High-response valve with integrated digital axis controller (IAC-Multi-Ethernet) and Ethernet interface

Transcription

1 High-response valve with integrated digital axis controller (IAC-Multi-Ethernet) and Ethernet interface Type 4WRPDH Type 4WRLD Operating instructions RE B/10.13 English

2 The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging. This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. The cover shows an example configuration. The product supplied may therefore differ from the photo shown. The original operating instructions were prepared in German.

3 Inhalt 3/44 Inhalt 1 About this documentation Validity of the documentation Required and amending documentation Representation of information 6 2 Safety instructions General information on this chapter Intended use Improper use Qualification of personnel General safety instructions Product-specific safety instructions Safety equipment Personal protective equipment 21 3 General information on damage to property and damage to the product 21 4 Scope of delivery 22 5 Information on this product Performance description Product description Product identification 24 6 Transport and storage Storaging the IAC-Multi-Ethernet-based high-response valve 25 7 Assembly Unpacking Installation conditions Required tools Recommended accessories Prior to assembly Place of installation Assembly of the IAC-Multi-Ethernet-based high-response valve 27 8 Commissioning First commissioning Installation requirements 33 9 Operation Maintenance and repair Cleaning and maintenance Inspection and maintenance Repair Disassembly and replacement Required tools Preparing for disassembly Performing disassembly Preparing storage and further use Disposal Environmental protection Return to Bosch Rexroth AG Packaging 38 RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

4 4/ Materials used Recycling Extension and modification Troubleshooting How to proceed for troubleshooting Fault table Technical data Appendix List of addresses Alphabetical index 42 Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

5 About this documentation 5/44 1 About this documentation 1.1 Validity of the documentation This documentation refers to the following high-response valves with integrated axis controller (IAC-Multi-Ethernet): 4WRPDH (direct operated high-response valve with Ethernet interface and axis control function) 4WRLD (pilot operated high-response valve with Ethernet interface and axis control function) This documentation is intended for assembly fitters, operators and service technicians and plant operators. This documentation contains important information on the safe and proper assembly, transport, commissioning, operation, use, maintenance, disassembly and simple troubleshooting of the product. You should read this documentation thoroughly, in particular chapter 2 "Safety instructions" on page 8 and chapter 3 "General information on damage to property and damage to the product" on page 21 before working with the product. 1.2 Required and amending documentation The product must not be commissioned until you have been provided with the documentation marked with the book symbol and you have understood and observed it. Bosch Rexroth data sheets are available online at Table 1: Required and amending documentation Title Document number Document type System documentation from the system manufacturer High-response valve with integrated digital RE Data sheet axis controller (IAC-Multi-Ethernet) and Ethernet interface Parameter description Rexroth Hydraulic- Description Drive HDS-xx 1) Description of diagnosis Rexroth Description HydraulicDrive HDS-xx 1) Functional description Rexroth Description HydraulicDrive HDS-xx 1) Declaration of conformity 4WRPDH Available from Bosch Rexroth on request Declaration of conformity 4WRLD Available from Bosch Rexroth on request General product information on hydraulic products RE Data sheet Hydraulic valves for industrial applications RE B Operating instructions 1) xx = software version RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

6 6/44 About this documentation 1.3 Representation of information Consistent safety instructions, symbols, terms and abbreviations are used in this documentation so that you can quickly and safely work with your 4WRPDH6,10. For a better understanding, they are explained in the following sections Safety instructions In this documentation, safety instructions are included in chapter 2.6 "Productspecific safety instructions" on page 11 and in chapter 3 "General information on damage to property and damage to the product" on page 21 or whenever a sequence of actions or instructions are explained which bear the risk of personal injury or damage to property. The measures described for preventing these hazards must be observed. Safety instructions are set out as follows: SIGNAL WORD Type and source of danger! Consequences in case of non-compliance Hazard avoidance measures <Enumeration> Warning sign: Draws attention to the danger Signal word: Identifies the degree of danger Type and source of danger: Specifies the type and source of danger Consequences: Describes the consequences of non-compliance Precaution: Specifies how the danger can be prevented Table 2: Risk classes according to ANSI Z Warning sign, signal word DANGER WARNING CAUTION NOTICE Meaning Indicates a dangerous situation which may cause death or severe personal injuries if not avoided. Indicates a dangerous situation which may cause death or severe personal injuries if not avoided. Indicates a dangerous situation which may cause minor or medium personal injuries if not avoided. Damage to property: The product or the environment could be damaged. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

7 About this documentation 7/ Symbols The following symbols indicate notices which are not safety-relevant but increase the comprehensibility of the documentation. Table 3: Meaning of the symbols Symbol Meaning If this information is not observed, the product cannot be used and/or operated optimally. Individual, independent action. Numbered instruction: The numbers indicate that the steps must be carried out one after the other Designations The following designations are used in this documentation: Table 4: Designations Designation IAC-Multi-Ethernet IndraWorks RE xxxxx sercos Meaning Integrated axis controller based on a high-response valve Operating software Rexroth document in English language Interface for motion control applications Abbreviations The following abbreviations are used in this documentation: Table 5: Abbreviations Abbreviation Meaning CANopen Controller Area Network CCF Common Cause Failure DC avg Average Diagnostic Coverage according to EN ISO E/A Input/output FU Frequency converter PC Personal Computer PELV Protective Extra Low Voltage PFH Probability of dangerous failure per hour PL Performance Level according to EN ISO SELV Separated extra-low voltage SPS Programmable Logic Control MTTF d Mean time to dangerous failure VARAN Versatile automation random access network (Ethernet bus system) EtherNet/IP EtherNet Industrial Protocol EtherCAT Real time Ethernet RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

8 8/44 Safety instructions 2 Safety instructions 2.1 General information on this chapter The IAC-Multi-Ethernet-based high-response valve was manufactured according to the generally accepted codes of practice. However, there is still the risk of personal injury and damage to property if you do not observe this chapter and the safety instructions in this documentation. Read this documentation completely and thoroughly before working with the product. Keep this documentation in a location where it is accessible to all users at all times. Always include the required documentation when you pass the high-response valve on to third parties. 2.2 Intended use A IAC-Multi-Ethernet-based high-response valve is a hydraulic valve with electrical control which can be used in two-channel safety applications (cat. 3, PL d and cat. 4, PL e according to EN ) as switch-off element for one channel. Depending on the application and the requirements of work equipment-related standards according to EN , the user must provide appropriate monitoring/ plausibility checks which comply with the required diagnostic coverage DC avg using a superior control. The IAC-Multi-Ehternet-based high-response valve is exclusively intended for the integration into a machine or system or for the assembly with other components to form a machine or a system. The product may be commissioned only if it is integrated in the machine/system for which it is designed. The technical data indicated in the operating conditions and the performance limits must be observed. You may use the IAC-Multi-Ethernet-based high-response valve as follows: To control position, pressure, force, velocity, pressure differential and flow When using the unit, you moreover need superior control logic with corresponding I/O components which in connection with the IAC-Multi-Ethernet-based high-response valve is responsible for the holistic control of the machine's motion sequence and also its safety-related monitoring. The IAC-Multi-Ethernet-based high-response valve may not be used in an explosive environment. The product is only intended for professional use and not for private use. Intended use includes having read and understood this documentation completely, especially chapter 2 "Safety instructions" on page 8. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

9 Safety instructions 9/ Improper use Any use deviating from the intended use is improper and thus not admissible. Improper use voids any warranty claims. It also counts as improper use if the IAC-Multi- Ethernet-based high-response valve is operated outside the indicated performance limits and operating conditions, especially the required environmental conditions. Bosch Rexroth AG does not assume any liability for damage caused by improper use. The user assumes all risks involved with improper use. 2.4 Qualification of personnel The activities described in this documentation require basic knowledge of electric installation, control technology, programming and hydraulics as well as knowledge of the appropriate technical terms. In order to ensure safe use, these activities may only be carried out by a corresponding expert or an instructed person under the direction and supervision of an expert. Experts are those who can recognize potential hazards and apply the appropriate safety measures due to their professional training, knowledge and experience, as well as their understanding of the relevant conditions pertaining to the work to be undertaken. An expert must observe the relevant specific professional rules and have the necessary hydraulic expert knowledge. Hydraulic expert knowledge means, amongst others: reading and completely understanding hydraulic schemes, in particular, completely understanding the correlations regarding the safety equipment and having knowledge of the function and set-up of hydraulic components. The operation of the IAC-Multi-Ethernet digital axis control requires experience in the use of the PC program IndraWorks. A description of the handling of the program as well as first steps for operation are available online at We recommend the participation in a product-specific training of Bosch Rexroth. Bosch Rexroth offers measures supporting the training in specific fields. An overview over the training content can be found online at: RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

10 10/44 Safety instructions 2.5 General safety instructions Observe the valid regulations on accident prevention and for environmental protection. Observe the safety regulations and provisions of the country where the product is implemented/used. Exclusively use Rexroth products in technically perfect condition. Observe all notices on the product. Persons assembling, operating, disassembling or maintaining Rexroth products must not be under the influence of alcohol, other drugs or medications influencing the ability to react. Only use original Rexroth accessories and spare parts in order to exclude hazards to persons due to unsuitable spare parts. Comply with the technical data and environmental conditions specified in the product documentation. The installation or use of inappropriate products in safety-relevant applications could result in unintended operating conditions when being used which in turn could cause personal injuries and/or damage to property. Therefore, only use a product for safety-relevant applications if this use is expressly specified and permitted in the documentation of the product, e.g. in explosion protection zones or in safety-related parts of control systems (functional safety). Do not commission the product until you can be sure that the end product (for example a machine/system) where the Rexroth products are installed complies with the country-specific provisions, safety regulations and standards of the application. Please observe the safety-relevant information and risk specifications in the operating instructions of the manufacturer of the connected hydraulic system before commissioning the control with a hydraulic system. Please observe the general installation and safety instructions when working on electric systems. The information given in the product documentation with regard to the use of the supplied components are only application examples and recommendations. The machine manufacturer and system installer must check the suitability of the supplied components and the information given in this documentation with regard to their use self-dependently for his individual application and adjust it to the safety instructions and standards valid for his application, and carry out the required measures, changes and amendments. Technical data as well as connection and installation conditions are available in the product documentation and must be imperatively observed. In case of failures impairing the safety and changes in the operating behavior, shut down the IAC-Multi-Ethernet immediately and report the failures to the responsible personnel. You must generally not modify or retrofit the product. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

11 Safety instructions 11/ Product-specific safety instructions WARNING Non-compliance with functional safety! Hydraulic valves control movements in machines or systems. In case of mechanical and electric faults, e.g. failure of the energy supply, persons may be caught by the system, kicked away or bruised. When setting up your circuit, observe functional safety e.g. according to EN ISO Dangerous motion! It is not allowed for persons to stay within the range of motion of machines and machine parts. The following are examples of possible measures against unintended access of persons: Protective fences Protective grids Protective covers Light barrier If persons must access the danger zone during active control, monitoring or measures must be provided for personal safety which are superior to the system. These measures must be provided according to the specific data of the system and on the basis of the risk and error analysis of the system manufacturer/ user. In this connection, the safety requirements applicable to the system must be taken into account. In case of faults impairing the safety and changes in the operating behavior, shut down the IAC-Multi-Ethernet-based high-response valve immediately and report the faults to the responsible personnel. Pressurized system parts and leaking hydraulic fluid! When working at hydraulic systems with stored pressure energy (accumulator or cylinders working under gravity), the IAC-Multi-Ethernet-based high-response valve may even be pressurized after the pressure supply has been switched off. During assembly and disassembly works, the IAC-Multi-Ethernet-based high-response valve or parts may fly around and cause personal injuries and/or damage to property. There is moreover the danger of serious injury caused by a powerful leaking hydraulic fluid jet. Before working at the IAC-Multi-Ethernet-based high-response valve, ensure that the hydraulic system is depressurized and the electrical control de-energized. Completely unload the pressure at machines and systems before working at hydraulic products. RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

12 12/44 Safety instructions WARNING High electric voltage by incorrect connection! Risk of death or bodily injury by electric shock! The IAC-Multi-Ethernet-based high-response valve must only be connected by a specialized electrician or under supervision of the same. Switch off the voltage supply before all maintenance, repair or installation works and secure it against restarting. Provide for proper, safe PE connection. For the supply voltage of the IAC-Multi-Ethernet-based high-response valve, functional low voltages with electric separation (PELV or SELV) according to VDE0100, part 410 must be used. For the external voltage supply, it must be ensured that, even in error cases, the voltage limitation defined for the IAC-Multi-Ethernet-based high-response valve is not exceeded. PELV power supply units according to EN 60204, section comply with these requirements. Only connect voltages and electric circuits provided with a safe isolation from dangerous voltages. Secure separation is achieved for example by means of isolation transformers, secure optocouplers or mains-free battery operation. Notice: When calculating the PFH (probability of dangerous failure per hour) of the safety function, the PFH of the external voltage supply must also be taken into account. Faulty fastening! Mounting of the IAC-Multi-Ethernet-based high-response valve with mounting screws of reduced stability, insufficient mounting or fastening at blocks and plates with insufficient stability may cause the high-response valve to become loose and fall down. Consequently, hydraulic fluid may leak and lead to personal injuries and/ or damage to property. Hydraulic valves with high weight may bruise or kill persons. Special care must be taken with hydraulic valves with suspended installation. Assemble the IAC-Multi-Ethernet-based high-response valve using appropriate assembly aids completely according to the assembly specifications. Only assemble the IAC-Multi-Ethernet-based high-response valve at blocks or plates suitable for the weight of the high-response valve. Comply with tightening torques and screw stabilities. Missing equipotential bonding! Electrostatic processes, an incorrect earthing concept or missing equipotential bonding may lead to malfunctions or uncontrolled movements at the machine and thus cause injuries. Provide for correct earthing and provide for proper equipotential bonding. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

13 Safety instructions 13/44 WARNING Penetrating water and humidity! In case of use in humid or wet environments, water or humidity may penetrate at electrical connectors or the valve electronics. This may lead to malfunctions at the high-response valve and to unexpected motions in the hydraulic system which may result in personal injury and damage to property. Only use the IAC-Multi-Ethernet-based high-response valve within the intended IP protection class or lower. Ensure before the assembly that all seals and caps of the plug-in connections are tight and intact. Easily inflammable hydraulic fluid! In connection with fire or other hot sources of heat, leaking hydraulic fluid mist may lead to fire or explosions due to defective or incompletely assembled high response valves and their connections. Do not use the high-response valve in areas with open fire and only at a sufficient distance to hot sources of heat. CAUTION Contaminated hydraulic fluid! Contamination in the hydraulic fluid may cause functional failures e.g. jamming or blocking of nozzles of the high-response valve. In the worst case, this may result in unexpected system movements and thus constitute a risk of injury for persons. Ensure adequate hydraulic fluid cleanliness according to the cleanliness classes of the high-response valve over the entire operating range. Hot surfaces! Hydraulic valves may heat up considerably during operation. This may lead to burns in case of skin contact. Avoid contact with the high-response valve during operation. Allow the high-response valve to cool down sufficiently before touching it or wear protective gloves. If necessary, attach protective covers. Exceedance of the maximum temperatures! Use of the high-response valve outside the specified temperature range may lead to functional failures like e.g. overheating of the valve solenoids. In the worst case, this may result in unexpected system movements and thus constitute a risk of injury for persons. Only use the high-response valve within the environmental and fluid temperatures intended for that purpose. RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

14 14/44 Safety instructions CAUTION Leakage in case of incorrect working temperatures! Use of the high-response valve outside the specified temperature range may lead to permanent leakage at the high-response valve. Thus, hydraulic fluid in the form of a leaking hydraulic fluid jet may injure persons, lead to damage to property and endanger the environment. Only use the high-response valve within the specified environmental and fluid temperatures. In case of leakage, immediately exchange damaged seal rings or the high-response valve. Corrosion! If the high-response valve is used in humid environments or water, the high-response valve and the mounting screws may corrode. Thus, the mounting screws and the high-response valve loose their stability and may become loose and constitute a risk of injury. Use mounting screws with adequate corrosion protection and exchange the mounting screws with serious corrosion damage. Provide for adequate corrosion protection and exchange valves with serious corrosion damage at an early stage. Contact with salt water leads to increased corrosion at the high-response valve. Thus, mounting screws and plug screws as well as moveable components such as hand levers may be chemically corroded and damaged. You should thus take suitable corrosion protection measures. 2.7 Safety equipment WARNING Dangerous motions! Danger to life, risk of injury or damage to property! You may only use the approved spool types specified in the corresponding valve data sheet. Otherwise, secure shut-off of the high-response valve and the related safety function are no longer provided Use of the IAC-Multi-Ethernet-based high-response valve according to EN The use of the IAC-Multi-Ethernet-based high-response valve according to EN is possible in systems up to PL e, category 4. The valve can be used as shut-down element to ensure compliance with the requirements of a secure start inhibitor according to EN stop category 0. In two-channel applications, i.e. applications with PL d, cat. 3 and PL e, cat. 4 according to EN , the high-response valve with IAC-Multi-Ethernet electronics can be used as shut-off channel. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

15 Safety instructions 15/44 As a precondition, appropriate monitoring/plausibility checks with the required DC avg for the entire application must be provided by the user or programmed into a superior control system. Regarding valve monitoring, the valve only provides feedback signals which must be evaluated by a superior control system in order to calculate the diagnostic coverage according to EN and prove that the requirements are complied with. In the case of an error, the superior control system must shut off the safety function. The superior control system must check the signals "enable" and "enable acknowledgement" for plausibility depending on the required safety level (cat., PL) and activate the shut-off/safety function in the case of an error. The 24 V supply voltage may be applied permanently as long as no error is detected by the superior control system. If the direction-dependent enable (P-A or P-B) is taken away, the supply voltage is disconnected by an high-side switch of the respective output stage. The electronics connect the disconnected output stage supply to the applicable spool position of the spool and thus create the direction-dependent enable acknowledgement. In addition, every change of the enable signal (L or H) must lead to a prompt reaction of the related enable acknowledgement signal (inverted to enable H or L). If this signal change does not occur in time, the superior control system must react and initiate the emergency shut-down of the system. The superior control system must check the signals or signal changes of "enable" and "enable acknowledgement" for plausibility. An application with two valves including two-channel control and monitoring (DC avg 99%) fulfills the requirements to achieve a PL e, cat. 4 according to EN With the exception of "enable" and "enable acknowledgement", all other signals do not form part of the safety function and must therefore not be used for safety-relevant functions. Despite all safety measures, using the IAC-Multi-Ethernet-based high-response valve involves significant residual risks. These must be evaluated by the machine integrator depending on the individual application. Rexroth provides the safety parameters of the high-response valve with IAC-Multi-Ethernet axis controller according to EN RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

16 16/44 Safety instructions Limits of the safety-relevant parts Evaluation of the IAC-Multi-Ethernet axis controller according to ISO : A valve with IAC-Multi-Ethernet axis controller is suitable for shutting off a channel according to EN An appropriate control system must be provided which conducts plausibility checks between the direction-dependent enable input of the IAC-Multi-Ethernet axis controller and the direction-dependent "enable acknowledgement" signal sent by the IAC-Multi-Ethernet (see chapter 2.7.1). The valve with IAC-Multi-Ethernet axis controller may also fail or error states may not be identified which means that, depending on the application, appropriate system-related measures according to EN must be provided (see chapter 2.7.1). A valve with IAC-Multi-Ethernet axis controller is not suitable as shut-off element according to category 1 if enable is used without a cyclic evaluation of the enable acknowledgement. The requirements for the cyclic evaluation must be observed depending on the specific application Residual risks/error states The following residual risks or error states may occur and must be taken into account regarding system design and by providing appropriate counter-measures. Complete failure of the electronics of the IAC-Multi-Ethernet axis controller. Faulty output of operating states. Failure of the enable inputs or enable acknowledgement outputs. Delayed reaction to signal changes. Uncontrolled movement of the valve spool (may e.g. lead to uncontrolled movement of the cylinder). Undefined behavior of the IAC-Multi-Ethernet electronics if signals "enable P-A" or "enable P-B" are provided in the overlap area ( V according to IEC :2008, type 1). Difficult level recognition of enable acknowledgement and thus no activation of the safety function if the enable acknowledgement outputs are not connected to current sinking inputs according to IEC :2008 (types 1, 2 or 3). Fuse protection in the case of short-circuits of the IAC-Multi-Ethernet axis controller by means of appropriate protection and design of the supply line (fuse protection against currents >4 A) MTTF d, DC, CCF The following MTTF d values can be assumed for the high-response valves in combination with the IAC-Multi-Ethernet axis controller: 4WRPDH, direct operated 60 years (high) 4WRLD, pilot operated 40 years (high) The DC depends on the system and on the use of a safety PLC (see chapter 2.2 "Intended use" on page 8). By using the IAC-Multi-Ethernet-based high-response valve as intended, a CCF of at least 65 points can be reached. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

17 Safety instructions 17/ Limits for the operation The following operating conditions apply to the IAC-Multi-Ethernet axis controller, see data sheet. Ambient temperature range: C Supply voltage range VDC, see data sheet. Voltage range of the enable inputs VDC. Additional external precautionary measures must be taken against overvoltage, e.g. in the form of fuses and varistors. Level recognition of the enable inputs according to IEC :2008, type 1 The enable acknowledgement outputs must be connected to switching inputs according to IEC :2008 (types 1, 2 or 3; current sinking). Variations may occur depending on the valve used. They can be found in the corresponding valve data sheet. There, you also find the valve-related operating conditions Independence of operating modes The safety function of the IAC-Multi-Ethernet is independent from operating modes. The safety function can only be used if the IAC-Multi-Ethernet axis controller is combined with appropriately designed valves. This information can be found in the corresponding valve data sheet. The data sheets also list which operating conditions are supported by the IAC-Multi-Ethernet together with the valve Response time The response time of IAC-Multi-Ethernet electronics is no more than 5 ms. To find out the total response time for valve and electronics, the response time of the valve, which can be found in the corresponding valve data sheet, must be added. RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

18 18/44 Safety instructions Connection example/block diagram for direct operated valves with one solenoid For type III according to EN 201:2009, two separate shut-off paths are required. The following overview illustrates exemplarily the realization of a shut-off path on an injection molding machine with a high-response valve on the basis of IAC-Multi- Ethernet electronics. For the second shut-off path, an additional, suitable valve must be provided. For this application, the specific requirements of EN 201:2009 must be observed. The connection example merely shows the safety-relevant signals of the IAC-Multi- Ethernet electronics. All the other signals and interfaces can be found in the relevant data sheets. PELV/SELV 24 V power supply unit acc. to VDE0100 part 410 1, 2, 3, 8 are safety-relevant connections of the 11+pe- connector of the IAC-Multi- Ethernet electronics; for additional connections see valve data sheet. (Values in brackets: Connections when a 8+4 connector is used) B1, switched by enable signal Hydraulics actuator side 3(3) 1(1) 2(2) Enable P-A 24 V ( V) GND Inputs IAC-Multi-Ethernet A P B T a 0 b G U b Outputs Enable acknowledgement P-A 8(6) Hydraulics supply side Fig. 1: Block diagram for direct operated valves with one solenoid Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

19 Safety instructions 19/ Connection example/block diagram for direct operated valves with two solenoids For type III according to EN 201:2009, two separate shut-off paths are required. The following overview illustrates exemplarily the realization of a shut-off path on an injection molding machine with a high-response valve on the basis of IAC-Multi- Ethernet electronics. For the second shut-off path, an additional, suitable valve must be provided. For this application, the specific requirements of EN 201:2009 must be observed. The connection example merely shows the safety-relevant signals of the IAC-Multi- Ethernet electronics. All the other signals and interfaces can be found in the relevant data sheets. PELV/SELV 24 V power supply unit acc. to VDE0100 part 410 1, 2, 3, 8, 9, 10 are safety-relevant connections of the 11+pe- connector of the IAC-Multi- Ethernet electronics; for additional connections see valve data sheet (Values in brackets: Connections when a 8+4 connector is used) B1, switched by enable signal Enable P-A B2, switched by enable signal 3(3) 10(4) Enable P-B 1(1) 2(2) 24 V GND ( V) Hydraulics actuator side Inputs IAC-Multi-Ethernet a A B a 0 b P T G U b Outputs Enable acknowledgement P-B 9(7) Enable acknowledgement P-A 8(6) Hydraulics supply side Fig. 2: Block diagram for direct operated valves with two solenoids RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

20 20/44 Safety instructions Connection example/block diagram for pilot operated valves (pilot valve with one solenoid) For type III according to EN 201:2009, two separate shut-off paths are required. The following overview illustrates exemplarily the realization of a shut-off path on an injection molding machine with a high-response valve on the basis of IAC-Multi- Ethernet electronics. For the second shut-off path, an additional, suitable valve must be provided. For this application, the specific requirements of EN 201:2009 must be observed. The connection example merely shows the safety-relevant signals of the IAC-Multi- Ethernet electronics. All the other signals and interfaces can be found in the relevant data sheets. B1, switched by enable signal PELV/SELV 24V power supply unit acc. to VDE0100 part 410 1, 2, 3, 8 are safety-relevant connections of the 11+pe- connector of the IAC- Multi-Ethernet electronics; for additional connections see valve data sheet (Values in brackets: Connections when a 8+4 connector is used) Hydraulics actuator side 3(3) 1(1) 2(2) Enable P-A 24 V ( V) GND Inputs A B U G IAC-Multi-Ethernet a P T b Outputs A B G Enable acknowledgement P-A X A a 0 b P T B Y U 8(6) Hydraulics supply side Fig. 3: Block diagram for pilot operated valves (pilot valve with one solenoid) Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

21 General information on damage to property and damage to the product 21/ Personal protective equipment Check specified personal protection for completeness and protective effect and have it available (please observe customer specification and list of personal protection!) 3 General information on damage to property and damage to the product NOTICE Inadmissible mechanical load! Impact or shock forces on the high-response valve may damage or even destroy it. Never use hydraulic components as handle or step. Do not place/put any objects on top of it. Dirt and foreign particles in hydraulic components! Penetrating dirt and foreign particles lead to wear and malfunctions. Safe function of the hydraulic components is no longer ensured. During assembly, ensure utmost cleanliness in order to prevent foreign particles such as welding beads or metal chips from getting into the hydraulic lines. Do not use linting fabric for cleaning. Ensure that no cleaning agents are able to penetrate the hydraulic system. Hydraulic fluid harmful to the environment! Leaking hydraulic fluid leads to environmental pollution. Immediately remedy possible leakage. Dispose of the hydraulic fluid in accordance with the currently applicable national provisions in your country. Uncontrolled disconnection and connection of plug-in connectors! Device might be destroyed! Before installation works, separate the device from the mains or from the voltage source or de-energize it. Do not plug in or pull the electric connector as long as the voltage supply is switched on. The warranty only applies to the delivered configuration. The claim to warranty expires if the product is incorrectly assembled, commissioned and operated, not used as intended and/or handled improperly. RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

22 22/44 Scope of delivery 4 Scope of delivery The scope of delivery includes: High-response valve with integrated digital axis controller (IAC-Multi-Ethernet) Accessories such as mating connectors, interface cables and cable sets are not included in the scope of delivery and must be ordered separately. Software is not covered by the scope of delivery. Download commissioning software online at: Check the scope of delivery for completeness. Check the scope of delivery for possible transport damage, see section "6 Transport and storage" on page 25. In case of complaints, please contact Bosch Rexroth AG, see section "16.1 List of addresses" on page 41. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

23 Information on this product 23/44 5 Information on this product 5.1 Performance description The IAC-Multi-Ethernet is an integrated axis controller designed for an electrohydraulic axis. The IAC-Multi-Ethernet can be connected to a superior control via an Ethernet-capable bus system (e.g.: sercos III, VARAN or EtherCAT) and programmed using a PC and the software program IndraWorks. The bus system must not be used to transfer safety-related signals. These must be provided or evaluated directly at the connector. Using the IAC-Multi-Ethernet-based high-response valve, position/pressure/force/velocity/flow control and alternating control (position/pressure) can be realized. 5.2 Product description The IAC-Multi-Ethernet-based valve is designed for being used in rough industrial environments as regards to interference resistance, mechanical vibration and shock resistance, and climate resistance. The IAC-Multi-Ethernet-based valve provides freely configurable controller variants: Position/pressure/force/velocity/flow controller Alternating control (position/pressure) The parameterization and diagnosis is done using the PC software IndraWorks, which can be downloaded from You can also use it for the individual parameterization of the IAC-Multi-Ethernet-based valve and for the adjustment to the requirements of your axis. For process connection, the IAC-Multi-Ethernet is equipped with digital as well as analog encoder interfaces and up to two freely configurable digital inputs/outputs. The communication with the superior control is done via Ethernet. For the use of the unit, you moreover need superior control logics with corresponding I/O components that in connection with the IAC-Multi-Ethernet are responsible for the holistic control of the machine's motion sequence and also its safety-related monitoring. The bus system must not be used to transfer safety-related signals. These must be provided or evaluated directly at the connector. The preparation of application-specific data sets forms the basis for the function of the IAC-Multi-Ethernet. These data sets are generated on the PC and sent to IAC- Multi-Ethernet via Ethernet. The connection between user program and data sets is referred to as project. The IAC-Multi-Ethernet includes different controller functions which are described in the data sheet Displays The LED displays and their meaning can be found in the data sheet. RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

24 24/44 Information on this product 5.3 Product identification Information on the name plate of the valve and the IAC-Multi-Ethernet electronics The meaning of the information on the name plates of the valve and the IAC-Multi- Ethernet electronics can be read in the correspondingly numbered fields of the following table Fig. 4: Name plate of valve 1 Word mark 2 Symbol 3 Material number of the valve 4 Serial number 5 Date of manufacture 6 Material short text 7 Production plant 8 Country of manufacture Fig. 5: Name plate of IAC-Multi-Ethernet electrics (connector side) 1 Bus connector 1 2 CE mark 3 Bus logo 4 Bus connector 2 5 Short-circuit data 6 Reference to documentation 7 LED designation 8 Connector 9 1.MAC address 10 Materialnumber of actuating solenoid 11 Date of production of actuating 12 DMC solenoid Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

25 Transport and storage 25/ Fig. 6: Name plate of IAC-Multi-Ethernet electrics (sensor side) 1 Sensor connector 1 2 Sensor connector 2 3 Sensor connector 3 4 Valve main stage (if required) 5 Manufacturer 6 Material number of actuating solenoid 7 Date of production of actuating solenoid 8 DMC 6 Transport and storage There are no special transport instructions for this product. You must, however, observe the notes in chapter 2 "Safety instructions" and comply with the environmental conditions for storage and transport which are detailed in the data sheet. 6.1 Storaging the IAC-Multi-Ethernet-based high-response valve The IAC-Multi-Ethernet-based high-response valve is supplied in perfect condition. Under the following conditions, the high-response valve can be stored up to 6 months: Do not store the high-response valve outdoors but in a well-ventilated room. Observe the admissible storage temperature range as indicated in the data sheet. Protect the high-response valve against humidity, particularly ground humidity. Store the high-response valve on a shelf or on a pallet. Store the high-response valve in the original packaging or comparable packaging in order to protect it from dust and dirt. All ports at the high-response valve must be closed with closing elements. RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

26 26/44 Assembly After opening the transport packaging, it must be closed properly again for the storage. Use the original packaging for storage. Remove the covers at the hydraulic connections of the high-response valve only before the assembly. In case of storage of more than six months or in case sea transport is necessary, please consult Bosch Rexroth. 7 Assembly Condensed water! Risk of short-circuit NOTICE Let the high-response valve acclimate itself for several hours, as otherwise water may condense in the housing. Penetrating humidity! The housing of the valve electronics is closed. However, according to the applicable protection class, fluids may enter and lead to faults and short-circuit. Safe function of the high-response valve is therefore no longer ensured. When working on the high-response valve, always ensure that no fluids can enter the electronics. Major potential differences! Danger of destroying the valve electronics by connecting or disconnecting plug-in connectors under voltage. Switch off power supply to the relevant system part before assembling the device or when connecting and disconnecting connectors. 7.1 Unpacking Dispose of the packaging in accordance with the currently applicable national provisions in your country. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

27 Assembly 27/ Installation conditions For installing the product always observe the environmental conditions specified in the technical data sheet. NOTICE: The environment must be free from aggressive substances (acids, bases, corrosive agents, salts, metal vapors, etc.) which may enter the device despite compliance with protection class IP 65. Before commissioning, make sure that all the seals and caps of the plug-in connections are installed correctly and undamaged to ensure that fluids and contamination parts are prevented from penetrating the product. 7.3 Required tools No special tools are required for the assembly. 7.4 Recommended accessories To connect the IAC-Multi-Ethernet-based high-response valves, we recommend using the accessories listed on the corresponding valve data sheet. 7.5 Prior to assembly Before assembling the high-response valve, check compliance of the type designation on the name plate with your order or job number. Observe the information on the maximum operating pressure on the name plate. 7.6 Place of installation The IAC-Multi-Ethernet-based high-response valve should not be installed next to power electronics (e.g. frequency converter etc.). 7.7 Assembly of the IAC-Multi-Ethernet-based high-response valve Mechanical assembly of the high-response valve WARNING Incorrect assembly of plug screws and lines! Improperly fastened plug screws and lines may become loose during subsequent operation and fly around due to the pressure. This may cause serious injuries. Only pressurize your system after all plug screws and lines have been completely and properly mounted according to the specifications. RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

28 28/44 Assembly CAUTION Insufficient installation space! Insufficient installation space may lead to jamming or abrasions in case of actuation and adjustment work at the high-response valve. Provide for sufficient installation space. Ensure that actuation, adjustment elements and plug-in connectors are easily accessible. Leaking hydraulic fluid! Hydraulic fluid may leak during assembly and disassembly of the high-response valve. Consequently, persons may slip or fall. Only remove the protective caps of the high-response valve directly before the assembly. After the disassembly, provide the bores containing the hydraulic fluid with suitable closing elements. Immediately remove hydraulic fluid that has leaked out. Sharp edges! High-response valves may have sharp edges at the valve openings. During transport or assembly/disassembly, cutting or abrasive injuries may result. Wear corresponding protective clothing during transport. Do not reach into valve openings! Have sufficiently dimensioned collecting containers, non-linting fabric and mediumbinding materials ready in order to collect or bind leaking medium. The mounting surfaces of the high-response valve and the subplate must be clean and free from hydraulic fluid. Use non-linting fabric for cleaning the subplate. 1. Remove the protective cover from the high-response valve. 2. Observe the correct positioning of the high-response valve. Observe the porting pattern of the high-response valve according to symbols and connection labeling on the valve. 3. Check whether all seal rings are available and intact. 4. Carefully place the high-response valve on the mounting surface. 5. Use mounting screws according to the dimensions and property classes specified in the data sheet. 6. Ensure that the mounting screws are tightened using the specified tightening torque. For the tightening torques, please refer to the corresponding data sheets. 7. Please note that the tightening torques may change if other screw types are used Hydraulic connection of the high-response valve 1. Depressurize the relevant part of the system. 2. Establish all connections observing the operating instructions of the system. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13

29 Assembly 29/44 3. Make sure that pipes and/or hoses are connected to all ports and/or that the ports are closed with plug screws. 4. Carry out a special check to make sure that the cap nuts and flanges are correctly tightened at the pipe fittings and flanges. 5. Make sure that all tubes and hose lines and every combination of connection pieces, couplings or connection points with hoses or tubes are checked for their operational safety by someone who has the appropriate knowledge and experience Electrical connection of the high-response valve CAUTION Damage to property! Improperly laid cables and lines may lead to damage to the IAC-Multi-Ethernetbased high-response valve. Lay the cables and lines so that they cannot be damaged and no one can trip over them. Faulty energy supply! Danger of damage to property and personal injuries! Faulty energy supply may lead to uncontrolled valve settings. These could result in possible malfunctions or failure of the high-response valve and cause injuries. Always connect the earthing connection of the high-response valve to the appropriate earthing system of your installation. Only use a power supply unit with safe separation. Always comply with the country-specific regulations. Lacking seals and caps! Risk of short-circuit! Fluids may enter the high-response valve and cause a short-circuit. Before commissioning, ensure that all seals and caps of the plug-in connections are leak-proof. Incorrect connection wiring! Risk of injury due to electric shock and malfunctions! The high-response valve must only be connected by a specialized electrician or under supervision of the same. The lines used have to be suitable for operating temperatures of 20 C C. De-energize the connection line before installation. Correctly connect the protective earthing conductor and the earthing. Avoid sharp bends in the connection line and the litz wires in order to avoid short-circuits and interruptions. Only mount the cable and line entry according to the assembly instructions. During the installation, ensure leak-tightness between cable and cable and line entry. Lay the connection line(s) in a pull-relieved form. The first mounting point must be within 15 cm of the cable entry. Only use lines which comply with the requirements specified in the data sheet. RE B/10.13; 4WRPDH,4WRLD Bosch Rexroth AG

30 30/44 Assembly NOTICE Lacking seals and caps! Protection class IP65 does no longer apply. Fluids and foreign particles may enter and destroy the high-response valve. Ensure before the assembly that all seals and caps of the plug-in connections are tight. Plugging or unplugging connectors while energized! High-response valve might be destroyed. Switch off power supply to the relevant system part before assembling the highresponse valve or when connecting and disconnecting connectors. Ensure a maintenance-friendly installation, i.e. simple access to the connection lines. Free access to the connection sides must be guaranteed. Before installation note down the information on the name plate. If after the installation, nameplates are not visible or readable any more, this data will be quickly available to you at any time. Voltage supply For the supply voltage of the IAC-Multi-Ethernet-based high-response valve, functional low voltages with electric separation (PELV or SELV) according to VDE0100, part 410 must be used. The external voltage supply must ensure that, even in error cases, the voltage limitation defined for the IAC-Multi-Ethernet electronics is not exceeded. PELV power supply units according to EN 60204, section comply with these requirements. Only connect voltages and electric circuits provided with a safe isolation from dangerous voltages. Safe electrical isolation can be achieved for example with isolating transformers, safe optocouplers or mains-free battery operation. When calculating the PFH (probability of dangerous failure per hour) of the safety function, the PFH of the external voltage supply must also be taken into account. Keep the connection as short as possible. Voltage V with a residual ripple <1.5 Vpp, I = 4 A. Supply of external components When supplying a 24 V encoder, the input voltage of the IAC-Multi-Ethernet must comply with the encoder's requirements (e.g.: 24 V ±5%, residual ripple < 500 mv). Analog components such as pressure load cells can be supplied directly via the sockets X2M1 or X2M2. Precondition: The supply of the IAC-Multi-Ethernet corresponds to the requirements of the pressure load cell. Further notes with regard to currents, etc. are available in the data sheet. Bosch Rexroth AG, 4WRPDH,4WRLD; RE B/10.13