8.1.2 Mounting the IndraControl L25
Mounting the IndraControl L25 on the top-hat rail
Adding Rexroth Inline terminals in series
End plate
Mounting function modules
Mount the IndraControl L25 by hanging it onto the top-hat rail from above and then exerting slight pressure to engage the control in the lower section of the housing.
If necessary, mount Rexroth Inline terminals in series. For further information, please refer to
chapter 8.2 "Mechanical Installation of Rexroth Inline Termi‐ nals" on page 45 .
The end plate has to form the mechanical termination to the right of the station, irrespective of whether Rexroth Inline terminals have been mounted in series or not. The end plate does not have any electrical function. The end plate pro‐ tects the station from ESD pulses and the user from dangerous contact voltag‐ es. The end plate is included in the scope of delivery of the IndraControl L25.
Therefore it is not necessary to order the end plate separately.
Thereafter, place the function modules onto the top-hat rail to the left of the
IndraControl L25, if necessary. Slide the function modules along the top-hat rail all the way to the left side of the IndraControl L25, until a secure connection via the PCI PLUS bus is established.
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Installation and Maintenance
Fixing the end clamp / CLIPFIX Finally, attach end clamps to both sides of the Rexroth Inline station. These end clamps ensure that the station is securely mounted to the top-hat rail and are also provided as lateral termination elements. These end clamps are included in the scope of delivery of the IndraControl L25.
8.1.3 Dismounting the IndraControl L25
Disconnecting additional modules from the IndraControl L25
Removing the first Rexroth Inline terminal
To dismount the IndraControl L25, first disconnect the function modules moun‐ ted to the left of the IndraControl L25 from the latter. First remove the left-hand end clamp (CLIPFIX) and slide the function modules along the top-hat rail to the left until the plug connection of the PCI PLUS bus is severed.
Thereafter, remove the first Rexroth Inline terminal that is mounted to the right of the IndraControl L25. Proceed as follows:
● Remove the labeling field, if present.
If any of the terminal is provided with more than one connector, all these connectors have to be removed from the terminal.
● Pry out the connector of the terminal to be removed by pressing on the rear connector shaft latch.
● Remove the connector(s).
● Remove the power connector from the IndraControl L25. This ensures that the feathers of the voltage jumpers and of the keyway/feather key con‐ nection are prevented from damage. Moreover, the terminal can be ac‐ cessed more easily.
● Actuate the release mechanism (see ① in the following figure) and remove the terminal perpendiculary to the top-hat rail (see ② in the following fig‐ ure).
Removing the IndraControl L25 from the top-hat rail
Fig.8-1: The first Rexroth Inline terminal has to be removed before dismounting the IndraControl L25.
Now the IndraControl L25 can be removed from the top-hat rail by loosening the fixing claw on the bottom side by means of a tool (screwdriver) and pulling
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 45/69
Installation and Maintenance the IndraControl L25 off the top-hat rail from below, tilting it and removing it upwards.
8.2 Mechanical Installation of Rexroth Inline Terminals
8.2.1 General Information
Top-hat rail
Rexroth Inline terminals can be added in series to the right of the IndraCon‐ trol L25 as appropriate. No tool is required. On connecting these modules in series, the potential and bus signal connection (voltage routing and data rout‐ ing) between the individual components of the station is established automati‐ cally.
The terminals are mounted perpendicularly to the top-hat rail.
Once the station has been set up, individual terminals can be replaced subse‐ quently by being pulled out or plugged in without any additional tools.
The Rexroth Inline terminals are mounted to the right of the IndraControl L25 on the 35 mm standard top-hat rail.
8.2.2 Mounting the Inline Terminals
Proceed as follows to latch on a terminal (see fig. 8-2 "Latching a terminal" on page 46
):
● First latch on the terminal that is required to set up the station, perpen‐ dicularly to the top-hat rail (see figure A).
Ensure that all feather keys and keyways of neighboring terminals are interlocked (figure B).
The keyway/feather key connection connects neighboring modules to each other. In this way the voltage routing is set up securely.
● Then fit the connectors onto the respective terminal.
First fit the front connector shaft latch in the front release mechanism (figure
C).
Then press the connector towards the terminal until it clicks into place in the rear release mechanism (figure D).
The keyways provided in the terminal are not continued in the con‐ nector. A terminal can only be latched on, if there is no connector to the left of it. If necessary, the connector has to be removed.
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Installation and Maintenance
A B
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Rexroth IndraControl L25
C D
Fig.8-2: Latching a terminal
8.2.3 Demounting the Inline Terminals
Proceed as follows to remove a terminal (see fig. 8-3 "Removing a terminal" on page 47
):
● Remove the labeling field, if present (A1 in figure A).
If any of the terminal is provided with more than one connector, all these connectors have to be removed. The following sections de‐ scribe how to remove a 2-slot terminal.
Pry out the connector of the terminal to be removed by pressing on the rear connector shaft latch (A2 in figure A).
● Remove the connector (figure B).
● Remove the adjacent connectors of the neighboring terminals (figure C).
This ensures that the feathers of the voltage jumpers and of the keyway/ feather key connection are prevented from damage. Moreover, the termi‐ nal can be accessed more easily.
● Actuate the release mechanism (D1 in figure D) and remove the terminal perpendicularly to the top-hat rail (D2 in figure D). If you have failed to loosen the connector of the neighboring terminal to the left, this connector now comes loose to protect the feathers of the voltage routing and the keyway/feather key connection.
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Bosch Rexroth AG 47/69
Installation and Maintenance
Changing a terminal
Fig.8-3: Removing a terminal
If you want to replace a terminal within the Rexroth Inline station, proceed as described above to remove it. Do not latch on the adjacent connector of the neighboring terminal to the left yet.
Fit the new terminal. Subsequently, refit all connectors.
8.2.4 Fuse Replacement
f segment terminals with fuse are used, the connected voltage and the state of the fuse are monitored and indicated by diagnostic displays.
A missing fuse has to be installed; a defective fuse has to be re‐ placed.
When replacing the fuse, please observe the following instructions on the safety of your health and the protection of your station!
1. Always use the screwdriver with care to prevent yourself and any other person from being injured
2. Pry out the fuse at the metal contact. Do not pry the fuse out at the glass body to prevent the latter from being broken.
3. Pry out the fuse carefully on one side and then remove it by hand. Take care not to drop the fuse into your station.
Proceed as follows to replace the fuse. Also see the illustrations in
"Fuse replacement" on page 48 :
● Swing up the fuse lever (A)
● Put a screwdriver behind a metal contact of the fuse (B)
● Carefully pry out the metal contact of the fuse (C)
● Remove the fuse by hand (D)
● Latch in the new fuse (E)
● Press the fuse lever down again until it clicks into place (F)
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Installation and Maintenance
A
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Rexroth IndraControl L25
B
C D
E F
Fig.8-4: Fuse replacement
8.3 Electrical Installation
8.3.1 General Information
The following rules for setting up a system, in which the electrical equipment like control systems are used, must be adhered to:
● DIN VDE 0100
● DIN EN 60 204-1
● DIN EN 50 178
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Bosch Rexroth AG 49/69
Installation and Maintenance
DANGER Danger of personal injury and material dam‐ age!
Any dangerous states of the system which might cause personal injury or ma‐ terial damage must be prevented!
The rules and regulations for setting up EMERGENCY STOP equipment ac‐ cording to EN 60 204-1 must be adhered to!
Any automatic restart of machines after power return, e. g. after an EMER‐
GENCY STOP, must be excluded!
Protection for direct and indirect contact must be ensured by the measures prescribed (connection to protective conductor, isolation, etc.).
8.3.2 External Power Supply Unit
All components of the IndraControl L25 are supplied with 24 V voltage supplies.
The power supply unit must be safety-separated according to DIN EN 50 178, section 5.2.18.1. Transformers must be designed with safety separation ac‐ cording to DIN EN 60 742.
If these requirements are complied with, the 24 V supply voltage is rated as safety-separated extra-low voltage according to DIN EN 50 178, section
5.2.8.1. This voltage is designed either as safety extra-low voltage (SELV) without ground connection of the reference conductor or as protective extralow voltage (PELV) with ground connection of the reference conductor.
A three-phase power supply unit with simple full-bridge rectification is sufficient.
The ripple voltage content must not exceed 5 %.
All 24 V voltage supply lines have to
● be laid such that they are isolated from lines carrying higher voltages, or
● be insulated to a particularly high degree, with the insulation having to be designed for the highest voltage present (see EN 60 204-1: 1997, section
14.1.3).
Any peripherals, e.g. digital sensors or actuators, which are connected to the interfaces of the IndraControl L25, have to comply also with the criteria of safe‐ ty-separated circuits.
8.3.3 24 V Voltage Supply
Setup without Electrical Isolation
The most easiest connection method is the establishment without an electrical isolation between the internal logic and the peripheral supply.
In this case, a power supply unit is appropriate to supply the IndraCon‐ trol L25. It is not permitted to use an autotransformer to ensure compliance with overvoltage category II.
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Rexroth IndraControl L25
Installation and Maintenance
L1
L2
L3
N
PE
Overvoltage category III
400 V
Power supply unit1
Overvoltage category II
24V
S1
Reset Stop
L
S X7E3
Ready
Dist.
X2R
X7E1
L
S
L
S
X7E2
1.1 2.1
1.2 2.2
1.3 2.3
1.4 2.4
FE
U
LS
GND
U
S
U
M
GND (U S , U )
Fig.8-5:
Setup with Electrical Isolation
Setup without electrical isolation
According to DIN EN 60204–1, electrical isolation should be provided between the logic of the central processing unit and the I/O interfaces of the peripheral devices. Accordingly, the voltage U
LS from the voltages U
S
IndraControl L25.
(24 logic voltage) is electrically isolated
(24 V segment voltage) and U
M
(24 V main voltage) in the
The following figure shows an example of a setup with electrical isolation:
L1
L2
L3
N
PE
Overvoltage category III, 400 V
Transformer
L
S
X7E1 Power supply unit 1
Overvoltage category II, 24 V
Power supply unit 3
230 V voltage for programming device, etc.
+
S1
Reset
Overvoltage category III 400 V
Stop
L
S
X7E3
Ready
Dist.
X2R
X7E2
L
S
1.1 2.1
1.2 2.2
1.3 2.3
1.4 2.4
Overvoltage category I, 24 V
2 2
U
LS GND
U S
U M
FE
GND (U S , U )
Fig.8-6: Setup with electrical isolation
Reference Conductor Connected to the Protective Conductor
If the reference conductor (N, 0 V) is connected to the protective conductor system, then this connection must be arranged at a central point (e. g. at the load power supply unit or at the isolating transformer). In addition, it must be
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Bosch Rexroth AG 51/69
Installation and Maintenance possible to break this connection for measuring ground leakage currents.
Hence, the supply current circuit is a PELV circuit.
L1
L2
L3
N
PE
0 V
24 V
+ 0 V
24 V
+
S1
Reset Stop
L
S
X7E3
Ready
Dist.
X2R
Disconnectable connections
X7E1
L
S
L
S
X7E2
U LS
1.1 2.1
1.2 2.2
1.3 2.3
1.4 2.4
GND
U S
U M
FE
GND (U
S , U )
Fig.8-7: Reference conductor connected to the protective conductor
Reference Conductor not Connected to the Protective Conductor
If the reference conductor (N, 0 V) is not connected to the protective conductor system, then an appropriate ground fault detector is to be used to prevent in‐ advertent power-up in case of insulation faults. Hence, the supply current circuit is a SELV circuit. Please note that any additionally connected equipment might also cancel the floating setup.
L1
L2
L3
N
PE
Fig.8-8:
E1
E2
0 V
24 V
+ 0 V
24 V
+
S1
Reset Stop
L
S
X7E3
Ready
Dist.
X2R
X7E1
L
S
L
S
X7E2
U LS
1.1 2.1
1.2 2.2
1.3 2.3
1.4 2.4
GND
U
S
U M
FE
GND (U
S , U )
Reference conductor not connected to the protective conductor
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Rexroth IndraControl L25
Installation and Maintenance
Programming Device and Grounding
Programming devices are almost always provided with a connection between the ground and the functional earth ground. This connection might cause prob‐ lems, if the voltage supply of the IndraControl L25 is provided with a ground fault detector and the programming device is connected to the IndraCon‐ trol L25. Owing to the non-isolated power supply unit device, the ground fault in the programming device effects the ground fault detector via the central pro‐ cessing unit and the power supply unit device. In this case, the detector should not deactivate the system automatically, but only indicate the ground fault.
Maintenance staff should be aware of this fact.
Dimensioning the Voltage Supply
When dimensioning the voltage supply, the maximum currents have to be ob‐ served, see DIN VDE 0100-523. A voltage between 20.4 V to 28.8 V must be applied directly to the device.
The voltage also must be maintained if:
● There are variations in the line voltage, e.g. caused by different loads of the power supply network.
● Different load states, e.g. short-circuit, normal load, lamp load, or no load.
The maximum line cross-section for the voltage supply is 1.5 mm 2 .
8.3.4 Main Switches and Fuses
Main Switches
A main switch according to DIN VDE 0100 must be provided for the IndraCon‐ trol L25 as well as for sensors and actuators.
Fuses
Fuses and circuit-breakers protect the supply lines in a network. The lines of the voltage supply of the IndraControl L25 must be protected. The sensor sup‐ ply and the actuator supply should each be protected by a separate fuse. If the supply lines are shorter than 3 m and are placed such that they are protected from ground faults and short-circuits, it is not necessary to provide fuses.
Further criteria for selecting protective devices are:
● Nominal voltage
● Temperature
● Internal resistances of the fuses
● Inrush currents
● Cable lengths
● External impedance of the power supply system
● Possible fault location
● Vibration
For further information, please refer to Manual No. 32, VDE publications, Di‐ mensioning and protecting lines and cables according to DIN 57 100,
VDE 0100–430 and –523.
Appropriate information is also provided by many manufacturers of fuses and circuit-breakers.
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Installation and Maintenance
8.3.5 Grounding
Functional earth ground
Voltage jumper
Potential equalization
8.3.6 Shield System
General Information
An optimum grounding is required to keep away possible interferences from the
IndraControl L25 and the Rexroth Inline modules and to discharge them to the ground.
The top-hat rail, which is used for mounting the IndraControl L25, must be mounted to a grounded metal carrier, e. g. the rear panel of the control cabinet.
A functional earth ground is required to ensure optimum noise immunity. The functional earth ground has to be connected via a cable, which is as short as possible or preferably via a ground strap.
Recommended value:
Length: 1 m max.
Cross-section: 6 mm 2
The IndraControl L25 as well as the power and segment terminals are provided with FE springs (metal clips) at their bottom side, which establish an electric connection to the top-hat rail. To ensure a reliable ground connection even in case of dirt or a damaged metal clip, the IndraControl L25 must be additionally grounded via the FE terminal point, using a conductor with a cross-section of at least 1.5 mm 2 .
The FE functional earth ground is used to discharge disturbances. It is not pro‐ vided as a protection against electric shock for persons.
Starting at the IndraControl L25, the FE (functional earth ground) voltage jump‐ er is routed through all connected Rexroth Inline modules. This ensures that these modules are grounded once the ground connection of the IndraCon‐ trol L25, the supply terminals and the top-hat rail has been properly established.
Potential equalization according to DIN VDE 0100 Part 540 must be provided between the system parts and the voltage supply.
All components of the system have to be connected to the PE protective con‐ ductor system at the connectors that are marked accordingly.
The shielding is intended to reduce any effects of interferences on the system.
The PROFIBUS line and the connection lines to modules for analog signals must be shielded.
Observe the following when shielding:
● Fit the shield over an area as large as possible under the clip in the shield connector.
● Ensure proper contact between the connector and the module.
● Avoid damaging or squeezing cores. Avoid stripping the lines too much.
● Connect the cores properly.
Shielding the PROFIBUS Cable
For noise immune transmission, Bosch Rexroth recommends a two-core twis‐ ted and shielded line pair, as specified as cable type A in EN 50 170, part 8-2.
Cable type B, which is also described in the above mentioned specification, is obsolete and must not be used any longer.
The cable parameters are described in section
(only for Device Variant CML...PN...)" on page 38
.
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Installation and Maintenance
The line shield must be applied in the bus connector. In case of installation in the control cabinet, the line shield of the connected PROFIBUS line must be connected to a shield bus using cable clips, if possible directly behind the cable bushing. Use an appropriate shield terminal.
8.3.7 Connecting Lines to Tension Spring Connection Points
General Information
Shielded/unshielded lines
AWG
Connecting Unshielded Lines
Connect the lines for peripheral equipment and voltage supply to the tension spring connection points.
Unshielded lines are used for the digital inputs and outputs as well as for the voltage supply. Shielded lines are connected to analog inputs and outputs.
Lines with an average wire gauge of 0.2 mm 2 to 1.5 mm 2 (AWG 24 – 16) can be connected. These lines can conduct signals up to 250 V AC/DC and 5 A.
8.4
Fig.8-9: Connecting lines to tension spring connectors
Wire the connectors as required according to the application.
Proceed as follows to wire the connectors:
● Strip the line to a length of 8 mm. Wiring is provided without core end sleeves. However, core end sleeves may be used, if desired. In this case, do ensure that the core end sleeves are properly crimped.
● Put a screwdriver into the actuation slot of the corresponding terminal point
(figure
, B). Pull the screwdriver out of the open‐ ing. This fixes the core. We recommend you to label the cores and terminal points after the installation.
Maintenance
Regular maintenance Include the following measures in the maintenance schedule:
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Bosch Rexroth AG 55/69
LC display
Installation and Maintenance
● At least once a year, check all plug and terminal connections of the com‐ ponents regarding proper tightness and possible damage. Verify that lines and cables are not broken or squeezed. Replace damaged parts imme‐ diately.
A fading readability of the display may cause that the display has to be ex‐ changed. For further information please contact the Bosch Rexroth Service.
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Environmental Protection and Disposal
9 Environmental Protection and Disposal
9.1 Environmental Protection
Production Processes
No Release of Hazardous Substan‐ ces
Significant Components
The products are made with energy- and resource-optimized production pro‐ cesses which allow re-using and recycling the resulting waste. We regularly try to replace pollutant-loaded raw materials and supplies by more environmentfriendly alternatives.
Our products do not contain any hazardous substances which may be released in the case of appropriate use. Normally, our products will not have any negativ influences on the environment.
Basically, our products contain the following components:
Electronic devices
∙ steel
∙ aluminum
∙ copper
∙ synthetic materials
∙ electronic components and modules
Motors
∙ steel
∙ aluminum
∙ copper
∙ brass
∙ magnetic materials
∙ electronic components and modules
9.2 Disposal
Return of Products
Packaging
Batteries and Accumulators
Our products can be returned to our premises free of charge for disposal. It is a precondition, however, that the products are free of oil, grease or other dirt.
Furthermore, the products returned for disposal must not contain any undue foreign material or foreign components.
Send the products ”free domicile” to the following address:
Bosch Rexroth AG
Electric Drives and Controls
Buergermeister-Dr.-Nebel-Strasse 2
97816 Lohr am Main, Germany
The packaging materials consist of cardboard, wood and polystyrene. These materials can be recycled anywhere without any problem.
For ecological reasons, please refrain from returning the empty packages to us.
Batteries and accumulators can be labeled with this symbol.
Recycling
The symbol indicating "separate collection" for all batteries and accu‐ mulators is the crossed-out wheeled bin.
The end user within the EU is legally obligated to return used batteries. Outside the validity of the EU Directive 2006/66/EC keep the stipulated directives.
Used batteries can contain hazardous substances, which can harm the envi‐ ronment or the people´s health when they are improper stored or disposed of.
After use, the batteries or accumulators contained in Rexroth products have to be properly disposed of according to the country-specific collection.
Most of the products can be recycled due to their high content of metal. In order to recycle the metal in the best possible way, the products must be disassem‐ bled into individual modules.
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Environmental Protection and Disposal
Metals contained in electric and electronic modules can also be recycled by means of special separation processes.
Products made of plastics can contain flame retardants. These plastic parts are labeled according to EN ISO 1043. They have to be recycled separately or disposed of according to the valid legal requirements.
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Ordering Information
10 Ordering Information
10.1 Type Designation Code
10.1.1 General Information
The IndraControl L25 is available in various versions according to the following type codes.
10.1.2 IndraControl L25
Abbrev.
column 1 2 3 4 5 6 7 8 9
1
0 1 2 3 4 5 6 7 8 9
2
0 1 2 3 4 5
Example: C M L 2 5 . 1 - 3 N - 4 0 0 - N N - N N N N - N W
6 7
Product
Main unit . . . . = CM
Housing design
Inline. . . . . . . . . . . . = L
Line
SH4 . . . . . . . . . . . . . . = 25
Design
1 . . . . . . . . . . . . . . . . . . . . . . = 1
Communication interface
Interface 1 Abbr. column
9
Interface 2 Abbr.
column
10
Not equipped N Not equipped N
SERCOS III 3
P
-
-
-
-
System configuration
DRAM (MB)
128
Abbr.
column
12
4
NvRAM (kB)
Without
Abbr.
column
13
SRAM (MB)
Abbr.
column
14
0 Without 0
Fan
Without . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = N
Digital inputs / outputs
Without . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . = N
Additional design
None. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN
With connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNC1
Firmware
Without firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NW
Fig.10-1: Type designation code L25
60/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Ordering Information
10.2 Accessories
10.2.1 Spare Part (Power Connector)
General Information
The connector for connecting the operating voltage is included in the scope of delivery. As spare part the following connector is available:
Order code
R-IB IL SCN-PWR IN
PWR 7261
Parts number Description
R911171765 Connector for connecting the operating voltage
10.2.2 Further Accessories (Rexroth Inline Terminals, Function Modules and
Interface Cables)
Rexroth Inline Terminals
The current Rexroth Inline terminals are listed in the Bosch Rexroth product catalog on the Internet http://www.boschrexroth.com/dcc/Vornavigation/Vor‐
Navi.cfm?PageID=g97568&Language=en
Rexroth Function Modules
Order code
CFL01.1-E2
CFL01.1-N1
CFL01.1-R3
CFL01.1-Q2
CFL01.1-TP
CFL01.1-G1
CFL01.1-Y1
Fig.10-2:
Parts number Description
R911170365 Fast I/O
R911170012
R911170008
R911170009
R911170832
R911171044
R911170007
Programmable limit switch
SERCOS III
SERCOS 2 / cross-communication
PROFIBUS DP + RT-Ethernet
EnDat interface (in preparation)
SRAM
Function modules
The function module support depends on the firmware used! Please refer to the relevant documentation!
EMI shielding If the "programmable limit switch" function module (CFL01.1-N1 R911170012) is used in noisy environment, this EMI shielding is to be mounted. This recom‐ mendation applies to programmable limit switch modules that are plugged in the 3rd or 4th slot at the left side of the function module bus.
Order code
CAL04.1-SH
Fig.10-3:
Parts number Description
R911172216 EMI shielding
EMI shielding
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 61/69
Ordering Information
Interface Cables
Ethernet interface
PROFIBUS DP
Order code
RKB0007/00,15
RKB0007/002,5
RKB0007/005,0
RKB0007/010,0
RKB0007/025,0
RKB0008/002,5
RKB0008/005,0
RKB0008/010,0
RKB0008/025,0
Parts number Description
R911170146
R911170147
R911170148
R911170149
R911170150
R911170151
R911170152
R911170153
R911170154
Ethernet cable, 100Base-TX, CAT.5, cross‐ link, ready-made, with RJ45 connector on both sides, 0.15 m
Ethernet cable, 100Base-TX, CAT.5, cross‐ link, ready-made, with RJ45 connector on both sides, 2.5 m
Ethernet cable, 100Base-TX, CAT.5, cross‐ link, ready-made, with RJ45 connector on both sides, 5.0 m
Ethernet cable, 100Base-TX, CAT.5, cross‐ link, ready-made, with RJ45 connector on both sides, 10.0 m
Ethernet cable, 100Base-TX, CAT.5, cross‐ link, ready-made, with RJ45 connector on both sides, 25.0 m
Ethernet cable, 100Base-TX, CAT.5, readymade, with RJ45 connector on both sides, 2.5
m
Ethernet cable, 100Base-TX, CAT.5, readymade, with RJ45 connector on both sides, 5.0
m
Ethernet cable, 100Base-TX, CAT.5, readymade, with RJ45 connector on both sides, 10.0
m
Ethernet cable, 100Base-TX, CAT.5, readymade, with RJ45 connector on both sides, 25.0
m
Fig.10-4:
Order code
REB0001
REB0002
REB0003
RBS0010/K02
RBS0011/K02
RBS0012/K02
RBS0013/F03
Interface cables - Ethernet interface
Parts number
R911170134
R911170136
R911170135
R911170137
R911170138
R911170139
R911170140
Description
PROFIBUS cable, Fast Connect, standard
PROFIBUS cable, Fast Connect, cable carrier, tensile force 100 N
PROFIBUS cable, cable carrier, tensile force 20 N
PROFIBUS connector 12 Mbaud
PROFIBUS connector 12 Mbaud, with PG female connector
PROFIBUS connector 12 Mbaud, 180° an‐ gular
PROFIBUS connector 12 Mbaud, 90° an‐ gular, Fast Connect
62/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Ordering Information
SERCOS III Ethernet
Order code
RBS0014/F03
RBS0015/F03
Parts number
R911170141
R911170142
Fig.10-5: Interface cables – PROFIBUS DP
Order code Parts num‐ ber
Description
R911171947 Bus cable, 1.0 m
RKB0008/00
2,5
RKB0008/00
5,0
RKB0008/01
0,0
RKB0008/01
5,0
RKB0008/02
0,0
RKB0008/02
5,0
RKB0008/03
0,0
RKB0008/03
5,0
RKB0008/04
0,0
RKB0007/00
1,0
RKB0007/00
2,5
RKB0007/00
5,0
RKB0007/01
0,0
RKB0007/02
5,0
RKB0007/03
0,0
RKB0007/03
5,0
RKB0008/00
0,5
RKB0008/00
1,0
R911170147 Bus cable, 2.5 m
R911170148 Bus cable, 5.0 m
R911170149 Bus cable, 10.0 m
R911170150 Bus cable, 25.0 m
R911171471 Bus cable, 30.0 m
R911171243 Bus cable, 35.0 m
R911171484 Bus cable, 0.5 m
R911171485 Bus cable, 1.0 m
R911170151 Bus cable, 2.5 m
R911170152 Bus cable, 5.0 m
R911170153 Bus cable, 10.0 m
R911171183 Bus cable, 15.0 m
R911171184 Bus cable, 20.0 m
R911170154 Bus cable, 25.0 m
R911171381 Bus cable, 30.0 m
R911171369 Bus cable, 35.0 m
R911171382 Bus cable, 40.0 m
Description
PROFIBUS connector 12 Mbaud, 90°an‐ gular, Fast Connect, with PG female con‐ nector
PROFIBUS connector 12 Mbaud, 180° an‐ gular, Fast Connect
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Bosch Rexroth AG 63/69
Ordering Information
Cap for CF slot
Tools for PROFIBUS cable
Order code Parts num‐ ber
RKB0008/05
0,0
Description
R911171383 Bus cable, 50.0 m
R911316888 Bus cable, variable length RKB0011/ xxx,x (var.)
RKB0011/00
5,0
RKB0013/00,
19
RKB0013/00,
25
R911321548 Bus cable, 5.0 m
R911329741 Bus cable, 19.0 m
R911317797 Bus cable, 25.0 m
RKB0013/00,
35
RKB0013/00,
55
RBS0016
R911317800 Bus cable, 35.0 m
R911317801 Bus cable, 55.00 m
R911315797 RJ45 Ethernet connector for self-assembly, angular, IP
20
Fig.10-6:
Order code
CAL02.1-S1
Interface cables – SERCOS III Ethernet
Parts number
R911171617
Description
Cap for CF slot
Fig.10-7: Cap for CF slot
Order code
WERKZ-ABISOLI‐
ERER-FC-KABEL
WERKZ-ABISOLI‐
ERER-FC-KABEL-
ERSATZMESSER
Parts number
R911170143
R911170144
Fig.10-8: Tools for PROFIBUS cables
Description
Stripping tool for PROFIBUS Fast Con‐ nect cable
Spare knife for stripping tool (packaging seize: 5 pieces)
64/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
11
Bosch Rexroth AG 65/69
Service and Support
Service and Support
Our service helpdesk at our headquarters in Lohr, Germany and our worldwide service will assist you with all kinds of enquiries. You can reach us around the clock - even on weekend and on holidays.
Preparing Information
Phone
Fax
Internet
Helpdesk
+49 (0) 9352 40 50 60
+49 (0) 9352 40 49 41 service.svc@boschrex‐ roth.de
Service Hotline
Worldwide
Outwith Germany please con‐ tact our sales/service office in your area first.
For hotline numbers refer to the sales office addresses on the Internet.
http://www.boschrexroth.com
You will also find additional notes regarding service, mainte‐ nance (e.g. delivery addresses) and training.
For quick and efficient help please have the following information ready:
● Detailed description of the fault and the circumstances
● Information on the type plate of the affected products, especially type co‐ des and serial numbers
● Your phone, fax numbers and e-mail address so we can contact you in case of questions.
66/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Index
A
Accessories......................................................... 60
Accumulators...................................................... 57
Ambient conditions
Ambient conditions ....................................... 22
ANA
)........................................... 36
Analog supply (U
Appropriate use
Introduction .................................................... 7
Use ................................................................. 7
B
Batteries.............................................................. 57
C
Cap for CF slot.................................................... 63
Compact Flash card............................................ 41
Compatibility test................................................. 23
Connections........................................................ 29
Overview ...................................................... 29
Voltage supply .............................................. 31
Contained substances
see "Significant components" ....................... 57
CSA certified....................................................... 23
D
Device variants..................................................... 5
Dimensioning the voltage supply........................ 52
Dimensions......................................................... 25
Bottom view .................................................. 25
Front view ..................................................... 25
Side view ...................................................... 26
Dismounting........................................................ 44
Display................................................................ 27
Display and operating components..................... 27
Disposal.............................................................. 57
Documentation...................................................... 6
Drive system......................................................... 9
E
Electrical Installation........................................... 48
Electrical isolation......................................... 49, 50
Electric drive system............................................. 9
EMI shielding...................................................... 60
Environmental protection.................................... 57
Ethernet interface.......................................... 36, 61
Ethernet X7E3, X7E4.......................................... 37
F
Front view........................................................... 25
Functional earth ground...................................... 53
Function module connector................................. 41
Function modules................................................ 60
Bosch Rexroth AG 67/69
Index
F
Fuse.................................................................... 52
Fuse replacement............................................... 47
G
Generation U
Generation U
M
S
..................................................... 34
..................................................... 35
Grounding........................................................... 52
Grounding
............................................................................ 53
H
Hazardous substances....................................... 57
Housing dimensions............................................ 25
I
Inappropriate use.................................................. 8
Consequences, exclusion of liability .............. 7
Inline bus............................................................. 41
Inline supply and analog circuit........................... 36
Inline terminals
Demounting .................................................. 46
Fuse replacement ........................................ 47
Mounting ...................................................... 45
Removing a terminal .................................... 47
Installation........................................................... 43
Electric ......................................................... 48
Installation, mechanical....................................... 43
Installation notes................................................. 26
Installing Inline terminals..................................... 45
Instructions on use................................................ 7
Interface cables................................................... 61
Interfaces...................................................... 29, 36
Ethernet X7E3, X7E4 ................................... 37
Overview ...................................................... 29
PROFIBUS ................................................... 38
SERCOS III .................................................. 39
Internally generated voltages.............................. 36
K
Keys.................................................................... 27
L
LC display........................................................... 55
Logic circuit......................................................... 36
M
Main circuit.......................................................... 34
Main switches..................................................... 52
Maintenance................................................. 43, 54
Mechanical installation........................................ 43
Memory card....................................................... 41
68/69 Bosch Rexroth AG
Index
M
Minimum distances............................................. 26
Mounting............................................................. 43
O
Operating components........................................ 27
Operating keys.................................................... 27
Ordering information........................................... 59
P
Packaging........................................................... 57
PELV................................................................... 14
Potential equalization.......................................... 53
Power connector................................................. 60
Power supply unit................................................ 49
Production processes......................................... 57
PROFIBUS cable
Shielding ...................................................... 53
PROFIBUS DP.................................................... 61
PROFIBUS DP connection................................. 38
Programming device........................................... 52
Protective conductor........................................... 50
Protective extra-low voltage................................ 14
R
Ready contact..................................................... 40
Recycling............................................................ 57
Reference conductor........................................... 50
Reset Button....................................................... 27
Return of products.............................................. 57
Rexroth Inline terminals...................................... 60
S
Safety instructions for electric drives and con‐
trols....................................................................... 9
Segment circuit................................................... 35
Segment circuit U
S
.............................................. 34
SERCOS III......................................................... 39
SERCOS III Ethernet.......................................... 62
Shielding the PROFIBUS cabIe.......................... 53
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
S
Shield system...................................................... 53
Side view............................................................. 26
Significant components....................................... 57
Spare part (connector)........................................ 60
Standards............................................................ 22
Stop LED............................................................. 27
Support
see Service Hotline ...................................... 65
System presentation............................................. 5
Brief description ............................................. 5
View ............................................................... 5
T
Technical data............................................... 21, 22
Equipment .................................................... 21
Used standards ............................................ 22
Voltage supply .............................................. 21
Tension spring connection point......................... 54
Tools for PROFIBUS cable................................. 63
Type designation code........................................ 59
U
UL and CSA certified.......................................... 23
Unshielded lines.................................................. 54
Used standards................................................... 22
V
View CML...3N... device variant.......................... 30
View CML...PN... device variant......................... 31
Voltage jumper FE.............................................. 53
Voltages, internally.............................................. 36
Voltage supply.............................................. 21, 31
24 V .............................................................. 49
Dimensioning ............................................... 52
Voltage supply U
LS
........................................ 33, 34
W
Wear parts.......................................................... 24
DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Notes
Bosch Rexroth AG 69/69
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Tel. +49 (0)93 52-40-0
Fax +49 (0)93 52-48 85 www.boschrexroth.com/electrics
R911328474
Printed in Germany
DOK-CONTRL-IC*L25*****-PR03-EN-P
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