Bosch Rexroth IndraControl VAU 01.1U, Project Planning Manual

Page 1: ...Project Planning Manual Electric Drives and Controls Pneumatics Service Linear Motion and Assembly Technologies Hydraulics Rexroth IndraControl VAU 01 1U UPS with USB interface R911323872 Edition 03 ...

Page 2: ... parties without its consent Liability The specified data is intended for product description purposes only and shall not be deemed to be a guaranteed characteristic unless expressly stipulated in the contract All rights are reserved with respect to the content of this docu mentation and the availability of the product Published by Bosch Rexroth AG Bgm Dr Nebel Str 2 97816 Lohr am Main Germany Pho...

Page 3: ... Low Voltage as Protection Against Electric Shock 14 3 3 3 Protection Against Dangerous Movements 15 3 3 4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting 16 3 3 5 Protection Against Contact With Hot Parts 16 3 3 6 Protection During Handling and Mounting 17 3 3 7 Battery Safety 17 3 3 8 Protection Against Pressurized Systems 18 3 4 Explanation of Signal Words a...

Page 4: ...Position of Rotary Switch S1 and Settings in the UPS NT Control Software 33 7 Interfaces and Wiring 39 7 1 Task 39 7 2 Connector Panel 39 7 2 1 General Information 39 7 2 2 Overview of the Connections 40 7 3 Voltage Connection 41 7 3 1 General Information 41 7 3 2 Wiring the Power Connection 41 7 3 3 Wiring of the VAU 01 1U Cable Lengths and Cable Cross Sections 44 7 4 Interface XUSB In 44 7 4 1 G...

Page 5: ...ental Protection and Disposal 55 10 1 Environmental Protection 55 10 2 Disposal 55 11 Service and Support 57 Glossary VAU 01 1U 59 Index 61 DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface Bosch Rexroth AG III 63 Table of Contents ...

Page 6: ...Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface IV 63 ...

Page 7: ...on nected device is realized via a USB interface XUSB In The VAU 01 1U consists of the following components Enclosed metal housing A battery integrated in the device Display and operating components on the front panel Integrated burst and surge protection for the connected device Fig 1 1 View VAU 01 1U with USB interface This documentation describes only the uninterruptible power sup ply UPS VAU01...

Page 8: ...urther Documentation Documentation Order code of the documenta tion Parts number Rexroth IndraControl VPB 40 3 DOK SUPPL VPB 40 3 PRxx EN P R911323876 Rexroth IndraControl VPP 16 3 40 3 60 3 DOK SUPPL VPP XX 3 PRxx EN P R911323511 Rexroth IndraControl VSB 40 3 DOK SUPPL VSB 40 3 PRxx EN P R911323880 Rexroth IndraControl VSP 16 3 40 3 DOK SUPPL VSP XX 3 PRxx EN P R911323882 Fig 1 2 Further document...

Page 9: ...nstructions and be familiar with the intended use of the products If the product takes the form of hardware then they must remain in the original state in other words no structural changes are permitted The decompilation of software products or the alteration of source codes is not permitted Do not install or operate damaged or faulty products Ensure that the products have been installed in the ma...

Page 10: ...fications is considered as uninten ded The UPS must not be used if it is exposed to operation conditions which do not correspond to the specified ambient conditions Operation under water extreme tempera ture fluctuations or extreme maximum temperatures is prohibited the intended applications have not expressly been allowed by Bosch Rexroth Please read the information given in the general safety in...

Page 11: ...nd ca bles Installation An installation consists of several devices or systems interconnected for a defined purpose and on a defined site which however are not intended to be placed on the market as a single functional unit Machine A machine is the entirety of interconnected parts or units at least one of which is movable Thus a machine consists of the appropriate machine drive elements as well as...

Page 12: ...k or even death 3 2 2 Requirements for Safe Use Read the following instructions before initial commissioning of the compo nents 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 maintena...

Page 13: ...pective application docu mentation 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 E...

Page 14: ...ng shearing cutting hitting Risk of injury by improper handling of batteries Risk of injury by improper handling of pressurized lines Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface 12 63 Safety Instructions for Electric Drives and Controls ...

Page 15: ...onnect electric components from the mains or from the power supply unit Secure the electric component from reconnec tion 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 equip...

Page 16: ... 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 ...

Page 17: ...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 possible if safety devices are disabled bypassed or not activate...

Page 18: ...tic 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 conduc tors 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 hear...

Page 19: ...ounting Risk of injury by improper handling Injury by crushing shearing cutting hit ting 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...

Page 20: ...e equipment safety goggles safety shoes safety gloves for example Immediately clean up any spilled liquids from the floor due to the risk of falling Environmental protection and disposal The agents e g fluids used to operate the product might not be environmentally friendly Dispose of agents harmful to the environment separately from other waste Observe the national regulations of your country 3 4...

Page 21: ...mpliance with this safety instruction minor or moderate in jury could occur NOTICE In case of non compliance with this safety instruction property damage could occur DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface Bosch Rexroth AG 19 63 Safety Instructions for Electric Drives and Controls ...

Page 22: ...Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface 20 63 ...

Page 23: ... charging the battery Reverse voltage protection Yes Fig 4 2 Input voltage 24 V 4 2 2 Output Voltage Nominal output voltage DC 24 V Output voltage range DC 24 V 20 15 Current output at UN 10 A max Switching time 1 ms Bridging time 3 minutes max Max output power 240 W Short circuit protection No Max capacitive load 5600 μF Fig 4 3 Output voltage Overheating and possible damage to the VAU 01 1U if t...

Page 24: ...0 m above sea level acc to EN 61131 2 Mechanical strength Maximum vibration Frequency range 10 Hz to 150 Hz Excursion 0 075 mm at 10 Hz to 57 Hz Acceleration 1 g at 57 Hz to 150 Hz Test duration for each axis 10 fre quency cycles Frequency sweep rate 1 octave min According to EN 60068 2 6 test Fc Maximum shock 15 g according to EN 60 068 2 27 no dis turbance of the func tion Maximum shock 15 g acc...

Page 25: ... 4 VDE 0839 6 4 Electromagnetic compatibility EMC Volume 6 4 Generic standards emitted interfer ence for industrial environments IEC 61000 6 4 2006 September 2007 DIN EN 61000 6 2 VDE 0839 6 2 Electromagnetic compatibility EMC Volume 6 2 Generic standards noise immunity for industrial environments IEC 61000 6 2 2005 March 2006 Fig 4 6 Electromagnetic compatibility EMC standards Note for the Machin...

Page 26: ...ges on the device NOTICE 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 veri fied 4 5 Wear Parts The service life of the battery is approximately ten years at 25 C The serv ice life is halved with each 10 C temperature rise For storing the VAU 01 1U please do observe chapter 8 4 Storing the VAU 01 1U on ...

Page 27: ...etc 5 2 Housing Dimensions The VAU 01 1U has the following dimensions Width 123 mm Height 145 mm Depth without plug 128 mm Fig 5 1 Dimensions of the VAU 01 1U 5 3 Mounting and Dismounting 5 3 1 Mounting Notes The VAU 01 1U is provided for mounting on a mounting rail Fig 5 2 Mounting rail holders on the rear panel of the VAU 01 1U Avoid installation positions that are exposed to direct UV sunlight ...

Page 28: ...mounting holes according to EN 60715 appen dix B Hang the UPS onto the mounting rail from above Then exert slight pressure to engage the UPS in the lower section of the housing Attaching the end clamps Mount end clamps on the mounting rail on both sides of the VAU 01 1U to avoid lateral moving of the UPS if vibrations occur The end clamps are avail able as accessories see chapter 9 2 Accessories o...

Page 29: ...sure that the PC is shutdown the VAU 01 1U has been disconnected from the voltage supply the cables of the VAU 01 1U have been removed Unlocking the UPS Unlock the VAU 01 1U from the mounting rail by pulling the release lev er to the bottom side by using a screwdriver see fig 5 4 Position of the release lever of the mounting rail holder on page 27 1 Release lever Fig 5 4 Position of the release le...

Page 30: ...Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface 28 63 ...

Page 31: ...re that fuse F1 is inserted Set the S1 rotary switch and the control time in the UPS NT software before using the UPS 6 2 Connector Panel 6 2 1 General Information In addition to the connection terminals display and operating elements are arranged on the connector panel 1 2 3 4 5 6 7 Voltage connection X1S1 Voltage output X1S2 USB interface XUSB In Fuse F1 Rotary switch S1 LEDs for operating and e...

Page 32: ...ff Normal mode LED is off Connected PC is booting Wait until the boot process of the connected PC is finished Interface cable be tween UPS and PC is not plugged XUSB In or The cable is defective Check the interface cable Connected PC power supply unit has no sup ply voltage or Connected PC power supply has not started yet Check the PC cable connec ted to X1S2 UPS software has not started or UPS so...

Page 33: ...s independently triggered by the UPS soft ware Check if the battery still works Check if the battery is con nected to the circuit board Keep the UPS switched on so that the battery can be loaded max five hours If the LED continues flashing after this time check the battery and if necessary replace the bat tery LED is off Normal mode Fig 6 2 Description of the LEDs 6 3 Fuse F1 The FKS fuse 20 A 32 ...

Page 34: ...ceonds is triggered which is integrated in the VAU 01 1U This time delay prevents that UPS operation is signaled to the connected PC and initiated during the first 120 seconds after switching on if the input voltage is switched off within these 120 seconds Nevertheless the output voltage of the VAU 01 1U is buffered by the integrated battery and thus remains available for the connected PC After th...

Page 35: ...s set to 2 UPS operation is 120 seconds with a time de lay of 120 seconds Switch position 3 If the rotary switch is set to 3 UPS operation is 180 seconds with a time de lay of 120 seconds Switch position 4 If the rotary switch is set to 4 UPS operation is 5 seconds without time delay Switch position 5 If the rotary switch is set to 5 UPS operation is 60 seconds without time de lay Switch position ...

Page 36: ...pera tion Signal to the connected PC that the UPS is in the buffer mode and that the supply voltage 24V Out switches off after a set time 24V Out Output voltage DC 24 V of the UPS to supply the connected PC Fig 6 7 Timing If the input voltage on the UPS drops after the time delay of 120 seconds has expired the output voltage is buffered via the battery and UPS operation is signaled to the connecte...

Page 37: ... signaled to the connected PC After the UPS time t has expired the output voltage on the VAU 01 1U is switched off Switch position S1 UPS time t 4 5 seconds 5 60 seconds 6 120 seconds 7 180 seconds Fig 6 11 Switch position S1 Activation of the supply voltage during UPS operation UPS operation 24V In 24V Out 120 seconds 5 seconds t 6 seconds 24V In Input voltage DC 24 V on the UPS of the power supp...

Page 38: ... 6 14 Timing Switch position S1 UPS time t 0 5 seconds 1 60 seconds 2 120 seconds 3 180 seconds Fig 6 15 Switching on switching off and switching on again for switch positions 0 to 3 Switching on switching off and and switching on again for switch positions 4 to 7 24V In UPS operation 24V Out 5 seconds t 6 seconds 24V In Input voltage DC 24 V on the UPS of the power supply unit UPS opera tion Sign...

Page 39: ...put voltage on the UPS drops the VAU 01 1U switches into the buffer mode or into UPS operation and signals this to the connected PC After the UPS time t has expired the output voltage 24V Out switches off at the VAU 01 1U DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface Bosch Rexroth AG 37 63 Operating and Display Components ...

Page 40: ...Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface 38 63 ...

Page 41: ... 31 Set S1 rotary switch before using the VAU 01 1U see also chapter 6 4 Rotary Switch S1 on page 32 7 2 Connector Panel 7 2 1 General Information The terminals for the voltage connection the voltage output and the USB in terface as well as the display and operating components are arranged on the connector panel 1 2 3 4 5 6 7 Voltage connection X1S1 Voltage output X1S2 USB interface XUSB In Fuse F...

Page 42: ...oenix connector terminal PC4 2 G 7 62 2 pin Phoenix female connector terminal PC4 2 St 7 62 2 pin XUSB In USB2 0 connection to the control cabi net PC Maximum 3 m Use only a high speed USB2 0 ca ble see chapter 9 2 Accessories on page 54 USB female con nector 4 pin type B USB plug 4 pin type B Functional earth ground FE M5 Ring cable lug Fig 7 2 Interfaces on the VAU 01 1U Bosch Rexroth AG DOK SUP...

Page 43: ... 5 5 lb in 0 6 Nm 7 3 2 Wiring the Power Connection The VAU 01 1U is specified for overvoltage category 1 High electrical voltage due to wrong connec tions Danger to life risk of injury by electric shock WARNING Do observe the overvoltage categories see chapter 7 3 2 Wiring the Power Connection on page 41 fig 7 5 Wiring of the DC 24 V power connection to the VAU 01 1U at 400 V voltage supply of th...

Page 44: ...pply voltages for which they are designed Do observe the overvoltage categories see chapter 7 3 2 Wiring the Power Connection on page 41 and fig 7 4 Wiring of the DC 24 V pow er connection to the VAU 01 1U at 230 V voltage supply of the 24 V power supply unit on page 42 Do not apply the supply voltage to the protective extra low voltage PELV Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth I...

Page 45: ...pply voltages for which they are designed Do observe the overvoltage categories see chapter 7 3 2 Wiring the Power Connection on page 41 and fig 7 5 Wiring of the DC 24 V pow er connection to the VAU 01 1U at 400 V voltage supply of the 24 V power supply unit on page 43 Do not apply the supply voltage to the protective extra low voltage PELV DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 0...

Page 46: ...cross section 7 4 Interface XUSB In 7 4 1 General Information During the connection of a VAU 01 1U to an USB interface at a PC the infor mation regarding the existence as well as the state of the VAU 01 1U are communicated to the PC via a USB connection The communication is estab lished via a virtual COM interface provided by the USB interface The electrical properties of the XUSB In interface cor...

Page 47: ...ground connections of the control and of the VAU 01 1U Ad ditionally the VAU 01 1U features a ferrite clamp between USB connection of the VAU 01 1U and the bonding clip of the VAU 01 1U Connecting the USB cable At first attach the shield connector of the USB cable to the functional earth ground connection FE of the VAU 01 1U see in the following figure USB interface Shield connector of the USB cab...

Page 48: ...Function 3 Data 4 USB ground Fig 7 11 Pin assignment of the XUSB In connector Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface 46 63 Interfaces and Wiring ...

Page 49: ... to be replaced please contact the Bosch Rexroth Service see chapter 11 Service and Support on page 57 or ensure that only qualified persons replace the respective components Maintenance Include the following measures in your maintenance schedule At least once a year check all plug and terminal connections of the components regarding proper tightness and possible damage Verify that lines and cable...

Page 50: ...pected must not exceed values of 60 C To exchange the battery proceed as described in the following sections Steps for replacing the battery 1 Shut down the PC 2 Disconnect the supply voltage of the VAU 01 1U 3 Remove fuse F1 on the front side 4 Open the cover by loosening the M5 screw at the VAU 01 1U see fig 8 1 Position of the M5 screw for opening the VAU 01 1U on page 48 1 Screw for opening th...

Page 51: ...g interlock Fig 8 2 Plug position at the battery 6 As soon as the cover is opened see fig 8 3 Opened cover of the VAU 01 1U on page 49 the cover can be separated from the housing 1 Connector at the VAU 01 1U Fig 8 3 Opened cover of the VAU 01 1U DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface Bosch Rexroth AG 49 63 Maintenance Storage and Transport ...

Page 52: ...n ger screw might damage the housing of the battery Observe that only a battery which is permitted by Bosch Rexroth is installed e g the battery AKKU24V 2 5Ah Bosch Rexroth parts number 1070923287 Tighten the four M3 screws see fig 8 4 Position of the four M3 screws on page 50 with a torque of 6 2 lbf in 0 7 Nm 9 Plug the battery connector until it clicks into place 10 Close the cover Attach the c...

Page 53: ...me has exceeded two years check the open circuit voltage of the battery regularly as described in the following section Checking the open circuit voltage To check the open circuit voltage of the battery insert a voltmeter between the fusible wire of fuse F1 see fig 7 1 Connector panel of the VAU 01 1U with USB interface on page 39 and the 0 V connection of X1S1 Damage to the VAU 01 1U due to short...

Page 54: ...Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface 52 63 ...

Page 55: ...llowing type designation code Fig 9 1 Type designation code for VAU 01 1U This documentation describes only the uninterruptible power sup ply UPS VAU01 1U 024 024 240 NN DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface Bosch Rexroth AG 53 63 Ordering Information ...

Page 56: ... immunity Length 1 m RKB0023 003 0 R911171414 USB connecting cable with in creased noise immunity Length 3 m Fig 9 3 Order data USB connecting cable with increased noise immunity 9 3 Further Documentation Documentation Order code of the documenta tion Parts number Rexroth IndraControl VPB 40 3 DOK SUPPL VPB 40 3 PRxx EN P R911323876 Rexroth IndraControl VPP 16 3 40 3 60 3 DOK SUPPL VPP XX 3 PRxx E...

Page 57: ...ree domicile to the following address Bosch Rexroth AG Electric Drives and Controls Buergermeister Dr Nebel Strasse 2 97816 Lohr am Main Germany Packaging 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 Batteries and...

Page 58: ...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 Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface 56 63 Environmental Protection and Disposal ...

Page 59: ... E mail service svc boschrexroth de Internet For additional information on service maintenance e g delivery addresses and training please go to http www boschrexroth com Required information Please provide the following information Detailed description of malfunction and circumstances leading to the malfunction Type plate name of the affected products in particular type codes and serial numbers Ph...

Page 60: ...Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface 58 63 ...

Page 61: ...uninterruptible power supply The UPS is used for timely limited voltage supply of the connected device if the voltage supply DC 24 V fails UPS NT Control software The UPS NT control software is used to monitor and control the UPS UPS operation buffer operation buffer mode Signal to the connected PC that the UPS is in the buffer mode and that the supply voltage 24V Out switches off after a set time...

Page 62: ...Bosch Rexroth AG DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface 60 63 ...

Page 63: ...voltage 21 Input voltage and output voltage 21 Installation Mounting notes 25 Intended use Introduction 7 Interfaces 39 Interface XUSB in 44 L LEDs 30 M Maintenance General information 47 Max shock 22 Max temperature gradient 22 Max vibration 22 Minimum distances 26 Mounting 26 Mounting notes 25 Mounting rail 25 O Open circuit voltage check 51 Operating and display components 29 Operating and erro...

Page 64: ...data 21 Ambient conditions 22 Degree of protection 21 Used standards 22 Voltages 21 Weight 21 T Testing the battery 51 Timing behavior 33 Transporting the 51 Type designation code 53 U UL and CSA certified 24 Unintended use 8 Consequences exclusion of liability 7 UPS NT control software 33 UPS operation Switching on the supply voltage 36 UPS times 32 USB interface 44 Use 7 V Voltage Input voltage ...

Page 65: ...Notes DOK SUPPL VAU 01 1U PR03 EN P Rexroth IndraControl VAU 01 1U UPS with USB interface Bosch Rexroth AG 63 63 ...

Page 66: ...SUPPL VAU 01 1U PR03 EN P R911323872 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 ...