31700802

Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Rexroth IndraWorks R911317008

Edition 02
Simulation
Application Description
Bosch Rexroth AG | Electric Drives Rexroth IndraWorks | Application Description
and Controls
Title Rexroth IndraWorks

Simulation
Type of Documentation Application Description
Document Typecode DOK-IWORKS-SIMU****V01-AW02-EN-P
Internal File Reference RS-de78b78b0a6846ac009c70d0829c30df-2-en-US-2
Purpose of Documentation This documentation describes the functions of simulation component View3D,
virtual control panel, virtual control and its operation in IndraWorks.
Record of Revision Edition Release Date Notes

120-2700-B304-01/EN 06.2006 First edition
120-2700-B304-02/EN 10.2006 Supplements
Copyright © 2006 Bosch Rexroth AG

Copying this document, giving it to others and the use or communication of the
contents thereof without express authourity, 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).
Validity 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.
Published by Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 ■ D-97816 Lohr a. Main
Phone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85
http://www.boschrexroth.com/
Dept. BRC/ESM4 (MiBr), BRC/ESM6 (DiLe)
Note This document has been printed on chlorine-free bleached paper.
Application Description | Rexroth IndraWorks Electric Drives | Bosch Rexroth AG I/III
and Controls
Table of Contents
Table of Contents
Page
1 General.......................................................................................................................... 1
1.1 Why Simulation?..................................................................................................................................... 1
1.2 What is Simulated?................................................................................................................................. 1
1.3 Goals of Simulation in IndraWorks......................................................................................................... 1
2 Important Instructions on Use........................................................................................ 3

2.1 Intended Use.......................................................................................................................................... 3
2.1.1 Introduction.......................................................................................................................................... 3
2.1.2 Area of Use and Application ............................................................................................................... 3
2.2 Improper Use.......................................................................................................................................... 3
3 Safety Instructions for Electric Drives and Controls ...................................................... 5

3.1 Safety Instructions - General Information............................................................................................... 5
3.1.1 Using the Safety Instructions and Passing them on to Others............................................................ 5
3.1.2 How to Employ the Safety Instructions................................................................................................ 5
3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness.............................................. 6
3.1.4 Hazards by Improper Use.................................................................................................................... 7
3.2 Instructions with Regard to Specific Dangers......................................................................................... 8
3.2.1 Protection Against Contact with Electrical Parts and Housings........................................................... 8
3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage................................................... 9
3.2.3 Protection Against Dangerous Movements......................................................................................... 9
3.2.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 12
3.2.5 Protection Against Contact with Hot Parts......................................................................................... 12
3.2.6 Protection During Handling and Mounting......................................................................................... 12
3.2.7 Battery Safety.................................................................................................................................... 13
3.2.8 Protection Against Pressurized Systems........................................................................................... 13
4 Quick Start................................................................................................................... 15
5 Components of the Simulation .................................................................................... 17

5.1 Project Explorer ................................................................................................................................... 17
5.2 3D Visualization.................................................................................................................................... 17
5.2.1 General Description........................................................................................................................... 17
5.2.2 Model Visualization ........................................................................................................................... 19
Basic functions............................................................................................................................... 19
Functions for manipulating 3D objects .......................................................................................... 21
5.2.3 Scene Tree ....................................................................................................................................... 21
General........................................................................................................................................... 21
Object properties ........................................................................................................................... 22
Assignment..................................................................................................................................... 23
5.2.4 OPC Configuration ........................................................................................................................... 23
5.2.5 Assignment List ................................................................................................................................ 24
5.2.6 Properties of the View3D Model ....................................................................................................... 25
II/III Bosch Rexroth AG | Electric Drives Rexroth IndraWorks | Application Description
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Table of Contents
Page
5.3 Virtual User Panel................................................................................................................................. 25
5.3.2 Configurator....................................................................................................................................... 26
5.3.3 The Application.................................................................................................................................. 27
5.4 Virtual Control....................................................................................................................................... 27
6 Operation in IndraWorks.............................................................................................. 29
6.1 Creating a Model.................................................................................................................................. 29
6.1.1 General.............................................................................................................................................. 29
6.1.2 Creating a Simple 3D Model ............................................................................................................. 29
6.1.3 Importing eM-RealNC Models .......................................................................................................... 29
6.2 Using the Virtual User Panel................................................................................................................. 29
6.2.1 Configuration..................................................................................................................................... 29
Configuration in IndraWorks........................................................................................................... 29
Supplements to the configuration file ............................................................................................ 30
6.2.2 Connection to Virtual Control ............................................................................................................ 31
6.2.3 Start................................................................................................................................................... 32
6.2.4 Error Messages and Remedies......................................................................................................... 32
6.3 Using 3D Visualization.......................................................................................................................... 32
6.3.1 3D Models in IndraWorks.................................................................................................................. 32
Importing 3D models ..................................................................................................................... 32
Opening, renaming and deleting 3D models ................................................................................. 34
6.3.2 Process Connection.......................................................................................................................... 34
Connecting 3D objects with IndraMotion MTX axis values ............................................................ 34
Configuring the process connection .............................................................................................. 34
Establishing a connection to the control ........................................................................................ 36
6.3.3 3D Visualization Operation................................................................................................................ 36
Basic 3D visualization functions .................................................................................................... 36
Manipulating 3D objects ................................................................................................................ 37
Changing settings of the View3D model ........................................................................................ 37
6.4 Using the Virtual Control....................................................................................................................... 37
6.4.1 Installation of MTX Emulation............................................................................................................ 37
General........................................................................................................................................... 37
6.4.2 Projecting Emulation.......................................................................................................................... 38
Restoring an existing project.......................................................................................................... 38
6.4.3 Projecting the HMI............................................................................................................................. 38
General........................................................................................................................................... 38
6.4.4 Designing the NC Core...................................................................................................................... 40
General........................................................................................................................................... 40
6.4.5 Projecting the PLC............................................................................................................................. 44
General........................................................................................................................................... 44
6.4.6 Starting and Exiting MTX Emulation.................................................................................................. 46
General........................................................................................................................................... 46
6.4.7 Starting Operation Desktop............................................................................................................... 47
Application Description | Rexroth IndraWorks Electric Drives | Bosch Rexroth AG III/III
and Controls
Table of Contents
Page
7 Communication............................................................................................................ 49
7.1 OPC...................................................................................................................................................... 49
7.2 SCP...................................................................................................................................................... 49
8 Service & Support........................................................................................................ 51

8.1 Helpdesk............................................................................................................................................... 51
8.2 Service Hotline...................................................................................................................................... 51
8.3 Internet.................................................................................................................................................. 51
8.4 Helpful Information................................................................................................................................ 51
Index............................................................................................................................ 53
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Application Description | Rexroth IndraWorks Electric Drives | Bosch Rexroth AG 1/53
and Controls
General
1 General
1.1 Why Simulation?
Due to the ever-increasing competitive pressure among the manufacturers of
machines, we are always looking for new ways of minimizing the costs for a
machine project. This includes every phase of the machine life cycle (construc‐
tion, commissioning, production). Due to more and more powerful computer
systems, simulation is becoming more and more important: in the future, there
may even be virtual factories in which all the processes of a production plant
can be reproduced virtually. One component of this virtual factory is the virtual
machine, which can be used, with the help of suitable simulation tools, to sup‐
port the individual phases of the machine life cycle.
1.2 What is Simulated?

There are suitable simulation techniques for every phase of the machine life
cycle. These simulation techniques are clearly delimited from one another, but
also have shared points of intersection, such as the transfer of construction data
for the machine from the CAD system to the 3D visualization system.
For example, FEM (Finite Element Method) analysis or MBS (Multi-Body Sim‐
ulation) analysis is used in the construction phase of a machine, while the
commissioning phase is more concerned with behavioral simulation. For pro‐
duction, on the other hand, process optimization (e.g. cycle time optimization)
is in the foreground.
Now, if we examine the simulation techniques during the commissioning phase,
we can make a further distinction. On the one hand, there is hardware-in-the-
loop simulation; on the other, there is software-in-the-loop simulation.
Hardware-in- In this simulation technique, a real control is a component of
the-loop the simulation setup. All other components are simulated on
one or more computers. Communication between the real con‐
trol and the simulation components is implemented using, for
example, Profibus slave cards.
Software-in- In this simulation technique, all the components are simulated
the-loop on one or more computers.
1.3 Goals of Simulation in IndraWorks

The emphasis for applying simulation techniques at Bosch Rexroth in the area
of system development for Motion Control lies on optimizing the commissioning
of controls and machine tools. This involves mainly behavioral simulation, such
as tests of the PLC program or of the NC program.
Components such as a virtual control (NC and PLC), a virtual control panel,
virtual drives, a 3D viewer and a peripherals simulation (I/O simulation) are
required to attain this goal. Only the interplay of all these components permits
effective behavioral simulation.
In addition to the shortening of commissioning times, however, there are other
areas of application for simulation that result in cost and time savings for the
user.
● Demonstrator for sales at the customer location
● Testing program procedures (both CNC and PLC)
● Setting the parameters of the control and the drives
● Application for training purposes
2/53 Bosch Rexroth AG | Electric Drives Rexroth IndraWorks | Application Description
and Controls
General
● Reproduction of problems (trouble-shooting)

● Validation of error solutions
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Important Instructions on Use
2 Important Instructions on Use

2.1 Intended Use
2.1.1 Introduction
The Bosch Rexroth products are developed and manufactured according to the
latest state of the art. Before delivery, they are checked for operational safety.
The products may only be used in the proper manner. When they are not used
as intended, situations may arise which result in damage to person or material.
Bosch Rexroth, as the manufacturer of the products, will not as‐

sume any warranty, liability or payment of damages in case of
damage resulting from a non-intended use of the products. If he
fails to use the products as intended, the user will be solely respon‐
sible for any resulting risks.
Before using the Bosch Rexroth products, the following prerequisites must be
fulfilled to ensure that they are used as intended:
● Everyone who in any way deals with one of our products must read and
understand the corresponding notes regarding safety and regarding prop‐
er use.
● If the products are hardware, they must be kept in their original state, i.e.
no constructional modifications may be made. Software products may not
be decompiled; their source codes may not be modified.
● Damaged or improperly working products must not be installed or put into
operation.
● It must be ensured that the products are installed according to the regu‐
lations mentioned in the documentation.
2.1.2 Area of Use and Application

In IndraWorks, simulation tools are used to
● Shorten the response times
● verify the application programs
● visualize the machine cinematics
The simulation consists of several components which must be com‐

patible to each other.
The virtual control panel is used in connection with the control emulation. During
utilizing the virtual control panel of the real control it has to be considered that
the signals can not arrive between virtual control panel and control because of
communication errors. Therefore a PLC program and a producing machine can
no longer be stopped via control.
2.2 Improper Use

Using the devices outside of the above-referenced areas of application or under
operating conditions other than described in the document and the technical
data specified is defined as "inappropriate use".
The Rexroth simulation tools may not be used if
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Important Instructions on Use
● Bosch Rexroth has not specifically released them for that intended pur‐
pose. In this connection, observance of the statements in the General
Safety Notes is imperative!
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Safety Instructions for Electric Drives and Controls
3 Safety Instructions for Electric Drives and Controls

3.1 Safety Instructions - General Information
3.1.1 Using the Safety Instructions and Passing them on to Others
Do not attempt to install or commission this device without first reading all doc‐
umentation provided with the product. Read and understand these safety
instructions and all user documentation prior to working with the device. If you
do not have the user documentation for the device, contact your responsible
Bosch Rexroth sales representative. Ask for these documents to be sent im‐
mediately to the person or persons responsible for the safe operation of the
device.
If the device is resold, rented and/or passed on to others in any other form,
these safety instructions must be delivered with the device in the official lan‐
guage of the user's country.
Improper use of these devices, failure to follow the safety instructions in

this document or tampering with the product, including disabling of safe‐
ty devices, may result in material damage, bodily harm, electric shock
WARNING or even death!
Observe the safety instructions!
3.1.2 How to Employ the Safety Instructions

Read these instructions before initial commissioning of the equipment in order
to eliminate the risk of bodily harm and/or material damage. Follow these safety
instructions at all times.
● Bosch Rexroth AG is not liable for damages resulting from failure to ob‐
serve the warnings provided in this documentation.
● Read the operating, maintenance and safety instructions in your language
before commissioning the machine. If you find that you cannot completely
understand the documentation for your product, please ask your supplier
to clarify.
● Proper and correct transport, storage, assembly and installation, as well
as care in operation and maintenance, are prerequisites for optimal and
safe operation of this device.
● Only assign trained and qualified persons to work with electrical installa‐
tions:
– Only persons who are trained and qualified for the use and operation
of the device may work on this device or within its proximity. The
persons are qualified if they have sufficient knowledge of the assem‐
bly, installation and operation of the product, as well as an under‐
standing of all warnings and precautionary measures noted in these
instructions.
– Furthermore, they must be trained, instructed and qualified to switch
electrical circuits and devices on and off in accordance with technical
safety regulations, to ground them and to mark them according to the
requirements of safe work practices. They must have adequate safe‐
ty equipment and be trained in first aid.
● Only use spare parts and accessories approved by the manufacturer.
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● Follow all safety regulations and requirements for the specific application
as practiced in the country of use.
● The devices have been designed for installation in industrial machinery.
● The ambient conditions given in the product documentation must be ob‐
served.
● Only use safety-relevant applications that are clearly and explicitly ap‐
proved in the Project Planning Manual. If this is not the case, they are
excluded. Safety-relevant are all such applications which can cause dan‐
ger to persons and material damage.
● The information given in the documentation of the product with regard to
the use of the delivered components contains only examples of applica‐
tions and suggestions.
The machine and installation manufacturer must
– make sure that the delivered components are suited for his individual
application and check the information given in this documentation
with regard to the use of the components,
– make sure that his application complies with the applicable safety
regulations and standards and carry out the required measures,
modifications and complements.
● Commissioning of the delivered components is only permitted once it is
sure that the machine or installation in which they are installed complies
with the national regulations, safety specifications and standards of the
application.
● Operation is only permitted if the national EMC regulations for the appli‐
cation are met.
● The instructions for installation in accordance with EMC requirements can
be found in the section on EMC in the respective documentation (Project
Planning Manuals of components and system).
The machine or installation manufacturer is responsible for compliance
with the limiting values as prescribed in the national regulations.
● Technical data, connection and installation conditions are specified in the
product documentation and must be followed at all times.
National regulations which the user must take into account
● European countries: according to 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)
3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness

The safety instructions describe the following degrees of hazard seriousness.
The degree of hazard seriousness informs about the consequences resulting
from non-compliance with the safety instructions:
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Warning symbol Signal word Degree of hazard seriousness acc. to ANSI Z 535.4-2002
Danger Death or severe bodily harm will occur.
Warning Death or severe bodily harm may occur.
Minor or moderate bodily harm or material damage may

Caution
occur.
Fig.3-1: Hazard classification (according to ANSI Z 535)
3.1.4 Hazards by Improper Use

High electric voltage and high working current! Risk of death or severe
bodily injury by electric shock!
DANGER
Dangerous movements! Danger to life, severe bodily harm or material

damage by unintentional motor movements!
DANGER
High electric voltage because of incorrect connection! Risk of death or

bodily injury by electric shock!
WARNING
Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electrical equipment!
WARNING
Hot surfaces on device housing! Danger of injury! Danger of burns!

CAUTION
Risk of injury by improper handling! Risk of bodily injury by bruising,

shearing, cutting, hitting or improper handling of pressurized lines!
CAUTION
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Risk of injury by improper handling of batteries!

CAUTION
3.2 Instructions with Regard to Specific Dangers

3.2.1 Protection Against Contact with Electrical Parts and Housings
This section concerns devices and drive components with voltages
of more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal
danger and electric shock. When operating electrical equipment, it is unavoid‐
able that some parts of the units conduct dangerous voltage.
High electrical voltage! Danger to life, electric shock and severe bodily
injury!
● Only those trained and qualified to work with or on electrical equipment
DANGER are permitted to operate, maintain and repair this equipment.
● Follow general construction and safety regulations when working on elec‐
trical power installations.
● Before switching on the device, the equipment grounding conductor must
have been permanently connected to all electrical equipment in accord‐
ance with the connection diagram.
● Do not operate electrical equipment at any time, even for brief measure‐
ments or tests, if the equipment grounding conductor is not permanently
connected to the mounting points of the components provided for this
purpose.
● Before working with electrical parts with voltage potentials higher than
50 V, the device must be disconnected from the mains voltage or power
supply unit. Provide a safeguard to prevent reconnection.
● For electrical drive and filter components, observe the following:
Wait 30 minutes after switching off power to allow capacitors to dis‐
charge before beginning to work. Measure the electrical voltage on the
capacitors before beginning to work to make sure that the equipment is
safe to touch.
● Never touch the electrical connection points of a component while power
is turned on.
● Install the covers and guards provided with the equipment properly before
switching the device on. Before switching the equipment on, cover and
safeguard live parts safely to prevent contact with those parts.
● A residual-current-operated circuit-breaker or r.c.d. cannot be used for
electric drives! Indirect contact must be prevented by other means, for
example, by an overcurrent protective device according to the relevant
standards.
● Secure built-in devices from direct touching of electrical parts by providing
an external housing, for example a control cabinet.
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For electrical drive and filter components with voltages of more than
50 volts, observe the following additional safety instructions.
High housing voltage and high leakage current! Risk of death or bodily
injury by electric shock!
● Before switching on, the housings of all electrical equipment and motors
DANGER must be connected or grounded with the equipment grounding conductor
to the grounding points. This is also applicable before short tests.
● The equipment grounding conductor of the electrical equipment and the
devices must be non-detachably and permanently connected to the power
supply unit at all times. The leakage current is greater than 3.5 mA.
● Over the total length, use copper wire of a cross section of a minimum of
10 mm2 for this equipment grounding connection!
● Before commissioning, also in trial runs, always attach the equipment
grounding conductor or connect to the ground wire. Otherwise, high vol‐
tages may occur at the housing causing electric shock.
3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage

Protective extra-low voltage is used to allow connecting devices with basic in‐
sulation to extra-low voltage circuits.
All connections and terminals with voltages between 5 and 50 volts at Rexroth
products are PELV systems. 1) It is therefore allowed to connect devices
equipped with basic insulation (such as programming devices, PCs, notebooks,
display units) to these connections and terminals.
High electric voltage by incorrect connection! Risk of death or bodily

injury by electric shock!
If extra-low voltage circuits of devices containing voltages and circuits of more
WARNING than 50 volts (e.g. the mains connection) are connected to Rexroth products,
the connected extra-low voltage circuits must comply with the requirements for
PELV. 2)
3.2.3 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:
● improper or wrong wiring of cable connections
● incorrect operation of the equipment components
● wrong input of parameters before operation
● malfunction of sensors, encoders and monitoring devices
● 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.
1) “Protective Extra-Low Voltage”

2) “Protective Extra-Low Voltage”
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The monitoring in the drive components will normally be sufficient to avoid faulty
operation in the connected drives. Regarding personal safety, especially the
danger of bodily harm and/or material damage, 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 movements depends upon the type of control and the
state of operation.
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Dangerous movements! Danger to life, risk of injury, severe bodily harm

or material damage!
● For the above reasons, ensure personal safety by means of qualified and
DANGER tested higher-level monitoring devices or measures integrated in the in‐
stallation.
They have to be provided for by the user according to the specific condi‐
tions within the installation and a hazard and fault analysis. The safety
regulations applicable for the installation have to be taken into consider‐
ation. Unintended machine motion or other malfunction is possible if safety
devices are disabled, bypassed or not activated.
To avoid accidents, bodily harm and/or material damage:
● Keep free and clear of the machine’s range of motion and moving parts.
Possible measures to prevent people from accidentally entering the
machine’s range of motion:
– use safety fences
– use safety guards
– use protective coverings
– install light curtains or light barriers
● Fences and coverings must be strong enough to resist maximum possible
momentum.
● Mount the emergency stop switch in the immediate reach of the operator.
Verify that the emergency stop works before commissioning. Do not op‐
erate the device if the emergency stop switch is not working.
● Isolate the drive power connection by means of an emergency stop circuit
or use a safety related starting lockout to prevent unintentional start.
● Make sure that the drives are brought to a 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 equilibration of the vertical axes.
● The standard equipment motor brake or an external brake controlled by
the drive controller are not sufficient to guarantee personal safety!
● Disconnect electrical power to the equipment using a master switch and
secure the switch against reconnection 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 electronics circuits and supply leads. If the use of such devices
cannot be avoided, verify the system and the installation for possible mal‐
functions in all possible positions of normal use before initial commission‐
ing. If necessary, perform a special electromagnetic compatibility (EMC)
test on the installation.
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3.2.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐

ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors
and permanent magnets in motors represent a serious personal danger to
those with heart pacemakers, metal implants and hearing aids.
Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electrical equipment!
● Persons with heart pacemakers and metal implants are not permitted to
WARNING enter following areas:
– Areas in which electrical equipment and parts are mounted, being
operated or commissioned.
– Areas in which parts of motors with permanent magnets are being
stored, repaired or mounted.
● If it is necessary for somebody with a pacemaker to enter such an area,
a doctor must be consulted prior to doing so. The noise immunity of pres‐
ent or future implanted heart pacemakers differs greatly so 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. Oth‐
erwise health hazards may occur.
3.2.5 Protection Against Contact with Hot Parts

Hot surfaces at motor housings, on drive controllers or chokes! Danger
of injury! Danger of burns!
● Do not touch surfaces of device housings and chokes in the proximity of
CAUTION heat sources! Danger of burns!
● Do not touch housing surfaces of motors! Danger of burns!
● According to the operating conditions, temperatures can be higher than
60 °C, 140 °F during or after operation.
● Before accessing motors after having switched them off, let them cool
down for a sufficiently long time. Cooling down can require up to 140 mi‐
nutes! Roughly estimated, the time required for cooling down is five times
the thermal time constant specified in the Technical Data.
● After switching drive controllers or chokes off, wait 15 minutes to allow
them to cool down before touching them.
● Wear safety gloves or do not work at hot surfaces.
● For certain applications, the manufacturer of the end product, machine or
installation, according to the respective safety regulations, has to take
measures to avoid injuries caused by burns in the end application. These
measures can be, for example: warnings, guards (shielding or barrier),
technical documentation.
3.2.6 Protection During Handling and Mounting

In unfavorable conditions, handling and mounting certain parts and compo‐
nents in an improper way can cause injuries.
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Risk of injury by improper handling! Bodily injury by bruising, shearing,

cutting, hitting!
● Observe the general construction and safety regulations on handling and
CAUTION mounting.
● Use suitable devices for mounting and transport.
● Avoid jamming and bruising by appropriate measures.
● Always use suitable tools. Use special tools if specified.
● Use lifting equipment and tools in the correct manner.
● If necessary, use suitable protective equipment (for example safety gog‐
gles, safety shoes, safety gloves).
● Do not stand under hanging loads.
● Immediately clean up any spilled liquids because of the danger of skidding.
3.2.7 Battery Safety

Batteries consist of active chemicals enclosed in a solid housing. Therefore,
improper handling can cause injury or material damage.
Risk of injury by improper handling!

● Do not attempt to reactivate low batteries by heating or other methods (risk
of explosion and cauterization).
CAUTION ● Do not 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 electrical parts in‐
stalled in the devices.
● Only use the battery types specified by the manufacturer.
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 separate from other waste. Observe the
local regulations in the country of assembly.
3.2.8 Protection Against Pressurized Systems

According to the information given in the Project Planning Manuals, motors
cooled with liquid and compressed air, as well as drive controllers, can be par‐
tially supplied with externally fed, pressurized media, such as compressed air,
hydraulics oil, cooling liquids and cooling lubricating agents. Improper handling
of the connected supply systems, supply lines or connections can cause injuries
or material damage.
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Risk of injury by improper handling of pressurized lines!

● Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐
sion).
CAUTION ● Observe the respective manufacturer's operating instructions.
● Before dismounting lines, relieve pressure and empty medium.
● Use suitable protective equipment (for example safety goggles, safety
shoes, safety gloves).
● Immediately clean up any spilled liquids from the floor.
Environmental protection and disposal! The agents used to operate

the product might not be economically friendly. Dispose of ecolog‐
ically harmful agents separately from other waste. Observe the local
regulations in the country of assembly.
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Quick Start
4 Quick Start
In the following, the execution sequence that makes it possible to sensibly op‐
erate the various simulation components of IndraWorks is described for an
IndraMotion MTX project. It is not suitable for a user who has no prior knowledge
of the simulation components. The inexperienced user should first read the
entire documentation to become familiar with the subject matter.
Execute the following steps to be able to simulate an IndraMotion MTX project
on a PC:
1. Start IndraWorks using the link on the desktop
2. Load the desired IndraMotion MTX project into IndraWorks
3. Start the IndraMotion MTX emulation (also see chapter 6.4.6 "Starting
and Exiting MTX Emulation" on page 46)
4. Set the communication settings for the IndraMotion MTX and the PLC to
“localhost”.
5. The PLC must be stopped.
6. The NC kernel data must be restored (also see chapter 6.4.4 "Designing
the NC Core" on page 40).
7. The PLC program must be loaded and started (also see chapter 6.4.5
"Projecting the PLC" on page 44)
8. Activate the IndraWorks project for Operation Desktop (also see chapter
6.4.3 "Projecting the HMI" on page 38)
9. Create the virtual control panel in IndraWorks Engineering (also see
chapter "Creating a Virtual User Panel" on page 29) and configure it
(also see chapter 6.2.1 "Configuration" on page 29)
10. Start the Windows program “Virtual Control Panel” (also seechapter 6.2.2
"Connection to Virtual Control " on page 31).
You can find detailed information about IndraMotion MTX emulation

in the “Virtual Commissioning of the MTX” chapter of the documen‐
tation “IndraMotion MTX Commissioning”.
If a machine model exists, it can be loaded into the 3D viewer and controlled
using data from the emulation via OPC. To do this, proceed as follows:
1. Add a new model to the project (also see chapter "Importing 3D models "
on page 32)
2. Link the OPC items to the objects of the model (also see chapter "Con‐
necting 3D objects with IndraMotion MTX axis values " on page 34)
3. Start the simulation of the model in IndraWorks
and Controls
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Components of the Simulation
5 Components of the Simulation

5.1 Project Explorer
The simulation components can be found in the Project Explorer in the node
Simulation -> 3D Visualization.
Fig.5-1: Project Explorer

Project node Simulation Within node Simulation, you can find the entry Virtual Control Panel, which can
be used to open the Configuration dialog box of the Virtual Control Panel.
If the node Simulation and/or the entry Virtual Control Panel does
not exist, it can be added as follows using the project node:
● Call menu item Add... in the contextual menu of the project
node.
● In the dialog box Add new element, open the template Virtual
Control Panel from the category Virtual Components.
The entry Virtual Control Panel is added to the project tree
within the node Simulation.
Project node 3D Visualization Node 3D Visualization can be used to access 3D models of the View3D appli‐
cation.
New 3D models can be added using the contextual menu Add... on node 3D
Visualization.
See also chapter "Handling instruction: Importing a 3D model" on page 32.
If node 3D Visualization does not exist, a new 3D model can be

added using the contextual menu Add... of the project node. See
also chapter "Handling instruction: Importing a 3D model" on page
32.
A View3D model can be opened using the contextual menu Open ... of the
corresponding node in the Project Explorer or by double-clicking it.
Furthermore, models can be renamed or deleted in the Project Explorer.
See also chapter "Opening, renaming and deleting 3D models " on page
34.
5.2 3D Visualization
5.2.1 General Description
The View3D 3D visualization system is used to represent a machine model as
a three-dimensional volume model (3D scene).
and Controls
Individual objects in the 3D scene can be combined with process values of the
IndraMotion MTX within View3D. If the NC program of the machine is executed
using the virtual control (also seechapter 5.4 "Virtual Control" on page 27),
the axis movements of the machine can be traced in the three-dimensional
machine model.
Additional functions in View3D include:
● Rotating a 3D scene
● Zoom function
● Wireframe representation
● Saving of camera positions (viewpoints)
Fig.5-2: View3D in IndraWorks

The View3D application consists of the following 4 areas:
1. 3D view
The 3D view is used to display the 3D scene (see chapter 5.2.2 "Model
Visualization " on page 19).
2. Scene tree
The scene tree represents the logical and kinematic structure of the scene.
Individual objects of the model can be marked for further processing in the
scene tree (for example, objects can be hidden in the 3D view).
and Controls
See chapter 5.2.3 "Scene Tree " on page 21.

3. OPC server
You can access the OPC server of the control in order to communicate
with the IndraMotion MTX here (see chapter 5.2 "3D Visualization" on
page 17).
4. OPC assignment list
The assignments between the 3D model and the process values (OPC
items) of the control are shown in the OPC assignment list (see chapter
5.2 "3D Visualization" on page 17).
Switching languages in View3D To change the language in View3D, use the IndraWorks language switching
method.
In the current version, portions of View3D are available only in Eng‐

lish.
5.2.2 Model Visualization

Basic functions
Coordinate system The following figure shows the basic arrangement of the main coordinate sys‐
tem of a View3D model.
and Controls
Fig.5-3: Coordinate system

Marking 3D objects An object can be marked by clicking the left mouse button; this is indicated by
a yellow frame. A marked object is also highlighted in the scene tree. Con‐
versely, clicking the left mouse button on a part of the scene tree highlights the
corresponding part in the model with a yellow frame.
The marking can be removed by clicking the left mouse button on a blank space
outside of the model.
Rotating a 3D scene To allow the 3D model to be viewed from every perspective, the 3D scene can
be rotated.
● Mouse operation
If the mouse is moved within the 3D view with the left mouse button held
down, the model rotates according to the mouse movements. If the mouse
is moved to the left or right, the model rotates around the Y-axis. If the
mouse is moved up or down, the model rotates around the X-axis.
● Keyboard operation
The model can be rotated around the Y-axis using keys <Ins> and
<Del>.
Moving a 3D scene To position the 3D model, the 3D scene can be moved in View3D.
and Controls
If the mouse is moved within the 3D view with the center mouse button held
down, the 3D scene is positioned according to the mouse movement.
Zooming a 3D scene To be able to better see the details in the 3D model, you can zoom into the 3D
scene.
● Mouse operation
If the mouse is moved within the 3D view with the right mouse button held
down, the view “zooms” into the 3D scene. Moving the mouse upwards
zooms out of the model. Moving the mouse downwards zooms into the
model.
● Keyboard operation
You can zoom within the 3D view using the <PgUp> and <PgDn> keys.
Pressing the <PgUp> key zooms into the model; pressing the <PgDn> key
zooms out of the model.
Functions for manipulating 3D objects
Control reset Pressing key <Pos 1> moves the 3D scene into a predefined camera position.
This is an internal basic setting that cannot be changed.
For these functions, the entry Rendering always active must have
been switched on in dialog box Model properties (also see chapter
5.2.6 "Properties of the View3D Model " on page 25).
Moving/rotating objects To move an object, it must be marked beforehand. Then press one of the keys
<X>, <Y> or <Z> to select the desired axis direction for the move. In addition,
you must now move the mouse (with the left mouse button held down) to the
left or right in order to move the object.
If you press and hold the right mouse button instead of the left one, the object
is rotated around the selected axis.
Saving camera positions Keys <0> to <9> can be used to save and call 10 different camera positions.
To do this - see the explanation in chapter "Basic functions" on page 19 - the
camera position is changed and then saved using key combination <Ctrl+num‐
ber>.
A camera position (viewpoint) can be called again by pressing one of the keys
<0> to <9>.
Explosion/implosion Pressing the <End> key brings manipulated objects back to the basic position
(implosion).
If you then press the <E> key, the objects move back to the manipulated posi‐
tion (explosion).
5.2.3 Scene Tree

General
The object structure of the 3D scenes is shown in the scene tree. Each indi‐
vidual kinematics object has 6 degrees of freedom: X-Y-Z translation and X-Y-
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Z rotation. The degrees of freedom are a component of the objects listed in the
tree, but are not shown explicitly. The individual nodes of the tree have a
checkbox with which they can shown or hidden in the 3D model. If an OPC item
is assigned to at least one of the degrees of freedom of the kinematics object,
the corresponding icon in the tree node changes.
Fig.5-4: Scene tree

Object properties
The properties of a 3D object can be changed using the Object properties dialog
box.
Fig.5-5: Object properties

The dialog box can be opened by calling contextual menu Properties for a 3D
object in the scene tree.
The menu item is active only if the selected node has subnodes.
and Controls
The point of rotation and the angle of a kinematics object can be modified in
the Object properties dialog box.
Also see chapter "Handling instruction: Rotating a View3D object around a
user-defined point of rotation" on page 35 and chapter "Handling instruction:
Moving a View3D object in any direction in space" on page 35
Assignment
Using drag-and-drop, an OPC item can be assigned to a degree of freedom of
a kinematics object. If an OPC item from the OPC tree is dropped onto a node
of the scene tree, the following dialog box opens.
Fig.5-6: Assigning an object

The dialog box contains a selection box in which you must specify precisely to
which of the 6 degrees of freedom the OPC item is assigned. An offset, which
is included in the calculation of the OPC item's value, can also be specified.
5.2.4 OPC Configuration

The OPC Server window is used to access process data via an OPC server.
All the OPC servers that are locally installed on the computer are located in
node “Local”. Use tree node “Manual” to explicitly search the network for a
computer whose locally installed OPC servers are listed.
All standard OPC items of an OPC server are listed in the node called “Basic
Items”. The items of the IndraMotion MTX OPC servers (OPC.IwSCP.1) are
grouped into “NC Axes”, “NC Corrections” and “NC Spindles”.
and Controls
Fig.5-7: OPC server

The contextual menu of node “Manual” contains menu items “Add Computer”
and “Remove Computer”. The first menu item can be used to search the net‐
work for a computer using its name or IP address. The second menu item is
active only if the computer found within the network is selected; it can be used
to remove the computer from the list.
5.2.5 Assignment List

General The assignment list indicates the assignment of the OPC item to a correspond‐
ing degree of freedom of a kinematics object. It contains the columns “OPC
Item”, “Offset”, “OPC Server” and “Computer”. This information precisely de‐
fines an OPC item.
Fig.5-8: OPC assignment list

Assignment Using drag-and-drop, an OPC item can be assigned to a degree of freedom of
the kinematics object selected in the scene tree. If the OPC item from the OPC
tree is dropped onto an appropriate line in the assignment list, the individual
information data are encrypted and written to the corresponding column of the
assignment list.
and Controls
5.2.6 Properties of the View3D Model

The Properties of the View3D model dialog box can be used to make settings
for the View3D model and for OPC.
Fig.5-9: Properties of the View3D model

See also chapter "Changing settings of the View3D model " on page 37.
Scaling factor for process values The scaling factor affects all the process values that are associated with 3D
objects in the View3D model.
It is used to globally adapt the scaling of the View3D model to the process
values.
See also chapter "Handling instruction Changing the scaling factor for process
values" on page 34.
Rendering always active When this setting is active, the 3D model is continuously rerendered (i.e. the
3D model is continuously recalculated). This is a good idea if, for example, you
want to switch between various viewpoints at the touch of a button.
When the process connection is active, rendering is automatically

activated.
OPC group name This is the name of the OPC group that is used when someone logs onto an
OPC server.
OPC update rate The OPC update rate specifies the time (in milliseconds) in which process val‐
ues are updated by the OPC server.
5.3 Virtual User Panel

The Virtual User Panel is used as a replacement for the real VAM 40 during
emulation. The appearance and functions replicate the real VAM 40. In the
current version, the texts are available only in English and German.
and Controls
Fig.5-10: Virtual User Panel
5.3.2 Configurator
The Virtual User Panel is configured in IndraWorks Engineering. Then the con‐
figuration file of the Virtual User Panel must be supplemented by the user (also
see chapter "Supplements to the configuration file " on page 30).
Fig.5-11: Configuration in IndraWorks

Project node Simulation with sub‐ Project node Virtual User Panel is used to call the pages for configuring the
node Virtual User Panel virtual VAM 40.
The configuration page of the key- The individual switch settings are labeled on the configuration page of the key-
operated switch operated switch.
and Controls
The configuration page of the key‐ This page is used to label the keypads with texts or previously generated im‐
pads ages. Each individual key can be allocated by entering a text or by dragging
and dropping an image from the symbol list.
The configuration page of the The configuration page of the quick-stop module can be used to make various
quick-stop module settings for the two keys:
● Labelling the key
● Function
Since the keys on the real VAM 40 are hardware-wired and the switches
are equipped with make and break contacts, these settings can also be
selected here. If a key is not wired, “None” can be set.
● Mutual locking of the keys
Since the keys are switches, the signals are continuously activated. To
mutually reset these signals, mutual locking of the two keys can be se‐
lected.
The labels for the EMERGENCY STOP and the spindle and fee‐
drate override are not affected.
The configuration file The configuration file contains the assignment of the individual keys. In addition,
the user must enter all the PLC variables that are required for communication
with the Virtual User Panel (also see chapter "Supplements to the configuration
file " on page 30).
The individual keys, switch settings, lamps and overrides can then use these
settings to control the PLC program and to display the status.
5.3.3 The Application

The application is separate; it is used to control the PLC program in IndraMotion
MTX emulation. This can be started independently of IndraWorks Engineering
or IndraWorks Operation. When the Virtual User Panel is started, the configu‐
ration is read out of the currently active project.
In this version, there must be a connection to the emulation when

the Virtual User Panel is started. This can be implemented, for ex‐
ample, by triggering a connection test in the contextual menu of the
MTX project node.
5.4 Virtual Control

A virtual control is the most important simulation component because, just like
the real control, it regulates the entire process. It contains the same functions
as the real control and is identically parametrized, programmed and operated.
Therefore, the method of operation does not change for the user if he switches
between a virtual control and a real one; only the communication parameters
of the Engineering interface must be reset. However, since the virtual control
runs under Windows, its only limitation is that it is not real-time-capable.
With the emulation of the IndraMotion MTX machine tool control, Bosch Rexroth
has such a virtual control.
For further information regarding IndraMotion MTX emulation, see chapter 6.4
"Using the Virtual Control" on page 37.
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and Controls
Operation in IndraWorks
6 Operation in IndraWorks
6.1 Creating a Model
6.1.1 General
The import format for 3D scenes into View3D is VRML (Virtual Reality Modeling
Language). Files in the format VRML 2.0 (or VRML97) are supported.
VRML files are recognized by the file extension “.wrl” (world).
Most 3D modelling tools can export 3D scenes in VRML format.
The import of compressed VRML files (the file extension is also

“.wrl”) is not supported by View3D.
6.1.2 Creating a Simple 3D Model

As a rule, any 3D modelling tool with VRML export can be used to create 3D
models. However, not all modelling tools can be used to create kinematic re‐
lationships between individual 3D objects.
Kinematic relationships have a fundamental significance for machine models.
In a compound table, for example, the X-axis also moves when the Y-axis is
moved.
A simple modelling tool to generate 3D scenes with kinematic relationships is,
for example, Vizx3D by “Virtock Technologies, Inc.” (http://www.vizx3d.com).
6.1.3 Importing eM-RealNC Models

View3D can also import VRML models that have been created using the NC
simulation software “Tecnomatix eM-RealNC” from Unigraphics Solutions
GmbH (http://www.tecnomatix.de). Tecnomatix eM-RealNC has provided a
VRML export interface for this purpose.
6.2 Using the Virtual User Panel

6.2.1 Configuration
Configuration in IndraWorks
Creating a Virtual User Panel
In order to be able to configure a Virtual User Panel, a project must have been
created in IndraWorks.
A Virtual User Panel is created in an existing project in IndraWorks by selecting
and confirming Project node ▶ right mouse button ▶ Add new element ▶ Virtual
User Panel. This then appears in the Simulation node as subnode “Virtual User
Panel”.
By <double-clicking> (or clicking the right mouse button on ▶ Open) the node
of the Virtual User Panel, the configuration pages open.
Configuration of the key-operated switch
By highlighting the key-operated switch in the display of the virtual VAM 40, its
configuration page opens. The switch positions are labelled in the individual
text fields.
The number of characters for the texts is unlimited; the new label appears im‐
mediately in the display of the Virtual User Panel.
and Controls
Configuration of the keypads

The configuration page of the keypads is opened by highlighting a key on the
keypad.
Assigning text to the keys When labelling an individual key, first highlight the desired key on the keypad.
Then switch to the text field of “Labelling the key” and enter the text.
Assigning images to the keys The keys are assigned using drag-and-drop. First select any image in the
“Symbols” category. Then press the left mouse button and drag the cursor to
the desired key.
Configuration of the quick-stop module
The configuration page of the quick-stop module is opened by selecting the
quick-stop module in the display of the virtual VAM 40.
Labelling the keys The new labels can be entered in the text fields of the “(Top) key ” and “(Bottom)
key”. Line breaks and line lengths are not taken into account. However, the
label is immediately shown in the VAM 40 display.
Functions of the keys Since the keys on the real VAM 40 are hardware-wired and the switches are
equipped with make and break contacts, these settings must be selected here.
This is accomplished by setting function “Break-contact” or “Make-contact”. If
the key was not wired, set “None”.
To execute mutual locking of the two keys, the checkmark “Mutual locking of
the keys” must be set.
Supplements to the configuration file
In order to supplement the configuration file, the hard disk path of the project
that was just edited in IndraWorks Engineering must be determined. Then open
in Simulation ▶ config the configuration file “VirtualControlPanel_VAM40.xml”
using the Editor. The following settings for communicating with the PLC varia‐
bles of the current PLC program in the control must be made:
Pay attention to capitalization!

Use only BOOL variables to communicate with the elements!
BYTE variables must be used for the overrides!
1. Enter the name of the logical device under “Logical_Device\ NameLD”.

e.g. <NameLD>IndraMotion_MTX_P60</NameLD>
2. Enter the PLC variables for the individual keys in the keypad under Keypad
1 and 2.
e.g. <KY_X1Y3>iStart</KY_X1Y3>
3. Enter the PLC variables for each individual LED under LED_Keypad_1
and LED_Keypad_2
e.g. <LED_X2Y2Y>qStart</LED_X2Y2>
4. Enter the PLC variables for the spindle and feedrate override under the
point “Override”
e.g. <OVR1>iFeedrate</OVR1> for the spindle and feedrate override
5. Enter the PLC variables for the key-operated switch under “Key-operated
switch/KEY_P1-4”
e.g. <KEY_P1>iVAM_KEY_S1</KEY_P1> for the first switch setting from
the left
6. Enter the PLC variables for the functions of the quick-stop module keys
under “Module_QuickStop”
and Controls
e.g. (Top) key <MOD_KY1>iK_Pow_On</MOD_KY1>

7. Enter the PLC variable for the LED in (Top) key under “Module_QuickStop”
e.g. <MOD_LED_KY1>qL_Pow_On</MOD_LED_KY1>
8. Enter the PLC variables for the simulation of the EMERGENCY STOP
under “Emergency stop”
e.g. <KY>iEmergency_stop</KY>
After making the supplements, save the file and close it.
6.2.2 Connection to Virtual Control

Before the Virtual User Panel can be started, a few things must be carried out
successfully for the connection:
Preparations in IndraWorks Engi‐ ● Set the project in which the Virtual User Panel was configured to Active.
neering This is accomplished by selecting and executing menu item Project ▶ Ac‐
tivate for IndraWorks Operation.
● Execute a connection test via the control, e.g.
IndraMotion_MTX_P60 ▶ right mouse button ▶ Connection test.
Preparations in IndraLogic .
Fig.6-1: Preparations in IndraLogic

● In the PLC program, create all the variables that are to receive a connec‐
tion with the Virtual User Panel as “Global variables”. These variables are
used to activate the individual switch settings, buttons, lamps and over‐
rides.
and Controls
These are created as follows: Variable name: BOOL, e.g. iStart: BOOL;
Do not assign an address; remove it if necessary!
● Reset the PLC program, log in and start.
6.2.3 Start
The Virtual User Panel is started via Start ▶ Program Files ▶ IndraWorks ▶ Vir‐
tual User Panel or using the “IndraWorks Virtual User Panel” icon on the
desktop.
6.2.4 Error Messages and Remedies

Error box “No active project exists!” Remedy: Open IndraWorks Engineering and set the project in which the Virtual
User Panel was configured to Active. This is accomplished by selecting menu
item Project ▶ Activate for IndraWorks Operation. Then restart the “IndraWorks
Virtual User Panel”.
Error box “No virtual user panel Remedy: Open IndraWorks Engineering and create an existing or new project.
configured!” Within it, create a Virtual User Panel via Project node ▶ right mouse
button ▶ Add new element ▶ Virtual User Panel . Then proceed according to
chapter "Configuration in IndraWorks" on page 29.
Error box “No connection to the Remedy: Close the Virtual User Panel, call IndraWorks Engineering and rees‐
PLC” tablish the connection via Control e.g. IndraMotion_MTX_P60 right mouse
button ▶ Execute connection test.
Error box “Error writing PLC varia‐ This error message can have various causes; therefore various remedies are
bles” available:
1. Check whether the variable name in the configuration file is written cor‐
rectly.
2. Check whether the PLC variables were stored under “Global variables”
and are of type BOOL. Exception: Override activation uses BYTE varia‐
bles.
3. Check the communication to the PLC and reestablish the connection if
necessary.
6.3 Using 3D Visualization

6.3.1 3D Models in IndraWorks
Importing 3D models
General
In order to be able to open a 3D model in the View3D 3D visualization system,
it must first be imported into the IndraWorks project. Models in VRML format
and in the internal d3d format are accepted as the import format (also
seechapter 6.1 "Creating a Model" on page 29).
Handling instruction: Importing a 3D model
Importing of a 3D model into the IndraWorks project is described here.
IW Engineering / Simulation: Importing a 3D model
● In the Project Explorer on node 3D visualization (or on the project node if
node 3D visualization does not yet exist), select the contextual menu
Add ▶ Add new element....
● In the dialog box Add new element, open the template 3D model from the
category Virtual components.
and Controls
Fig.6-2: Adding a new element

● Enter a name for the View3D model.
● Select an import file for the 3D scene. Press the <Browse...> button to
open a file selection dialog box in which the 3D model (VRML/d3d) can
be selected.
Fig.6-3: Adding a View3D model

and Controls
● Press the <Finish> key. The View3D model is added to node 3D visuali‐
zation in the project tree.
Opening, renaming and deleting 3D models
Opening a 3D model in View3D Highlight the desired View3D model within node 3D visualization using the
mouse or the cursor keys and open it using contextual menu Open or by double-
clicking.
Renaming a 3D model The name of the View3D model can be changed in the Project Explorer. To do
this, select contextual menu Rename on the View3D model in the Project Ex‐
plorer or press key <F2>. Then the name can be changed and entered by
pressing the <Enter> key.
Deleting a 3D model A View3D model can be deleted from the IndraWorks project in the Project
Explorer using contextual menu Delete or with key <Del>.
6.3.2 Process Connection

Connecting 3D objects with IndraMotion MTX axis values
Handling instruction: Controlling a View3D object using an IndraMotion
MTX process value
The procedure for connecting a 3D object in View3D with an IndraMotion MTX
process value is described here.
Boundary condition Communication with the IndraMotion MTX must have been established in order
to be able to access IndraMotion MTX OPC items.
To establish communication to the IndraMotion MTX, one of the following steps
must be carried out once before opening a 3D model in View3D:
● Execute a connection test on node IndraMotion MTX in the Project Ex‐
plorer
● Open IndraWorks Operation Desktop
IW Engineering / Simulation: Connecting a 3D object with an OPC item
● The object that is to be connected to an OPC item must be selected in the
3D view or in the scene tree. The actions translation (movement in axis
direction X, Y or Z) and rotation (turning around axis X, Y or Z) appear in
the OPC assignment list for the selected object.
● In window OPC Server, open the node for the IndraMotion MTX OPC
server (OPC.IwSCP.1) in node Local (local OPC server).
● Select an OPC item and, with the left mouse button held down, drag it onto
a translation or rotation action in the OPC assignment list (e.g. in group
NC Axes “X (Phys.No.=1), command position, ACS” for the command po‐
sition of the X-axis in the axis coordinate system).
● The data of the OPC item now appear in the OPC assignment list. The
object receives a green marking in the scene tree.
Configuring the process connection
Handling instruction Changing the scaling factor for process values
Adapting the scaling of a 3D model to the process values of the OPC item is
described here.
IW Engineering / Simulation: Changing the scaling of a View3D model
● Using menu item View3D ▶ Model properties... in the main menu, open
dialog box Properties of the View3D model.
● The scaling of the 3D model can be adapted to the values of the OPC item
using Scaling factor for process values.
and Controls
The scaling factor can also be changed while a process connection

is active. In this way, the 3D model can be used to immediately
check the changes.
● If the scaling factor is set too high, the 3D objects move beyond
the end position (they may even be moved out of the visible
area of the 3D Viewer).
● If the scaling factor is too low, it may be impossible to detect
the movement of the 3D objects.
Handling instruction Changing the offset for process values

An offset can be added to each process value of an OPC item. The entry of
offset values is described in this handling instruction.
IW Engineering / Simulation: Adding an offset to the process value of a View3D
object
● Select a 3D object with a configured process connection from the scene
tree (can be recognized by the green marking).
● Change the offset value of the OPC item in the OPC assignment list.
Handling instruction: Rotating a View3D object around a user-defined
point of rotation
If a 3D object is to be rotated by a process value (OPC item is connected with
the action rotation in the OPC assignment list), the point of rotation of the object
may need to be adapted. This handling instruction can be used to change the
point of rotation of a View3D object.
Boundary condition It is not possible to change the point of rotation using end elements of the scene
tree.
IW Engineering / Simulation: Changing the point of rotation of a View3D object
● Select contextual menu Properties on the desired 3D object in the scene
tree in order to open dialog box Object properties.
See also chapter "Object properties " on page 22.
● Enter the X, Y and Z coordinates of the point of rotation and activate the
values by pressing the <OK> or <Accept> button.
The coordinates for the point of rotation can be determined using

the cursor function. See chapter "Basic 3D visualization functions "
on page 36.
Handling instruction: Moving a View3D object in any direction in space

If a 3D object is to be moved by a process value in a direction in space that
does not correspond to one of the X, Y or Z coordinate axes, the angle of the
object must be adapted accordingly.
Boundary condition It is not possible to change the angle using end elements of the scene tree.
IW Engineering / Simulation: Changing the angle of a View3D object
● Open dialog box Object properties using contextual menu Properties on
the desired 3D object in the scene tree.
See also chapter "Object properties " on page 22.
● Enter the angles for the X, Y and Z coordinates and confirm these by
pressing the <OK> or <Accept> button.
Example: If a machining station in the XY plane is rotated by 30° relative
to the main coordinate system, this angle must be entered for the Z coor‐
and Controls
dinate (rotation around the Z-axis) to correct the direction of movement for
the X- and Y-axes.
Establishing a connection to the control
Handling instruction: Starting a View3D process connection
This handling instruction describes how to activate the View3D process con‐
nection in order to control 3D objects using process values.
Boundary condition Communication with the IndraMotion MTX must have been established in order
to be able to access IndraMotion MTX OPC items.
To establish communication to the IndraMotion MTX, one of the following steps
must be carried out once before opening a 3D model in View3D:
● Execute a connection test on node IndraMotion MTX in the Project Ex‐
plorer
● Open IndraWorks Operation Desktop
IW Engineering / Simulation: Establishing a View3D process connection for
control
In the main menu, select menu item View3D ▶ Start.
The following actions are now carried out:
● Windows OPC server and OPC assignment are hidden.
● The process connection is started and the 3D objects are supplied with
the process values of the control.
Handling instruction: Stopping a View3D process connection
An active process connection in View3D can be stopped using this handling
instruction.
Boundary condition The process connection must be active (this can be recognized by the check‐
mark on menu item Start in the main View3D menu).
IW Engineering / Simulation: Terminating a View3D process connection for
control
In the main menu, select menu item View3D ▶ Start.
The following actions are now carried out:
● The process connection is stopped.
● Windows OPC server and OPC assignment are displayed.
6.3.3 3D Visualization Operation

Basic 3D visualization functions
Handling instruction: Determining the coordinates of a point in space
This handling instruction describes how the Cursor dialog box can be used to
determine the coordinates of a point in space.
IW Engineering / Simulation: Cursor function
● Open the Cursor dialog box via the main menu View3D ▶ Cursor ....
● If necessary, activate the cursor. The checkmark on entry Visible must be
set.
● Using the arrow keys of the input fields for the X-, Y- and Z-coordinates,
move the cursor to the desired point in space. The increment of the cursor
movement can be set via Delta to “1” “0.1” “0.01” or “0.001”.
● The coordinates of the point can now be read in the Cursor dialog box.
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Wireframe representation
The representation of the 3D model can be switched between Solid and Wire‐
frame in View3D. If the checkmark on menu item Wireframe is set in the main
View3D menu, the model is displayed as a wireframe. Otherwise, the 3D model
is shown as a solid.
Manipulating 3D objects
Handling instruction: Moving a View3D object
This handling instruction describes how a single View3D object in the 3D model
can be moved.
IW Engineering / Simulation: Moving a View3D object
● Select the 3D object using the left mouse button.
● Press the <X>, <Y> or <Z> key while simultaneously pressing the left
mouse button. The object can now be moved in the X, Y or Z coordinate
direction by moving the mouse to the left or right.
Handling instruction: Rotating a View3D object
The procedure for rotating a View3D object in the 3D scene is described here.
IW Engineering / Simulation: Rotating a View3D object
● Select the 3D object using the left mouse button.
● Press the <X>, <Y> or <Z> key while simultaneously pressing the right
mouse button. The object can now be rotated around the X, Y or Z coor‐
dinate axis by moving the mouse to the left or right.
Changing settings of the View3D model
Settings of the View3D model are changed in the Properties of the View3D
modeldialog box.
See also chapter 5.2.6 "Properties of the View3D Model " on page 25.
The dialog box can be opened in the main menu using menu item
View3D ▶ Model properties....
Changing the scaling factor for The scaling factor for process values can be changed using the corresponding
process values input field in the dialog box.
Switching rendering on and off Rendering of the 3D scene can be switched on/off using the Rendering always
active checkmark.
Changing the name of the OPC The name of the OPC group can be changed in field Group name under OPC
group settings.
Changing the OPC update time The update time for the OPC group can be entered (in milliseconds) in input
field Update rate under OPC settings.
OPC settings can be changed only if the process is inactive.
6.4 Using the Virtual Control

6.4.1 Installation of MTX Emulation
General
Description
Brief Description MTX Emulation is copied from the installation CD; proceed according to the
dialog boxes of the installation program. We recommend using the default val‐
ues.
and Controls
Boundary conditions If the default memory size of 0.5 MB is not sufficient, the RAM file system
memory of the emulation must be increased to 3 MB:
Handling instruction: Increasing the RAM file system memory of the
emulation
If the application requires more memory, proceed as follows to increase it:
Windows / Windows Explorer: Change file names
● In folder “D:\Program Files \Rexroth\IndraWorks\mtx\emu”
– rename file “t3usrfep.pxf” to “t3usrfep.pxf.1MB” and
– rename file “t3usrfep.pxf.3MB” to “t3usrfep.pxf”.
Figure Flowchart Example Instruction Documentation
Documentation : IndraWorks Commissioning Instructions MTX Emulation
Fig.6-4: Link
6.4.2 Projecting Emulation

Restoring an existing project
General
Brief Description IndraWorks Engineering can be used to restore existing projects that were cre‐
ated previously or on another computer for real systems or MTX emulation.
Description The transfer (= restoration) of an IndraWorks project from a real control to em‐
ulation is described here. An IndraWorks project file contains, among other
things, the control parameters, the Profibus configuration, the PLC program,
the definition files for the M- and F-keys and the logbooks, as well as the user
screens.
The project is restored using function “Restore” in menu “Project”.
Handling instruction Restoring an existing project for MTX emulation
The transfer (= restoration) of an IndraWorks project from a real control to em‐
ulation is described here.
IW Engineering / Motion: Restore control data
Instruction : Restoring data
Documentation : IndraWorks Commissioning Instructions Data backup
Fig.6-5: Link
6.4.3 Projecting the HMI

General
Description
Brief Description The projected HMI data can be effective in the user interface only if they are
downloaded to the Runtime folder of the user interface.
Boundary conditions The Runtime folder need be set only if the installation path of the target control
(emulation) differs from the installation path of the source control on which the
project was created.
Handling instruction Projecting the HMI for MTX emulation
This handling instruction describes how to make the HMI-specific settings that
are required to use MTX emulation.
IW Engineering / HMI BTV 40: Open the Properties dialog box and make set‐
tings
and Controls
● Click the right mouse button on the node of the HMI device in the Project
Navigator.
Fig.6-6: IndraWorks project - Properties

● Select the Properties dialog box by clicking the left mouse button on
“Properties”. The dialog box for setting the properties for the HMI project
opens.
Fig.6-7: IndraWorks project – “Properties” dialog box

● Enter the path for the Runtime installation of the MTX (this is usually iden‐
tical to the installation path of the MTX).
● Exit the Properties dialog box by pressing “OK”.
IW Engineering / Project: Activating an IndraWorks project
and Controls
● The IndraWorks project is activated in the main menu under “Project / Ac‐
tivate for operation”.
Fig.6-8: Activating a IndraWorks project

● Download the HMI project in the Runtime folder by pressing the Activate
command.
● This IndraWorks project is displayed the next time that the MTX user in‐
terface is started.
6.4.4 Designing the NC Core

General
Description
Brief Description Among other things, the NC core data contains the the usrfep and the root files,
the machine data as well as the database tables for the system and tool data.
The data of the NC core is located in the IndraWorks project tree below the
device node “IndraMotion MTX P60”.
To restore the NC core data of a project, which has been created on a real
control, one first has to adapt the “Properties of the IndraMotion MTX P60” and
then activate the NC core data in two steps.
Handling Instruction: Designing the NC Core
The handling instruction contains instructions for adaptations for the NC core
specific to the use of the MTX Emulation. These instructions refer to existing
data which is to be activated by restoring them.
IW Engineering / IndraMotion MTX P60: Adapt the properties of the device
“IndraMotion MTX P60”
● With the right mouse key, click on the device node “IndraMotion MTX
P60”. The properties dialog box of the “IndraMotion MTX P60” will open.
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Fig.6-9: IndraMotion - “Properties” dialog box

● Select the tab “Communication” using the left mouse key.
● In the input field “IP address”, select the entry “localhost” and exit the di‐
alog box by pressing OK.
IW Engineering / IndraMotion MTX P60: Restore NC core data
● Start the IndraMotion MTX Emulation by executing the file “emu.bat”. The
file “emu.bat” is located in the following directory: “...\Program Files
\Rexroth\IndraWorks\mtx\emu\” (see also handling instruction “Start-up of
the Emulation”).
● Stopping of the IndraLogic in the Program “IndraLogic” by pressing “F5”.
● In IndraWorks, highlight the node “IndraMotion MTX P60\Motion” and call
the function “Restore” with the right mouse key.
● In the following dialog boxes, select the desired archive and, for the time
being, load only the data of the “User FEPROM”.
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Fig.6-10: Restoring NC core data

● Afterwards exit IndraWorks Engineering and emulation.
● The emulation is closed by entering “14” in the DOS window.
Fig.6-11: DOS prompt for emulation

● Start the emulation and IndraWorks Engineering again (see handling in‐
struction “Start-up of Emulation”).
● Stopping of the PLC via IndraLogic.
● Now, select and reload all NC core data, except for the already loaded
data of the user FEPROM.
● Close the emulation and IndraWorks Engineering again and restart them.
The emulation is now working with the loaded NC core data.
and Controls
Any changed data (e.g. configuration parameter, tool data) will only
be effective if the emulation is ended by entering “14” in the DOS
window.
Characteristics during working with the MTX emulation

The MTX emulation does not have a “CMP60 Control” with which the startup
modus is set, the startup phase is observed and different commands to save
parameters, load Firmware, start/stop PLC,... can be executed. The following
sequence describes how this functions can be executed in the MTX emulation.
System restart of emulation (start‐ It is necessary to restart the system for example to apply modifications for ma‐
up mode 0) chine parameter (Macoda).
1. Exits IndraWorks.
2. Exit the emulation in the DOS window by entering “14”. The changed pa‐
rameters are saved on the computer by writing the files “typ3ram.pxf” and
“t3usrfep.pxf” on the PC and the changes become effective upon the next
startup of the emulation.
3. Restart emulation.
4. Restart IndraWorks.
Bootstrap (startup mode 6) Via bootstrap which can be compared to the execution of startup of a real MTX
with startup mode 6, the RAM file system of control is created again.
A new root file system is created via bootstrap; as a result, all the
data of the old file system are lost. If an intact user FEPROM file
system exists, the PLC boot project and configuration data are loa‐
ded from there.
Bootstrap is necessary to apply for example the modifications on the tool da‐
tabase size as well as the structure of tool data records.
1. Copy modifications on tool data record into usrfep.
3. Exit the emulation in the DOS window by entering “14”.
4. Delete the RamFileSystem, i.e. delete the file “...\Program Files\Rexroth
\IndraWorks\mtx\emu\typ3ram.pxf”.
Creation of the user FEPROM file Creating a user FEPROM file system which can be compared to execution of
system (startup mode 7) startup mode 7 of real MTX is necessary if all project-specific data can be de‐
leted on a control or if the user FEPROM file system can is damaged.
The user FEPROM is created via creation of the user FEPROM file
system , but all the data of the old file system are lost. The root file
system remains. The permanent CPL variables will be deleted.
2. Exit the emulation in the DOS window by entering “14”.
3. Delete the user FEPROM file system, i.e. delete the file “...\Program Files
\Rexroth\IndraWorks\mtx\emu\typ3ram.pxf”.
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6.4.5 Projecting the PLC

General
Description
Brief Description If the IndraWorks PLC project originates from a real control or if IndraWorks
was previously installed in a directory that is different from the active version,
the communication settings of the PLC project must first be modified. Then the
PLC project can be activated.
Handling instruction Restoring a PLC project
This handling instruction describes the steps involved in commissioning a PLC
project that has already run on a real control.
IW Engineering / Logic: Restoring a PLC project
● Highlight node “IndraMotion MTX P90\Logic” and use the right mouse
button to open the “Properties” dialog box.
● In the “Properties” dialog box, select tab “Communication settings”.
Fig.6-12: PLC communication parameters

● Press the “Communication parameters” button. The “Communication pa‐
rameters” dialog box opens.
● Here, make the settings in dialog “communication parameter” shown in
the figure below and confirm them by pressing OK. The existing settings
may need to be deleted first.
and Controls
Fig.6-13: Settings in the “Communication parameters” dialog box

● In the “Properties” dialog box (see above), open tab “IndraLogic directo‐
ries” and, if necessary, change the path information for the installation
paths of the emulation. Only one path entry may be made.
Fig.6-14: Settings in the “Properties/Directories” dialog box

● Exit the Properties dialog box by pressing “OK”.
● In IndraWorks, click the right mouse button on node “Logic” and execute
command “Update”. The IndraLogic project is now set to “Emulation” and
can be started.
● Start IndraLogic by double-clicking node “Logic” and transfer and down‐
load the PLC project.
and Controls

Documentation : IndraWorks System Description Working with projects
Fig.6-15: Link
6.4.6 Starting and Exiting MTX Emulation

General
Description
Brief Description Emulation covers both the NC kernel and the PLC; these can be started and
stopped together. Windows application Sco.exe is provided for this purpose; its
functionality at runtime can be checked using a DOS window.
The emulation system must be restarted to, for example, transfer MACODA
changes or tool data configuration modifications.
Boundary conditions Emulation must always be started before beginning work with IndraWorks En‐
gineering (project interface) and the IndraMotion MTX user interface.
Handling instruction: Starting Emulation
This handling instruction describes how to start emulation (CNC and PLC).
Windows: Starting emulation
● Emulation is started using batch file “...\Program Files\Rexroth
\IndraWorks\ mtx\emu\emu.bat”.
● You can see if emulation has started up without errors if the feedback is
the following screen.
Fig.6-16: Starting emulation
Emulation must always be started before beginning work with

IndraWorks Engineering and IndraMotion MTX. It is recommended
that a link to the start of the batch file be created on the Windows
desktop.

Documentation : IndraWorks Commissioning Starting emulation
Fig.6-17: Link
Handling instruction: Stopping emulation
This handling instruction describes how to stop emulation (CNC and PLC).
Windows: Starting emulation
and Controls
● Emulation is exited by entering “14” in the DOS window.
Fig.6-18: Stopping emulation
Modified data (e.g. machine parameters or tool data) are saved only
after emulation is exited by entering “14” in the DOS window.

Documentation : IndraWorks Commissioning Stopping emulation
Fig.6-19: Link
Handling instruction: Restarting the emulation system
This handling instruction describes how to restart emulation (CNC and PLC).
The emulation system must be restarted to, for example, allow modified ma‐
chine data to go into effect.
Windows: Restarting emulation
● Exit IndraWorks Engineering Desktop and/or Operation Desktop.
● Exit emulation by entering “14” in the DOS window. The modified param‐
eters are saved by writing the files of file system typ3ram.pxf and the user
feprom t3usrfep.pxf to the PC; the modifications go into effect the next
time that emulation is started.
● Restart emulation.
● Restart IndraWorks Engineering Desktop and/or Operation Desktop.
Modified data (e.g. MACODA, tool data) go into effect only after
emulation is exited by entering “14” in the DOS window. For MTX
emulation, it is not necessary to set different startup modes.

Documentation : IndraWorks Commissioning Restarting the Emulation System
Fig.6-20: Link
6.4.7 Starting Operation Desktop

Brief Description The MTX user interface is started for a real application. To do this, a link
(“IndraWorks HMI”) is placed on the desktop during the installation of MTX
Emulation.
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Communication
7 Communication
7.1 OPC
The View3D 3D visualization system can access IndraMotion MTX process
data via OPC.
Data are exchanged with the IndraMotion MTX using OPC items, which are
provided by the IndraMotion MTX OPC server (OPC.Iw.SCP.1).
Queries are passed on internally to the OPC server using the Scalable Com‐
munication Platform (SCP), which is also used for communication with the
IndraMotion MTX user interface.
7.2 SCP
The SCP (Scalable Communication Platform) is the standardized IndraWorks
communication platform. All communication between Bosch Rexroth products,
such as Virtual Control Panel and the PLC, is carried out using SCP.
Data are exchanged between Virtual Control Panel and the PLC using SCP
items, which consist of the names of PLC variables, starting with PLC.Pvl,.PLC
variable name.
You can find additional information in the SCP documentation.
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Service & Support
8 Service & Support

8.1 Helpdesk
Our service helpdesk at our headquarters in Lohr, Germany, will assist you with
all kinds of enquiries.
Contact us:
● By phone through the Service Call Entry Center,
Mo - Fr 7:00 am - 6:00 pm CET
+49 (0) 9352 40 50 60
● By Fax
+49 (0) 9352 40 49 41
● By email: service.svc@boschrexroth.de
8.2 Service Hotline

Out of helpdesk hours please contact our German service department directly:
+49 (0) 171 333 88 26
or
+49 (0) 172 660 04 06
Hotline numbers for other countries can be found in the addresses of each
region (see below).
8.3 Internet
Additional notes regarding service, maintenance and training, as well as the
current addresses of our sales and service offices can be found on
http://www.boschrexroth.com
Outwith Germany please contact our sales/service office in your area first.
8.4 Helpful Information

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
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Index
Index
Symbols Restoring an existing project for MTX emulation
3D visualization 38
Assignment list 24 Restoring a PLC project 44
Basic 3D visualization functions 36 Rotating a View3D object 37
Changing settings of the View3D model 37 Rotating a View3D object around a user-defined
Configuring the process connection 34 point of rotation 35
Connecting 3D objects with IndraMotion MTX ax‐ Starting a View3D process connection 36
is values 34 Starting emulation 46
Creating a simple 3D model 29 Stopping a View3D process connection 36
Establishing a connection to the control 36 Stopping emulation 46
Functions for manipulating 3D objects 21 Handling Instruction
Importing 3D models 32 Designing the NC Core 40
Importing eM-RealNC models 29 Hardware-in-the-loop 1
Manipulating 3D objects 37
Model visualization 19 I
Object properties 22 Inappropriate use 3
OPC configuration 23 Intended Use
Opening, renaming and deleting 3D models 34 Applications 3
Properties of the View3D model 25 Cases of Application 3
Scene tree 21 Introduction 3
Wireframe representation 37
K
B Key-operated switch 29
Behavioral simulation 1
L
C Language 19
Configuration file 26, 30
Connection to virtual control 31 M
Machine model 15
E MBS 1
Error messages 32
N
F Non-Intended Use
FEM 1 Consequences, Exclusion of Liability 3
H P
Handling instruction Project explorer 17
Changing the offset for process values 35
Changing the scaling factor for process values Q
34 Quick-stop module 30
Controlling a View3D object using an
IndraMotion MTX process value 34 S
Determining the coordinates of a point in space Safety instructions for electric drives and controls 5
36 SCP 49
Importing a 3D model 32 Software-in-the-loop 1
Increasing the RAM file system memory of the
emulation 38
Moving a View3D object 37 V
Moving a View3D object in any direction in space Virtual factory 1
35 Virtual machine 1
Projecting the HMI for MTX emulation 38 Virtual User Panel 25
Restarting the emulation system 47
and Controls
Application Description | Rexroth IndraWorks Electric Drives | Bosch Rexroth AG
and Controls
Notes
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Phone +49 (0)93 52-40-50 60
Fax +49 (0)93 52-40-49 41
service.svc@boschrexroth.de
www.boschrexroth.com
Printed in Germany
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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Rexroth IndraWorks R911317008

Title Rexroth IndraWorks

Type of Documentation Application Description

Document Typecode DOK-IWORKS-SIMU****V01-AW02-EN-P

Internal File Reference RS-de78b78b0a6846ac009c70d0829c30df-2-en-US-2

Record of Revision Edition Release Date Notes

Copyright © 2006 Bosch Rexroth AG

2 Important Instructions on Use........................................................................................ 3

3 Safety Instructions for Electric Drives and Controls ...................................................... 5

5 Components of the Simulation .................................................................................... 17

8 Service & Support........................................................................................................ 51

1.2 What is Simulated?

1.3 Goals of Simulation in IndraWorks

● Reproduction of problems (trouble-shooting)

Important Instructions on Use

2 Important Instructions on Use

Bosch Rexroth, as the manufacturer of the products, will not as‐

2.1.2 Area of Use and Application

The simulation consists of several components which must be com‐

2.2 Improper Use

Important Instructions on Use

Safety Instructions for Electric Drives and Controls

3 Safety Instructions for Electric Drives and Controls

Improper use of these devices, failure to follow the safety instructions in

3.1.2 How to Employ the Safety Instructions

Safety Instructions for Electric Drives and Controls

3.1.3 Explanation of Warning Symbols and Degrees of Hazard Seriousness

Safety Instructions for Electric Drives and Controls

Danger Death or severe bodily harm will occur.

Warning Death or severe bodily harm may occur.

Minor or moderate bodily harm or material damage may

Fig.3-1: Hazard classification (according to ANSI Z 535)

3.1.4 Hazards by Improper Use

Dangerous movements! Danger to life, severe bodily harm or material

High electric voltage because of incorrect connection! Risk of death or

Hot surfaces on device housing! Danger of injury! Danger of burns!

Risk of injury by improper handling! Risk of bodily injury by bruising,

Safety Instructions for Electric Drives and Controls

Risk of injury by improper handling of batteries!

3.2 Instructions with Regard to Specific Dangers

Safety Instructions for Electric Drives and Controls

3.2.2 Protection Against Electric Shock by Protective Extra-Low Voltage

High electric voltage by incorrect connection! Risk of death or bodily

3.2.3 Protection Against Dangerous Movements

1) “Protective Extra-Low Voltage”

Safety Instructions for Electric Drives and Controls

Safety Instructions for Electric Drives and Controls

Dangerous movements! Danger to life, risk of injury, severe bodily harm

Safety Instructions for Electric Drives and Controls

3.2.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐

3.2.5 Protection Against Contact with Hot Parts

3.2.6 Protection During Handling and Mounting

Safety Instructions for Electric Drives and Controls

Risk of injury by improper handling! Bodily injury by bruising, shearing,

3.2.7 Battery Safety

Risk of injury by improper handling!

Environmental protection and disposal! The batteries contained in

3.2.8 Protection Against Pressurized Systems

Safety Instructions for Electric Drives and Controls

Risk of injury by improper handling of pressurized lines!

Environmental protection and disposal! The agents used to operate