Bosch Rexroth ctrlX SAFETY SAFEX-C.12 User manual

Operating instructions

R911405651, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03, Bosch Rexroth AG

ctrlXSAFETY

Compact safety controller

Devices SAFEX-C.12 / SAFEX-C.15

R911405651, Bosch Rexroth AG, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03

The provided data is intended for product

description purposes. If any information on

product use is given, such information may

only be viewed as application examples and

suggestions. Catalog information does not

constitute guaranteed properties. The

information does not release users from the

responsibility to perform their own

assessments and tests. Our products are

subject to a natural wear and aging process.

disposal, utilization, reproduction,

processing, transfer, as well as in the event

of property rights applications.

An example configuration is depicted on the

title page. The delivered product may

therefore differ from the depicted image.

The original operating instruction was

created in German.

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Content

About this documentation 6

1.1

Editions 6

1.2

Validity of the documentation 6

1.3

Required and supplementary documentation 7

1.4

Presentation of information 7

1.4.1

Safety instructions 7

1.4.2

Symbols 8

1.4.3

Terms 9

1.4.4

Abbreviations 9

Safety instructions 10

2.1

About this section 10

2.2

Intended use 10

2.3

Improper use 10

2.4

Qualification of personnel 11

2.5

General safety instructions 11

2.6

Product- and technology-dependent safety instructions 12

2.7

Obligations of the operator 13

General information about property damage and product damage 14

Scope of delivery 15

Delivery condition, identification, transport and storage 16

5.1

Delivery condition 16

5.1.1

Factory inspection 16

5.1.2

Customer-side inspection 16

5.2

Identification 16

5.2.1

Signs 16

5.2.1.1

Location of the signs 16

5.2.1.2

Name plate 17

5.3

Transport of components 18

5.3.1

Ambient and operating conditions - Transport 18

5.4

Storage of components 18

5.4.1

Ambient and operating conditions - Storage 18

Installation, removal, replacement and electrical installation 19

6.1

Installation instructions 19

6.2

Installation of the ctrlX SAFETY controller 21

6.3

Removal of the ctrlX SAFETY controller 21

6.3.1

Removal steps 22

6.3.2

Locking mechanism for mounting on standard DIN rail 23

6.4

Replacement of the ctrlX SAFETY controller 24

6.5

Electrical installation 25

6.5.1

External power supply 25

6.5.2

Voltage supply for the controller 26

6.5.3

Terminal blocks for voltage supply and inputs/outputs 27

6.5.4

Connection of the safe digital inputs and outputs 29

Commissioning 30

7.1

ctrlX SAFETY Engineering 30

7.2

μSD memory card 31

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R911405651, Bosch Rexroth AG, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03

7.3 Switch-on sequence and device status 32

7.4 Reset behavior 34

7.4.1 Reset types and triggering events 34

7.4.2 Reset timing 34

7.4.3 Reset function 35

8Maintenance 37

8.1 Regular maintenance activities 37

9Device type SAFEX-C.12 38

9.1 Device characteristics 38

9.1.1 Safety-related characteristics 38

9.1.2 General technical characteristics 39

9.1.3 Electrical data 40

9.1.4 Ambient data 41

9.1.5 Mechanical data 42

9.2 Device interfaces 43

9.2.1 Interface for voltage supply and inputs/outputs 44

9.2.2 Ethernet interface 1 (XF28 / XF29) 45

9.2.2.1 EtherCAT 45

9.2.2.2 TCP/IP (in preparation) 46

9.2.3 Pin assignment of Ethernet interface 1 (RJ45 sockets) 47

9.2.4 ctrlX SAFETYlink master interface 47

9.2.5 USB-C interface 48

9.3 Device diagnostics 49

10 Device type SAFEX-C.15 53

10.1 Device characteristics 53

10.1.1 Safety-related characteristics 53

10.1.2 General technical characteristics 54

10.1.3 Electrical data 55

10.1.4 Ambient data 56

10.1.5 Mechanical data 57

10.2 Device interfaces 58

10.2.1 Interface for voltage supply and inputs/outputs 59

10.2.2 Ethernet interfaces 60

10.2.3 Ethernet 1 interface (XF28 / XF29) 60

10.2.3.1 EtherCAT 60

10.2.3.2 TCP/IP (in preparation) 61

10.2.4 Ethernet 2 interface (XF30 / XF31) 61

10.2.4.1 EtherCAT / FSoE slave (in preparation) 61

10.2.4.2 PROFINET / PROFIsafe slave (in preparation) 62

10.2.4.3 TCP/IP (in preparation) 62

10.2.5 Pin assignment of the Ethernet interfaces (RJ45 sockets) 63

10.2.6 CtrlX SAFETYlink interface 63

10.2.7 USB-C interface 64

10.3 Device diagnostics 65

10.3.1 Ethernet 1 interface: 68

10.3.2 Ethernet 2 interface: 69

11 Order information 70

11.1 Control device SAFEX-C.12 70

11.2 Control device SAFEX-C.15 70

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11.3

Accessories and spare parts 70

11.4

Wearing parts 72

Additional information 73

12.1

Cable lengths 73

Standards 74

13.1

EU directives 74

13.2

CE marking 75

13.2.1

Declaration of conformity 75

13.3

UL/CSA - Certification 77

Causes and correction of errors 78

General ordering information 79

15.1

Type code 79

15.2

Controller devices 80

15.3

Accessories and spare parts 80

List of abbreviations 81

6/83 ctrlX SAFETY | About this documentation

R911405651, Bosch Rexroth AG, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03

1About this documentation

1.1 Editions

Tabelle 1: Index of editions

Edition No. Edition date Changes

01 2021-01 First edition

02 2021-11 Addition of notes on mechanics and response times

03 2022-01 Addition of accessories and spare parts

1.2 Validity of the documentation

This documentation applies to the following products:

•R911175242 SAFEX-C.12

•R911175243 SAFEX-C.15

This documentation is intended for designers, installers, commissioning engineers,

maintenance technicians, service technicians and waste disposal companies.

This documentation contains important information for the safe and proper installation,

commissioning, operation, use, maintenance, independent troubleshooting of minor faults,

disassembly and disposal of the product.

This manual contains instructions for technical staff of the machine manufacturer for safe

mechanical and electrical installation and commissioning of the controller.

Required qualifications: Person who is able to assess the work assigned to them and

identify potential risks on the basis of their professional training, knowledge and experience,

as well as their knowledge of the relevant standards and regulations.

Read this documentation in its entirety and pay particular attention to Section 2 "Safety

instructions" before working with the product.

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1.3 Required and supplementary documentation

Only commission the product after making sure that the documentation marked with the

book symbol ( ) is available and you have understood and observed it.

Tabelle 2: Required and supplementary documentation

Title Document number Document type

Installation manual ctrlX SAFETY

SAFEX-C.1* devices DOK-XSAFE*-

SAFEX-C.1XC-COxx-DE-P 1)

R911405649 Installation manual

Programming manual for ctrlX

SAFETY SAFEX-C.1* devices with

ctrlX SAFETY Engineering DOK-

XSAFE*-SAFEX-C.1XC-PRxx-DE-P2)

R911405647 Programming manual

Error list / Diagnostic messages for

ctrlX SAFETY SAFEX-C.1* devices

DOK-XSAFE*-SAFEX-C.1XC-RExx-

DE-P 3)

R911406843 Error and diagnostic

reference

Application description for the

integration of the ctrlX SAFETY

SAFEX-C.1* devices in ctrlX

AUTOMATION DOK-XSAFE*-

SAFEX-C.1XC-APxx-DE-P 4)

R911407750 Application description

1) COxx: latest edition of installation manual

2) PRxx: latest edition of programming manual

3) RExx: latest edition of error list / diagnostic messages

4) APxx: latest edition of application description in ctrlX AUTOMATION

1.4 Presentation of information

Uniform safety instructions, symbols, terms and abbreviations are used in this

documentation to make working with your product quick and safe. For better understanding

these are explained in the following sections.

1.4.1 Safety instructions

In this documentation, safety instructions precede action sequences in which there is a risk

of personal injury or property damage. The described safety measures must be adhered to.

Safety instructions are structured as follows:

SIGNAL WORD

Type and source of the danger

Consequences of non-compliance

Safety measure

<List>

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R911405651, Bosch Rexroth AG, DOK-XSAFE*-SAFEX-C.1XC-IT03-EN-P, Edition 03

•Warning sign: draws attention to the danger

•Signal word: indicates the severity of the danger

•Type and source of danger: identifies the type and source of the danger

•Consequences: describes the consequences of non-compliance

•Protection: indicates how to avert the danger

Tabelle 3: Hazard classes according to ANSI Z535.6-2006

Warning sign, signal word Meaning

DANGER

indicates a hazardous situation which, if not avoided, will

result in death or serious injury

WARNING

indicates a hazardous situation which, if not avoided, could

result in death or serious injury

CAUTION

indicates a hazardous situation which, if not avoided, could

result in minor to moderate injury

NOTE

indicates property damage: Damage to the product or the

environment could occur.

1.4.2 Symbols

The following symbols indicate information that is not related to safety, but instead improves

your understanding of the documentation.

Tabelle 4: Meaning of the symbols

Symbol Meaning

If this information is not observed, the product cannot be used or operated

optimally.

This is a note.

individual, independent action step

numbered instructions for action:

The digits indicate that the action steps are sequential.

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1.4.3 Terms

The following terms are used in this documentation:

The term “safe” is used in accordance with/within the meaning of the following standards:

DIN EN ISO 13849-1, DIN EN 61508-1:2011-02 (cf. the Relevant standards section). The

term “safe function for application up to PL e/SIL 3” specifies functions with appropriate

integrity (reliability) within the meaning of the standards mentioned above.

The ctrlX SAFETY controllers are devices for the implementation of safety-related functions

with safe communication via FSoE and non-safety-related data communication via

EtherCAT. These are internally structured as two channels: System A and System B.

The “ctrlX SAFETY Engineering” system software is used for the programming and

configuration of ctrlX SAFETY controllers, ctrlX DRIVE

plus

and 3rd party FSoE devices. It

implements safety-oriented functions.

Tabelle 5: Terms

Term Meaning

ctrlX SAFETY refers to the compact safety controllers SAFEX-C.12 / SAFEX-C.15

in the document

ctrlX SAFETY

link

master

interface

is a safe communication interface between a ctrlX SAFETY

(SAFEX-C.1*) controller and a ctrlX DRIVE

plus

drive

EtherCAT® is a registered trademark and patented technology,

licensed via Beckhoff Automation GmbH, Germany.

Safety over EtherCAT® is a registered trademark and patented

technology, licensed via Beckhoff Automation GmbH, Germany.

E /PE Programmable electronic controller/programmable electronic system

POR Power Off Reset, reset by switching the voltage supply off and on

SAFEX-C.1* Compact safety controller ctrlX SAFETY, safety master and slave

SMMC Safe master-to-master communication

SRP/CS Safety related parts of control systems

1.4.4

Abbreviations

The abbreviations used in this documentation can be found in the List of abbreviations

section at the end of this documentation.

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2Safety instructions

2.1 About this section

The product has been developed, tested and manufactured in accordance with generally

accepted rules of technology. Nevertheless, there is a risk of personal injury and property

damage if the safety instructions in this documentation and this section are not observed.

Read the documentation listed in Section 1.2 thoroughly and completely before working

with the product.

Store the documentation in such a way that it is accessible to all users at all times.

Always pass the product on to third parties together with the necessary documentation.

2.2 Intended use

The product is a programmable safety controller.

You may use the product as follows:

•for provision safety shut-off systems and safety functions

•as a safety component within the meaning of the Machinery Directive 2006/42/EC,

•as an E/PE for risk reduction within the meaning of IEC 61508,

•in safety circuits according to EN 60204-1 and EN 60204-32,

•as an E/PE for functional safety within the meaning of 62061,

•as SRP/CS (see abbr.) within the meaning of EN 13849,

•as a device for the provision of safety functions according to EN 61800-5-2,

•as a logic unit for signal conversion and processing in two-hand controls according to EN

574.

The device is a safety component according to Annex IV of the EU Directive 2006/42/EC

(Machinery Directive). It was developed, designed and manufactured in accordance with the

above-mentioned directive, as well as EU Directive 2014/30/EU (EMC Directive)

The product is intended for professional use only and not for private use.

Intended use also includes and requires fully reading and understanding this documentation

and, in particular, the 2 “Safety instructions section.

2.3 Improper use

Any use other than the use described in the Intended use section is considered improper

use and is therefore not permitted.

If unsuitable products are installed or used in safety-related applications, this could lead to

the occurrence of unintended operating conditions in the application, which could cause

personal injury and/or property damage. Therefore, only use products in safety-related

applications if such use is explicitly specified and permitted in the product documentation.

For example, in EX-protected areas or in safety-related parts of a controller (functional

safety).

Bosch Rexroth AG disclaims liability for damage caused by improper use. All risks

associated with improper use are borne solely by the user.

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