Rexroth Indracontrol L25: Project Planning Manual

Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Rexroth IndraControl R911328474

Edition 03
L25
Project Planning Manual

Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Rexroth IndraControl L25
Title Rexroth IndraControl

L25
Type of Documentation Project Planning Manual
Document Typecode DOK-CONTRL-IC*L25*****-PR03-EN-P
Internal File Reference RS-7395430658d72e230a6846a00141db89-3-en-US-4
Purpose of Documentation This documentation describes the IndraControl L25 controls.
Record of Revision Edition Release Date Notes

120-0401-B356/EN-01 08.2009 First edition
120-0401-B356/EN-02 10.2010 Second edition
120-0401-B356/EN-03 04.2011 Third edition
Copyright © Bosch Rexroth AG 2009

Copying this document, giving it to others and the use or communication of the
contents thereof without express authority, are forbidden. Offenders are liable
for the payment of damages. All rights are reserved in the event of the grant of
a patent or the registration of a utility model or design (DIN 34-1).
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 ■ 97816 Lohr am Main, Germany
Phone +49 (0)93 52/ 40-0 ■ Fax +49 (0)93 52/ 40-48 85
http://www.boschrexroth.com/
Development Control Platform TL (CS)
Note This document has been printed on chlorine-free bleached paper.
DOK-CONTRL-IC*L25*****-PR03-EN-P Bosch Rexroth AG I/69
Table of Contents
Table of Contents
Page
1 System Presentation...................................................................................................... 5
1.1 Brief Description IndraControl L25.......................................................................................................... 5
1.2 Device Variants....................................................................................................................................... 5
1.3 View........................................................................................................................................................ 5
1.4 Further Documentation........................................................................................................................... 6
2 Important Instructions on Use........................................................................................ 7

2.1 Intended Use.......................................................................................................................................... 7
2.1.1 Introduction.......................................................................................................................................... 7
2.1.2 Areas of Use and Application.............................................................................................................. 7
2.2 Inappropriate Use................................................................................................................................... 8
3 Safety Instructions for Electric Drives and Controls....................................................... 9

3.1 Definitions of Terms................................................................................................................................ 9
3.2 General Information.............................................................................................................................. 10
3.2.1 Using the Safety Instructions and Passing Them on to Others......................................................... 10
3.2.2 Requirements for Safe Use............................................................................................................... 10
3.2.3 Hazards by Improper Use.................................................................................................................. 11
3.3 Instructions with Regard to Specific Dangers....................................................................................... 13
3.3.1 Protection Against Contact With Electrical Parts and Housings........................................................ 13
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock ................................................ 14
3.3.3 Protection Against Dangerous Movements....................................................................................... 14
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting.............. 16
3.3.5 Protection Against Contact With Hot Parts........................................................................................ 16
3.3.6 Protection During Handling and Mounting......................................................................................... 17
3.3.7 Battery Safety.................................................................................................................................... 17
3.3.8 Protection Against Pressurized Systems........................................................................................... 18
3.4 Explanation of Signal Words and the Safety Alert Symbol................................................................... 18
4 Technical Data............................................................................................................. 21
4.1 Equipment............................................................................................................................................. 21
4.2 Voltage Supply...................................................................................................................................... 21
4.3 Ambient Conditions............................................................................................................................... 22
4.4 Used Standards.................................................................................................................................... 22
4.5 UL and CSA certified............................................................................................................................ 23
4.6 Compatibility Test................................................................................................................................. 23
4.7 Wear Parts............................................................................................................................................ 24
5 Dimensions.................................................................................................................. 25
5.2 Housing Dimensions............................................................................................................................. 25
5.3 Installation Notes.................................................................................................................................. 26
II/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
Table of Contents
Page
6 Display and Operating Components............................................................................ 27

6.2 Display and Operating Keys................................................................................................................. 27
6.3 Reset Button and Stop LED.................................................................................................................. 27
7 Connections and Interfaces......................................................................................... 29

7.1 Connections on the Front Panel – Overview........................................................................................ 29
7.2 Voltage Supply...................................................................................................................................... 31
7.2.1 Supply Voltages to be Connected Externally.................................................................................... 31
General Information........................................................................................................................ 31
24 V Voltage Supply ULS................................................................................................................ 33
24 V Voltage Supply of the Main Circuit UM................................................................................... 34
+24 V Supply of the Segment Circuit US ....................................................................................... 34
7.2.2 Internally Generated Voltages........................................................................................................... 36
+7.5 V Inline Supply UL................................................................................................................... 36
24 V Analog Supply (UANA)............................................................................................................. 36
7.3 Interfaces.............................................................................................................................................. 36
7.3.1 Ethernet Interfaces............................................................................................................................ 36
7.3.2 Ethernet Interface (only for Device Variant CML...PN ...).................................................................. 37
7.3.3 PROFIBUS DP (only for Device Variant CML...PN...)....................................................................... 38
7.3.4 SERCOS III (only for Device Variant CML...3N...)............................................................................. 39
7.3.5 Ready Contact................................................................................................................................... 40
7.3.6 Interface for Compact Flash Card..................................................................................................... 41
7.4 Inline Bus.............................................................................................................................................. 41
7.5 Function Module Connector.................................................................................................................. 41
8 Installation and Maintenance....................................................................................... 43

8.1 Mechanical Installation of IndraControl L25.......................................................................................... 43
8.1.1 General Information........................................................................................................................... 43
8.1.2 Mounting the IndraControl L25.......................................................................................................... 43
8.1.3 Dismounting the IndraControl L25..................................................................................................... 44
8.2 Mechanical Installation of Rexroth Inline Terminals............................................................................. 45
8.2.2 Mounting the Inline Terminals........................................................................................................... 45
8.2.3 Demounting the Inline Terminals....................................................................................................... 46
8.2.4 Fuse Replacement............................................................................................................................ 47
8.3 Electrical Installation............................................................................................................................. 48
8.3.2 External Power Supply Unit .............................................................................................................. 49
8.3.3 24 V Voltage Supply.......................................................................................................................... 49
Setup without Electrical Isolation ................................................................................................... 49
Setup with Electrical Isolation ........................................................................................................ 50
Reference Conductor Connected to the Protective Conductor...................................................... 50
Reference Conductor not Connected to the Protective Conductor................................................ 51
Programming Device and Grounding............................................................................................. 52
DOK-CONTRL-IC*L25*****-PR03-EN-P Bosch Rexroth AG III/69
Table of Contents
Page
Dimensioning the Voltage Supply................................................................................................... 52
8.3.4 Main Switches and Fuses.................................................................................................................. 52
Main Switches ............................................................................................................................... 52
Fuses.............................................................................................................................................. 52
8.3.5 Grounding
........................................................................................................................................................... 53
8.3.6 Shield System.................................................................................................................................... 53
Shielding the PROFIBUS Cable..................................................................................................... 53
8.3.7 Connecting Lines to Tension Spring Connection Points................................................................... 54
Connecting Unshielded Lines......................................................................................................... 54
8.4 Maintenance......................................................................................................................................... 54
9 Environmental Protection and Disposal ...................................................................... 57

9.1 Environmental Protection...................................................................................................................... 57
9.2 Disposal................................................................................................................................................ 57
10 Ordering Information.................................................................................................... 59
10.1 Type Designation Code........................................................................................................................ 59
10.1.2 IndraControl L25................................................................................................................................ 59
10.2 Accessories.......................................................................................................................................... 60
10.2.1 Spare Part (Power Connector).......................................................................................................... 60
10.2.2 Further Accessories (Rexroth Inline Terminals, Function Modules and Interface Cables)................ 60
Rexroth Inline Terminals................................................................................................................. 60
Rexroth Function Modules.............................................................................................................. 60
Interface Cables............................................................................................................................. 61
11 Service and Support.................................................................................................... 65
Index............................................................................................................................ 67
IV/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
DOK-CONTRL-IC*L25*****-PR03-EN-P Bosch Rexroth AG 5/69
System Presentation
1 System Presentation
1.1 Brief Description IndraControl L25
The IndraControl L25 is a modular and scalable control. The control combines
the benefits of a compact small control with a standardized I/O system based
on terminal technology. The control is a universal hardware platform that can
be used for motion-logic and PLC applications. The control provides commu‐
nication interfaces such as Ethernet, EtherNet/IP as well as a SERCOS III
interface. Up to two function modules extend the IndraControl L25 via integra‐
ted PCI bus and additional fieldbus interfaces and technology interfaces. The
locally available I/O units can be extended by the Rexroth Inline I/O system,
just by simply mounting the components side by side. The complete application
programs, including runtime, are stored on an easily accessible Compact Flash
card.
1.2 Device Variants

The IndraControl L25 control is available in several device variants. The devi‐
ces differ mainly in the availability of SERCOS III and PROFIBUS DP interfaces
(see also fig. 1-1 "Device variants" on page 5 and chapter 7.1 "Connections
on the Front Panel – Overview" on page 29).
Connection Connection type Device variant
X7E1 and X7E2 Ethernet (SERCOS III) CML...3N...

X7E3 and X7E4 Ethernet (TCP/IP, RT Ethernet) CML...PN...
X7P RS485 (PROFIBUS DP) CML...PN...
Fig.1-1: Device variants

Further characteristic features are listed in the type designation code in chapter
10.1 "Type Designation Code" on page 59.
1.3 View
Operating elements and interfaces are arranged on the front panel:
In the left part is a display with eight characters and four operating keys, the
reset button, a LED, the Ethernet interface, the ready contact and a receptacle
for a Compact Flash card. The interfaces for SERCOS III are located in the
center. The voltage supply is located in the right part.
Fig.1-2: View of a typical IndraControl L25

6/69 Bosch Rexroth AG DOK-CONTRL-IC*L25*****-PR03-EN-P
System Presentation
1.4 Further Documentation

Title Identification Parts number
PLC Programming with Rexroth DOK-CONTRL-IL**PRO*V01- R911305036

IndraLogic 1.0; AW02-EN-P
Operating and Programming
Guide
RECO-Inline PROFIBUS DP; DOK-CONTRL-R-IL-PBSSYS- R911289597
Application Manual AW02-EN-P
RECO Inline PROFIBUS DP Ter‐ DOK-CONTRL-R-IL-PB*-BK- R911289587

minal and Module Supply; FK02-EN-P
Application Manual
Rexroth IndraWorks 10VRS En‐ DOK-IWORKS-ENGINEE*V10- R911327718
gineering; AW01-EN-P
Application Manual
Rexroth WinStudio; DOK-CONTRL-WIS*PC**V06- R911307630
Application Manual KB01-DE-P
Automation Terminals of the DOK-CONTRL-ILSYSINS***- R911317021

Rexroth Inline Range; AW01-EN-P
Application Manual
Rexroth IndraControl L Function DOK-CONTRL-IC*L*FM****- R911326408
Modules PR01-EN-P
Project Planning Manual
Fig.1-3: Further documentation

Important Instructions on Use
2 Important Instructions on Use

2.1 Intended Use
2.1.1 Introduction
Rexroth products represent state-of-the-art developments and manufacturing.
They are tested prior to delivery to ensure operational safety and reliability.
Therefore the products may only be used for the intended purpose. If they are
not used as intended, situations causing personal injury as well as material
damage can occur.
Bosch Rexroth disclaims as manufacturer any warranty, liability or

damages occurring due to inappropriate use of the products. Fur‐
thermore, Rexroth is not paying any compensation; the user is
responsible for any risks resulting from inappropriate use of the
products.
Before using Bosch Rexroth products, the following requirements must be met
to ensure intended use of the products:
● Anyone handling one of the Rexroth products in any way has to read and
understand the respective safety-related guidelines as well as the instruc‐
tions on intended use.
● Hardware products have to remain in their original state, in other words,
no modification regarding the design are allowed. Software products must
not be decompiled and their source codes must not be modified.
● Damaged or faulty products must not be implemented or put into opera‐
tion.
● It must be ensured that the products are installed as specified in the doc‐
umentation.
2.1.2 Areas of Use and Application

The Bosch Rexroth IndraControl L25 is suitable for logic and motion applica‐
tions.
The IndraControl L25 may only be used with the accessories and
mounting parts which are listed in this documentation. Components
not named expressly mentioned must neither be mounted nor con‐
nected. The same applies to cables and conduits.
The products may only be operated with the expressly stated con‐
figurations and component combinations as well as with the soft‐
ware and firmware which is given and specified in the respective
functional description.
In case of non-compliance, the guarantee and warranty claims shall
automatically expire.
Typical fields of use of the IndraControl L25 are:

● Handling systems and assembly systems
● Packaging and food processing machines
● Printing machines and paper converting machines
● Machine tools
Important Instructions on Use
The IndraControl L25 may only be operated under the assembly and installation
conditions, in the position of application and under the ambient conditions (tem‐
perature, degree of protection, humidity, EMC, etc.) specified in this documen‐
tation.
2.2 Inappropriate Use

Any use of IndraControl L25 in applications other than those specified above
or under operating conditions other than those described in the documentation
and the technical specifications is considered to be "non-intended use".
IndraControl L25 must not be used if
● it is exposed to operating conditions that do not fulfill the ambient condi‐
tions specified. For instance, operation under water, in case of extreme
variations of temperature or in extreme maximum temperatures is not al‐
lowed.
● they are used in household devices or devices belonging to categories 1
to 7 and 10 specified in Appendix IA of the Directive 2002/96/EC
("WEEE").
Safety Instructions for Electric Drives and Controls
3 Safety Instructions for Electric Drives and Controls

3.1 Definitions of Terms
Application Documentation Application documentation comprises the entire documentation used to inform
the user of the product about the use and safety-relevant features for config‐
uring, integrating, installing, mounting, commissioning, operating, maintaining,
repairing and decommissioning the product. The following terms are also used
for this kind of documentation: User Guide, Operation Manual, Commissioning
Manual, Instruction Manual, Project Planning Manual, Application Manual, etc.
Component A component is a combination of elements with a specified function, which are
part of a piece of equipment, device or system. Components of the electric drive
and control system are, for example, supply units, drive controllers, mains
choke, mains filter, motors, cables, etc.
Control System A control system comprises several interconnected control components placed
on the market as a single functional unit.
Device A device is a finished product with a defined function, intended for users and
placed on the market as an individual piece of merchandise.
Electrical Equipment Electrical equipment encompasses all devices used to generate, convert, trans‐
mit, distribute or apply electrical energy, such as electric motors, transformers,
switching devices, cables, lines, power-consuming devices, circuit board as‐
semblies, plug-in units, control cabinets, etc.
Electric Drive System An electric drive system comprises all components from mains supply to motor
shaft; this includes, for example, electric motor(s), motor encoder(s), supply
units and drive controllers, as well as auxiliary and additional components, such
as mains filter, mains choke and the corresponding lines and cables.
Installation An installation consists of several devices or systems interconnected for a de‐
fined purpose and on a defined site which, however, are not intended to be
placed on the market as a single functional unit.
Machine A machine is the entirety of interconnected parts or units at least one of which
is movable. Thus, a machine consists of the appropriate machine drive ele‐
ments, as well as control and power circuits, which have been assembled for
a specific application. A machine is, for example, intended for processing,
treatment, movement or packaging of a material. The term "machine" also cov‐
ers a combination of machines which are arranged and controlled in such a way
that they function as a unified whole.
Manufacturer The manufacturer is an individual or legal entity bearing responsibility for the
design and manufacture of a product which is placed on the market in the in‐
dividual's or legal entity's name. The manufacturer can use finished products,
finished parts or finished elements, or contract out work to subcontractors.
However, the manufacturer must always have overall control and possess the
required authority to take responsibility for the product.
Product Examples of a product: Device, component, part, system, software, firmware,
among other things.
Project Planning Manual A project planning manual is part of the application documentation used to
support the sizing and planning of systems, machines or installations.
Qualified Persons In terms of this application documentation, qualified persons are those persons
who are familiar with the installation, mounting, commissioning and operation
of the components of the electric drive and control system, as well as with the
hazards this implies, and who possess the qualifications their work requires. To
comply with these qualifications, it is necessary, among other things,
1) to be trained, instructed or authorized to switch electric circuits and devices

safely on and off, to ground them and to mark them
2) to be trained or instructed to maintain and use adequate safety equipment
3) to attend a course of instruction in first aid
User A user is a person installing, commissioning or using a product which has been
placed on the market.
3.2 General Information

3.2.1 Using the Safety Instructions and Passing Them on to Others
Do not attempt to install and operate the components of the electric drive and
control system without first reading all documentation provided with the product.
Read and understand these safety instructions and all user documentation prior
to working with these components. If you do not have the user documentation
for the components, contact your responsible Bosch Rexroth sales partner. Ask
for these documents to be sent immediately to the person or persons respon‐
sible for the safe operation of the components.
If the component is resold, rented and/or passed on to others in any other form,
these safety instructions must be delivered with the component in the official
language of the user's country.
Improper use of these components, failure to follow the safety instructions in
this document or tampering with the product, including disabling of safety de‐
vices, could result in property damage, injury, electric shock or even death.
3.2.2 Requirements for Safe Use

Read the following instructions before initial commissioning of the components
of the electric drive and control system in order to eliminate the risk of injury
and/or property damage. You must follow these safety instructions.
● Bosch Rexroth is not liable for damages resulting from failure to observe
the safety instructions.
● Read the operating, maintenance and safety instructions in your language
before commissioning. If you find that you cannot completely understand
the application documentation in the available language, please ask your
supplier to clarify.
● Proper and correct transport, storage, mounting and installation, as well
as care in operation and maintenance, are prerequisites for optimal and
safe operation of the component.
● Only qualified persons may work with components of the electric drive and
control system or within its proximity.
● Only use accessories and spare parts approved by Bosch Rexroth.
● Follow the safety regulations and requirements of the country in which the
components of the electric drive and control system are operated.
● Only use the components of the electric drive and control system in the
manner that is defined as appropriate. See chapter "Appropriate Use".
● The ambient and operating conditions given in the available application
documentation must be observed.
● Applications for functional safety are only allowed if clearly and explicitly
specified in the application documentation "Integrated Safety Technolo‐
gy". If this is not the case, they are excluded. Functional safety is a safety
concept in which measures of risk reduction for personal safety depend

on electrical, electronic or programmable control systems.
● The information given in the application documentation with regard to the
use of the delivered components contains only examples of applications
and suggestions.
The machine and installation manufacturers must
– make sure that the delivered components are suited for their individ‐
ual application and check the information given in this application
documentation with regard to the use of the components,
– make sure that their individual application complies with the appli‐
cable safety regulations and standards and carry out the required
measures, modifications and complements.
● Commissioning of the delivered components is only allowed once it is sure
that the machine or installation in which the components are installed
complies with the national regulations, safety specifications and standards
of the application.
● Operation is only allowed if the national EMC regulations for the applica‐
tion are met.
● The instructions for installation in accordance with EMC requirements can
be found in the section on EMC in the respective application documenta‐
tion.
The machine or installation manufacturer is responsible for compliance
with the limit values as prescribed in the national regulations.
● The technical data, connection and installation conditions of the compo‐
nents are specified in the respective application documentations and must
be followed at all times.
National regulations which the user must take into account
● European countries: In accordance with European EN standards
● United States of America (USA):
– National Electrical Code (NEC)
– National Electrical Manufacturers Association (NEMA), as well as
local engineering regulations
– Regulations of the National Fire Protection Association (NFPA)
● Canada: Canadian Standards Association (CSA)
● Other countries:
– International Organization for Standardization (ISO)
– International Electrotechnical Commission (IEC)
3.2.3 Hazards by Improper Use

● High electrical voltage and high working current! Danger to life or serious
injury by electric shock!
● High electrical voltage by incorrect connection! Danger to life or injury by
electric shock!
● Dangerous movements! Danger to life, serious injury or property damage
by unintended motor movements!
● Health hazard for persons with heart pacemakers, metal implants and
hearing aids in proximity to electric drive systems!
● Risk of burns by hot housing surfaces!
● Risk of injury by improper handling! Injury by crushing, shearing, cutting,

hitting!
● Risk of injury by improper handling of batteries!
● Risk of injury by improper handling of pressurized lines!
3.3 Instructions with Regard to Specific Dangers

3.3.1 Protection Against Contact With Electrical Parts and Housings
This section concerns components of the electric drive and control
system with voltages of more than 50 volts.
Contact with parts conducting voltages above 50 volts can cause personal
danger and electric shock. When operating components of the electric drive
and control system, it is unavoidable that some parts of these components
conduct dangerous voltage.
High electrical voltage! Danger to life, risk of injury by electric shock or serious
injury!
● Only qualified persons are allowed to operate, maintain and/or repair the
components of the electric drive and control system.
● Follow the general installation and safety regulations when working on
power installations.
● Before switching on, the equipment grounding conductor must have been
permanently connected to all electric components in accordance with the
connection diagram.
● Even for brief measurements or tests, operation is only allowed if the
equipment grounding conductor has been permanently connected to the
points of the components provided for this purpose.
● Before accessing electrical parts with voltage potentials higher than 50 V,
you must disconnect electric components from the mains or from the pow‐
er supply unit. Secure the electric component from reconnection.
● With electric components, observe the following aspects:
Always wait 30 minutes after switching off power to allow live capacitors
to discharge before accessing an electric component. Measure the elec‐
trical voltage of live parts before beginning to work to make sure that the
equipment is safe to touch.
● Install the covers and guards provided for this purpose before switching
on.
● Never touch electrical connection points of the components while power
is turned on.
● Do not remove or plug in connectors when the component has been pow‐
ered.
● Under specific conditions, electric drive systems can be operated at mains
protected by residual-current-operated circuit-breakers sensitive to uni‐
versal current (RCDs/RCMs).
● Secure built-in devices from penetrating foreign objects and water, as well
as from direct contact, by providing an external housing, for example a
control cabinet.
High housing voltage and high leakage current! Danger to life, risk of injury by
electric shock!
● Before switching on and before commissioning, ground or connect the
components of the electric drive and control system to the equipment
grounding conductor at the grounding points.
● Connect the equipment grounding conductor of the components of the

electric drive and control system permanently to the main power supply at
all times. The leakage current is greater than 3.5 mA.
● Establish an equipment grounding connection with a minimum cross sec‐
tion according to the table below. With an outer conductor cross section
smaller than 10 mm2 (8 AWG), the alternative connection of two equip‐
ment grounding conductors is allowed, each having the same cross
section as the outer conductors.
Cross section outer con‐ Minimum cross section equipment grounding conductor
ductor Leakage current ≥ 3.5 mA
1 equipment grounding 2 equipment grounding con‐
conductor ductors
1.5 mm2 (16 AWG) 2 × 1.5 mm2 (16 AWG)

2.5 mm2 (14 AWG) 2 × 2.5 mm2 (14 AWG)
4 mm2 (12 AWG) 10 mm2 (8 AWG) 2 × 4 mm2 (12 AWG)
6 mm2 (10 AWG) 2 × 6 mm2 (10 AWG)

10 mm2 (8 AWG) -
16 mm2 (6 AWG) -
25 mm2 (4 AWG) 16 mm2 (6 AWG) -
35 mm2 (2 AWG) -
50 mm2 (1/0 AWG) 25 mm2 (4 AWG) -
70 mm2 (2/0 AWG) 35 mm2 (2 AWG) -

... ... ...
Fig.3-1: Minimum Cross Section of the Equipment Grounding Connection
3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock

Protective extra-low voltage is used to allow connecting devices with basic in‐
sulation to extra-low voltage circuits.
On components of an electric drive and control system provided by Bosch
Rexroth, all connections and terminals with voltages between 5 and 50 volts
are PELV ("Protective Extra-Low Voltage") systems. It is allowed to connect
devices equipped with basic insulation (such as programming devices, PCs,
notebooks, display units) to these connections.
Danger to life, risk of injury by electric shock! High electrical voltage by incorrect
connection!
If extra-low voltage circuits of devices containing voltages and circuits of more
than 50 volts (e.g., the mains connection) are connected to Bosch Rexroth
products, the connected extra-low voltage circuits must comply with the re‐
quirements for PELV ("Protective Extra-Low Voltage").
3.3.3 Protection Against Dangerous Movements

Dangerous movements can be caused by faulty control of connected motors.
Some common examples are:
● Improper or wrong wiring or cable connection

● Operator errors
● Wrong input of parameters before commissioning
● Malfunction of sensors and encoders
● Defective components
● Software or firmware errors
These errors can occur immediately after equipment is switched on or even
after an unspecified time of trouble-free operation.
The monitoring functions in the components of the electric drive and control
system will normally be sufficient to avoid malfunction in the connected drives.
Regarding personal safety, especially the danger of injury and/or property dam‐
age, this alone cannot be relied upon to ensure complete safety. Until the
integrated monitoring functions become effective, it must be assumed in any
case that faulty drive movements will occur. The extent of faulty drive move‐
ments depends upon the type of control and the state of operation.
Dangerous movements! Danger to life, risk of injury, serious injury or property

damage!
A risk assessment must be prepared for the installation or machine, with its
specific conditions, in which the components of the electric drive and control
system are installed.
As a result of the risk assessment, the user must provide for monitoring func‐
tions and higher-level measures on the installation side for personal safety. The
safety regulations applicable to the installation or machine must be taken into
consideration. Unintended machine movements or other malfunctions are pos‐
sible if safety devices are disabled, bypassed or not activated.
To avoid accidents, injury and/or property damage:
● Keep free and clear of the machine’s range of motion and moving machine
parts. Prevent personnel from accidentally entering the machine’s range
of motion by using, for example:
– Safety fences
– Safety guards
– Protective coverings
– Light barriers
● Make sure the safety fences and protective coverings are strong enough
to resist maximum possible kinetic energy.
● Mount emergency stopping switches in the immediate reach of the oper‐
ator. Before commissioning, verify that the emergency stopping equip‐
ment works. Do not operate the machine if the emergency stopping switch
is not working.
● Prevent unintended start-up. Isolate the drive power connection by means
of OFF switches/OFF buttons or use a safe starting lockout.
● Make sure that the drives are brought to safe standstill before accessing
or entering the danger zone.
● Additionally secure vertical axes against falling or dropping after switching
off the motor power by, for example,
– mechanically securing the vertical axes,
– adding an external braking/arrester/clamping mechanism or
– ensuring sufficient counterbalancing of the vertical axes.
● The standard equipment motor holding brake or an external holding brake

controlled by the drive controller is not sufficient to guarantee personal
safety!
● Disconnect electrical power to the components of the electric drive and
control system using the master switch and secure them from reconnec‐
tion ("lock out") for:
– Maintenance and repair work
– Cleaning of equipment
– Long periods of discontinued equipment use
● Prevent the operation of high-frequency, remote control and radio equip‐
ment near components of the electric drive and control system and their
supply leads. If the use of these devices cannot be avoided, check the
machine or installation, at initial commissioning of the electric drive and
control system, for possible malfunctions when operating such high-fre‐
quency, remote control and radio equipment in its possible positions of
normal use. It might possibly be necessary to perform a special electro‐
magnetic compatibility (EMC) test.
3.3.4 Protection Against Magnetic and Electromagnetic Fields During Oper‐

ation and Mounting
Magnetic and electromagnetic fields generated by current-carrying conductors
or permanent magnets of electric motors represent a serious danger to persons
with heart pacemakers, metal implants and hearing aids.
Health hazard for persons with heart pacemakers, metal implants and hearing
aids in proximity to electric components!
● Persons with heart pacemakers and metal implants are not allowed to
enter the following areas:
– Areas in which components of the electric drive and control systems
are mounted, commissioned and operated.
– Areas in which parts of motors with permanent magnets are stored,
repaired or mounted.
● If it is necessary for somebody with a heart pacemaker to enter such an
area, a doctor must be consulted prior to doing so. The noise immunity of
implanted heart pacemakers differs so greatly that no general rules can
be given.
● Those with metal implants or metal pieces, as well as with hearing aids,
must consult a doctor before they enter the areas described above.
3.3.5 Protection Against Contact With Hot Parts

Hot surfaces of components of the electric drive and control system. Risk of
burns!
● Do not touch hot surfaces of, for example, braking resistors, heat sinks,
supply units and drive controllers, motors, windings and laminated cores!
● According to the operating conditions, temperatures of the surfaces can
be higher than 60 °C (140 °F) during or after operation.
● Before touching motors after having switched them off, let them cool down
for a sufficient period of time. Cooling down can require up to 140 mi‐
nutes! The time required for cooling down is approximately five times the
thermal time constant specified in the technical data.
● After switching chokes, supply units and drive controllers off, wait 15 mi‐
nutes to allow them to cool down before touching them.
● Wear safety gloves or do not work at hot surfaces.
● For certain applications, and in accordance with the respective safety reg‐
ulations, the manufacturer of the machine or installation must take meas‐
ures to avoid injuries caused by burns in the final application. These
measures can be, for example: Warnings at the machine or installation,
guards (shieldings or barriers) or safety instructions in the application
documentation.
3.3.6 Protection During Handling and Mounting

Risk of injury by improper handling! Injury by crushing, shearing, cutting, hitting!
● Observe the relevant statutory regulations of accident prevention.
● Use suitable equipment for mounting and transport.
● Avoid jamming and crushing by appropriate measures.
● Always use suitable tools. Use special tools if specified.
● Use lifting equipment and tools in the correct manner.
● Use suitable protective equipment (hard hat, safety goggles, safety shoes,
safety gloves, for example).
● Do not stand under hanging loads.
● Immediately clean up any spilled liquids from the floor due to the risk of
falling!
3.3.7 Battery Safety

Batteries consist of active chemicals in a solid housing. Therefore, improper
handling can cause injury or property damage.
Risk of injury by improper handling!
● Do not attempt to reactivate low batteries by heating or other methods (risk
of explosion and cauterization).
● Do not attempt to recharge the batteries as this may cause leakage or
explosion.
● Do not throw batteries into open flames.
● Do not dismantle batteries.
● When replacing the battery/batteries, do not damage the electrical parts
installed in the devices.
● Only use the battery types specified for the product.
Environmental protection and disposal! The batteries contained in

the product are considered dangerous goods during land, air, and
sea transport (risk of explosion) in the sense of the legal regulations.
Dispose of used batteries separately from other waste. Observe the
national regulations of your country.
3.3.8 Protection Against Pressurized Systems

According to the information given in the Project Planning Manuals, motors and
components cooled with liquids and compressed air can be partially supplied
with externally fed, pressurized media, such as compressed air, hydraulics oil,
cooling liquids and cooling lubricants. Improper handling of the connected sup‐
ply systems, supply lines or connections can cause injuries or property damage.
Risk of injury by improper handling of pressurized lines!
● Do not attempt to disconnect, open or cut pressurized lines (risk of explo‐
sion).
● Observe the respective manufacturer's operating instructions.
● Before dismounting lines, relieve pressure and empty medium.
● Use suitable protective equipment (safety goggles, safety shoes, safety
gloves, for example).
● Immediately clean up any spilled liquids from the floor due to the risk of
falling!
Environmental protection and disposal! The agents (e.g., fluids)

used to operate the product might not be environmentally friendly.
Dispose of agents harmful to the environment separately from other
waste. Observe the national regulations of your country.
3.4 Explanation of Signal Words and the Safety Alert Symbol

The Safety Instructions in the available application documentation contain spe‐
cific signal words (DANGER, WARNING, CAUTION or NOTICE) and, where
required, a safety alert symbol (in accordance with ANSI Z535.6-2006).
The signal word is meant to draw the reader's attention to the safety instruction
and identifies the hazard severity.
The safety alert symbol (a triangle with an exclamation point), which precedes
the signal words DANGER, WARNING and CAUTION, is used to alert the
reader to personal injury hazards.
DANGER
In case of non-compliance with this safety instruction, death or serious injury
will occur.
WARNING
In case of non-compliance with this safety instruction, death or serious injury
could occur.
CAUTION
In case of non-compliance with this safety instruction, minor or moderate injury
could occur.
NOTICE
In case of non-compliance with this safety instruction, property damage could
occur.
Technical Data
4 Technical Data
4.1 Equipment
Processor Renesas SH 7785
RAM Min. 128 MByte DRAM and min. 256 kByte RDS1)
Clock frequency 576 MHz (CPU CLK)
Interfaces:
Interface to function ● Bosch Rexroth PC104Plus
modules
Interface to I/O terminals ● Rexroth Inline interface
Communication interfa‐ ● 1 × Ethernet connection (RJ 45, 10/100 base-T)
ces ● 1 × SERCOS III Master/Slave interface
Ready contact ● 1 single-pin ready contact
4.2 Voltage Supply

The IndraControl L25 is supplied with 24 V. The following values of the oper‐
ating voltage comply with DIN EN 61131-2:
Nominal value DC 24 V
Tolerances -15 %, +20 % (without residual ripple)

Residual ripple ±5%
Umax 30 V
Umin 19.2 V
Fig.4-1: Operating voltage according to DIN EN 61131-2

Three operating voltages have to be applied on the IndraControl L25 (see
chapter 7.2.1 "Supply Voltages to be Connected Externally" on page 31).
Taking the function modules and Inline terminals into consideration, the current
consumption from these voltages is:
Current consumption from ULS and maximum ex‐ Maximum 2 A

tension
Current consumption from UM and US Max. of 8 A in total
Fig.4-2: Power consumption
The power consumption of IndraControl L25 (without connected I/

Os and function modules) is typically 8.7 watts.
1) RDS - Remanent Data Storage

Remanent data is automatically written to the Compact Flash card after voltage loss.
The data is restored after rebooting the control.
Technical Data
4.3 Ambient Conditions

In operation Storage / Transport
Max. surrounding air +5 ... +55 °C -25 ℃ to +70 ℃

temperature
Relative humidity RH-2; 5 % to 95 % acc. to DIN EN 61131-2, RH-2; 5 % to 95 % acc. to DIN EN 61131-2,
non-condensing. non-condensing.
Air pressure Up to 2,700 m above MSL according to Up to 3,000 m above MSL according to
DIN 60204 DIN 60204
Mechanical strength Max. vibration: Max. shock:
Frequency range: 10 to 150 Hz 15 g according to EN 60 068-2-27, no disturbance
Excursion: 0.075 mm of the function
for 10 ... 57 Hz
Acceleration: 1 g
for 57 to 150 Hz
acc. to EN 60068-2-6
Fig.4-3: Ambient Conditions
The surrounding air must be free from acids, alkaline solutions,

corrosive agents, salts, metal vapors, and other electrically con‐
ductive contaminants in high concentrations.
The ambient air must be dust-free. Housings and installation com‐
partments must at least comply with degree of protection IP 54
according to DIN VDE 0470-1.
DANGER Danger of destruction by overheating

Operation is allowed up to 45 ℃ and if the air recirculates.
If the internal temperature reaches approx. 92 ℃, the control switches off au‐
tomatically.
If the internal temperature is 87 °C or higher, the display indicates the warning
"Temp !!!".
The internal temperature of IndraControl L25 can be read out with the "IH_Tem‐
perature" function in the "RIH_HWTestLib" library of the application program in
order to trigger further reactions.
4.4 Used Standards

The IndraControl L25 complies with the following standards:
Standard Meaning
DIN EN 60 204-1 Electrical equipment of machines

DIN EN 61 131-2 Programmable logic controllers
Equipment and tests requirements
Technical Data
Standard Meaning
DIN EN 60 529 Degrees of protection (including housings and installa‐
tion compartments)
UL 508 Industrial Control Equipment
Fig.4-4: Used standards
The IndraControl L25 as well as the additionally available function

modules and the Inline terminals correspond to the CE require‐
ments!
Systems with the IndraControl L25 that are used in residential areas
(housing, business and commercial areas as well as small-sized
enterprises) require a single approval by an authority or a testing
agency. In Germany, such single approvals are issued by the ”Reg‐
ulierungsbehörde für Telekommunikation und Post (RegTP)” (Ger‐
man Regulatory Authority for Telecommunications and Posts).
4.5 UL and CSA certified
The devices of the IndraControl L25 product family are certificated according
to
● UL508 (Industrial Control Equipment) and
● C22.2 no. 142-M1987 (CSA)
UL file no. E210730
However, there can be combinations or stages of expansions with limited or
missing certification. Therefore verify the certification by using the UL label on
the device.
To guarantee an UL- and CSA-compliant operation, the following

conditions have to be fulfilled:
● Use only insulated copper wire suitable for at least 60/75 °C.
NOTICE Loss of UL and CSA compliance due to

changes on the device.
The UL- and CSA- marking is only valid for the device in its delivery status. After
having modified the device the UL and CSA compliance must be verified.
4.6 Compatibility Test

All Rexroth controls and drives are developed and tested according to the latest
state-of-the-art of technology.
As it is not possible to follow the continuing development of all materials (e. g.
lubricants in machine tools) which may interact with our controls and drives, it
cannot be completely ruled out that any reactions with the materials used by
Bosch Rexroth might occur.
Technical Data
For this reason, before using the respective material a compatibility test has to
be carried out for new materials (e. g. lubricants and cleaning agents) and our
housing or our housing materials.
4.7 Wear Parts

This section describes the wear parts as well as their service life. Wear parts
are not subject to any warranty.
Display The service life of the display is limited. A progressive deterioration of the dis‐
play takes place after the service life was exceeded.
The manufacturer specifies the following service life of the displays:
● 60,000 h for 23 ± 5°C and 60 ± 20% RH (relative air humidity)
Dimensions
5 Dimensions
All values in the illustrations are given in mm.
5.2 Housing Dimensions

The width of the IndraControl L25 is 175.4 mm, the height is 120 mm and the
depth is 84.7 mm. Please refer to the following figures for detailed dimensions:
Fig.5-1: Bottom view
Fig.5-2: Front view

Dimensions
Fig.5-3: Left view (the cut-out for the top-hat rail is located in the center)
5.3 Installation Notes

● Avoid installation locations that are exposed to direct sunlight because this
causes additional heat.
● Keep as much distance as possible to noise sources
● Lay all connecting cables in loops and use strain reliefs for all cables.
● Keep as much distance as possible to noise sources.
● Provide the following minimum clearances for sufficient cooling:
100 mm
30 mm
30 mm
30 mm
100 mm
Fig.5-4: Minimum distances for the circulation of surrounding air
● Additionally, provide sufficient clearance for mounting, dismounting, con‐
nector and cable length.
Display and Operating Components
6 Display and Operating Components

On its front, the IndraControl L25 is provided with the following display and
operating components: a single-line display with four operating keys as well as
a LED and a Reset button.
6.2 Display and Operating Keys

Display The display is a LCD with eight characters (5 × 10 dot matrix).
Fig.6-1: Display with four operating keys

The keys below the display have the following functions:
Key Menu navigation Input functions
<Esc> One level up Cancel input

<Down> One menu entry down Reduce parameter value
(down arrow)
<Up> One menu entry up Increase parameter value
(up arrow)
<Enter> One level down Confirm input
Fig.6-2: Functions of the operating keys
6.3 Reset Button and Stop LED

The reset button and a red LED are arranged in the section below the display.
Fig.6-3: Reset button and STOP LED

Reset button
By activating the reset button, the whole device is reset and a restart
is forced, without the need to switch off the supply voltages.
The reset button can only be actuated with a sharp tool (e. g. tip of a pencil).
LED The LED serves for diagnostics and status display.
The states indicated by the LED depend on the firmware used and are included
in the description of the particular system.
Connections and Interfaces
7 Connections and Interfaces

7.1 Connections on the Front Panel – Overview
Designa‐ Connection type Connector type Mating connec‐ Notes on de‐
tion at the (integrated) tor and cable vice variants
housing (from outside)
X7E5 Ethernet RJ45 female RJ45 connector -

(TCP/IP, program‐ connector (twisted pair, 8-
ming device) 8-pin wire)
X7E1 Ethernet RJ45 female RJ45 connector Only available
(SERCOS III) connector (twisted pair, 8- on CML...3N...
8-pin wire) device variant

(SERCOS III) connector (twisted pair, 8- on CML...3N...
8-pin wire) device variant
X2R Ready contact Connector strip 3-pin female -

3-pin, 3.5 mm connector strip,
spring force,
3.5 mm (inclu‐
ded in the
scope of deliv‐
ery)
(TCP/IP, RT connector (twisted pair, 4-/ on CML...PN...
Ethernet) 8-pin 8-wire) device variant

(TCP/IP, RT connector (twisted pair, 4-/ on CML...PN...
Ethernet) 8-pin 8-wire) device variant
X7P RS485 D-Sub female D-Sub bus con‐ Only available

(PROFIBUS DP) connector nector, IP 20, on CML...PN...
9-pin 9-pin device variant
View IndraControl L25, CML...3N...

device variant
L
SERCOS
X7E1
X7E2
X7E5
X2R
1 2
① Slot for Compact Flash card
② PWR IN voltage supply
Fig.7-1: IndraControl L25 connections, CML...3N... device variant
CAUTION Fitting or removing connectors when voltage is

applied, may damage the IndraControl L25, a
function module or an Inline terminal!
Turn off the supply voltage before establishing or breaking any connections!
View IndraControl L25, CML...PN...

device variant
L
X7E3
ETH
L
X7E4
X7E5
PROFIBUS DP
9
X2R
1
X7P
1 2
① Slot for Compact Flash card
② PWR IN voltage supply
Fig.7-2: IndraControl L25 connections, CML...PN... device variant
CAUTION Fitting or removing connectors when voltage is

applied, may damage the IndraControl L25, a
function module or an Inline terminal!
Turn off the supply voltage before establishing or breaking any connections!
7.2 Voltage Supply

7.2.1 Supply Voltages to be Connected Externally
General Information
PWR IN The IndraControl L25 as well as any connected function modules and Inline
terminals are supplied with power via the black connector to the right side of
the IndraControl L25.
Fig.7-3: Connector for supply voltages
Observe the color-coding of the connectors.
For connecting the operating voltages only the power connector (R-
IB IL SCN-PWR IN-PWR) may be used. The connector is contained
in the scope of delivery. TheR-IB IL SCN-PWR IN-CP connector,
which is available for other power terminals, is not allowed for the
IndraControl L25!
NOTICE Insufficient contact, loss of UL certification due

to inadequate wire.
Use only copper wire (cross-section AWG 22 to 16; 0.34 mm2 to 1.5 mm2) for
wiring the connection terminals.
Connector con‐ Signal

tact
1.1 DC +24 V segment voltage (US)
1.2 DC +24 V supply voltage (ULS)
1.3 LGND (ground, supply voltage)

1.4 and 2.4 FE (functional earth ground)
2.1 DC 24 V main voltage (UM)
2.2 DC 24 V main voltage (UM)
2.3 PGND (ground main and segment voltage)
Fig.7-4: Pin assignment on the voltage terminal

Five LEDs are arranged at the upper edge. The LEDs have the following mean‐
ing:
LED "UM" Meaning
Off Main circuit supply is missing.

Green 24 V supply UM of the main circuit is present.
Fig.7-5: Diagnostic LED of the power terminal
LED Meaning
"US"
Off Segment circuit supply is missing

Green 24 V supply ULS of the segment circuit is present
Fig.7-6: Diagnostic LED of the segment terminal
LED "UL" Meaning
Off Supply voltage ULS is missing
Green 24 V supply voltage ULS is present
Fig.7-7: Diagnostic LED of the supply voltage
LED "FS" and Meaning

"FN"
At the moment without function
Fig.7-8: LED FS and FN

The 7.5 V Inline voltage and the +24 V analog voltage UANA are derived from
the external +24 V voltage ULS.
24 V Voltage Supply ULS

The 24 V supply voltage ULS (contact 1.2) generates the internally required
voltages in the IndraControl L25.
ULS is electrically isolated from the voltages UM and US.

Requirement: A power supply unit that is electrically isolated from
the power supply units for UM and US is used for ULS.
UM and US are not electrically isolated from each other.
24 V Voltage Supply of the Main Circuit UM

The 24 V voltage for the main circuit supply UM on terminal 2.2 is not used for
IndraControl L25.
A main circuit UM begins at a power terminal at the IndraControl L25 and is lead
to the next power terminal through all following terminals. At the next power
terminal, a new circuit is started; its potential is isolated from the previous one.
Several power terminals can be used within one station.
Function Several segments, independent from each other, can be created within the
main circuit. The main circuit provides the voltage potential, from which the
segment voltages (US) are derived. The splitting into segments permits to pro‐
tect or switch e. g. the supply of several actuators separately.
Current carrying capacity The maximum current carrying capacity is 8 A (total current with the segment
circuit). If the limit value has been reached, a new power terminal must be used.
IndraControl Rexroth Inline
PWR IN PWR IN SEG/F
UL
UANA
GNDL
ULS
US
UM
UM UM
PWR IN Voltage terminal at IndraControl L25

R-IL 24 Power terminal
PWR IN
R-IL 24 Segment terminal with fuse
SEG/F
Fig.7-9: Main circuit
Generation of UM In the simplest case, the main voltage UM can be supplied at the IndraCon‐
trol L25.
UM can also be supplied via a power terminal. A power terminal has to be used
in the following cases:
1. An electrical isolation has to be set up.
2. The maximum current carrying capacity of a voltage jumper (M, US or GND,
total current of US and UM) is reached.
+24 V Supply of the Segment Circuit US

Segment circuit supply US has to be connected to contact 1.1 and is lead
through the following series Rexroth Inline I/O terminals. It forms the segment
circuit or auxiliary circuit (via voltage jumpers) of the Rexroth Inline terminals
and the onboard I/Os.
The segment circuit with the segment voltage US starts at the IndraCon‐
trol L25 or a supply terminal (power terminal or segment terminal) and is
supplied through all following terminals up to the next supply terminal.
Function Several segment terminals can be used within a main circuit and thereby seg‐
ment the main circuit. The reference to ground is the same as that of the main
circuit. Thus, different fused electric circuits can be implemented within the sta‐
tion without any external cross-wiring.
Voltage The voltage in the segment circuit is DC 24 V.
Current carrying capacity The maximum current carrying capacity is 8 A (total current with the main cir‐
cuit). If the limit value for a voltage jumper UM is reached (total current of US
and UM), a new power terminal must be used.
Generation US The segment voltage US can be provided in various ways:
1. The segment voltage can be fed at the IndraControl L25 or at a power
terminal.
2. The segment voltage can be tapped from the main voltage, either at the
IndraControl L25 or at a power terminal using a jumper or a switch.
3. A segment terminal with fuse can be used. In this terminal, the segment
voltage is automatically tapped from the main voltage.
At the 120 V and 230 V voltage levels, it is not possible to set up

segments. Only the manin circuit is used in this level. Special power
terminals must be used.

PWR IN 24 PWR IN 24 SEG/F
UL
UANA
GNDL
ULS
US
UM
US UM

PWR IN
SEG/
Fig.7-10: Segment circuit
The voltages M and US are electrically isolated from UL.

Requirement: Power supply units that are electrically isolated from
the power supply unit for UL are used for voltages UM and US.
When designing the station, do observe that the total current in the
segment circuit US and in the main circuit UM must not exceed 8 A.
UM is interrupted by the PWR IN terminal.

US is interrupted by the PWR-IN and SEG/F terminals.
7.2.2 Internally Generated Voltages

+7.5 V Inline Supply UL
The +7.5-V Inline supply voltage is generated from the supply voltage ULS inside
the IndraControl L25 and is supplied through all connected Rexroth Inline I/O
terminals. It is the logic voltage supply (via voltage jumpers) of the Rexroth
Inline terminals.
This logic circuit starts at the IndraControl L25 and is supplied through all ter‐
minals of a station.
Function Logic voltage is supplied from the Inline supply to all terminals of the station.
Voltage The voltage in this circuit is 7.5 V.
Generation of the Inline supply The Inline supply is generated from the supply voltage ULS of the IndraCon‐
trol L25.
Current carrying capacity The maximum current carrying capacity of the Inline supply is 2 A.
24 V Analog Supply (UANA)
The 24 V analog supply is also generated from the voltage ULS. It starts in the
IndraControl L25 and is supplied through all Rexroth Inline I/O terminals. It is
the voltage supply (via voltage jumpers) UANA of the Rexroth Inline analog ter‐
minals.
Function The peripheral equipment of the terminals for analog signals is supplied from
the analog circuit.
Voltage The voltage in this circuit is 24 V.
Provision The analog voltage UANA is generated from the IndraControl L25 from the logic
voltage ULS
Current carrying capacity The current carrying capacity of UANA is max. 0.5 A.
PWR IN 24 PWR IN 24 SEG/F
UL
U ANA
GNDL
ULS
US
UM
ULS

PWR IN
SEG/F
Fig.7-11: Inline supply and analog circuit
For comments on the wiring, please refer to chapter 8.3 "Electrical Installa‐
tion" on page 48.
7.3 Interfaces
7.3.1 Ethernet Interfaces
X7E5 Ethernet network connection Connector X7E5 can be used to connect the IndraControl L25 to an Ethernet
network.
The connection requirements defined for 100BaseT in IEEE 802.3 are appli‐
cable.
RJ45, female connector, 8-pin

Type: Ethernet 100BaseT
Cable length: 100 m max.
Cable type: CAT5e with S/STP
Transmission rate: 10 or 100 MBit/s
Ethernet
max. 100 m
Ethernet RJ45 2
ToZum
the Network
Netzwerk
L 3
8
4
5
1 6
S
7
8
Fig.7-12: Ethernet interface

Bosch Rexroth recommends to use a STP cable of category 5.
This port is intended for the programming device network!
LED Status
L (link) On: Link to network is available

Off: No connection to network is available
S (send) On: Data packets are sent
Off: No data is sent
7.3.2 Ethernet Interface (only for Device Variant CML...PN ...)

X7E3, X7E4 Ethernet network con‐ Connectors X7E3 and X7E4 can be used to connect the IndraControl L25 to
nection an Ethernet network.
The connection requirements defined for 100BaseTX in IEEE 802.3 are appli‐
cable.
Type Ethernet 100Base TX

Cable length 100 m max.
Cable type CAT5e with S/STP
Transmission rate 10 or 100 MBit/s
Ethernet
max. 100 m
Ethernet RJ45 2
ToZum
the Network
Netzwerk
L 3
8
4
5
1 6
S
7
8

Bosch Rexroth recommends to use a STP cable of category 5.
According to the configuration in the application software, these connections
can be used for another TCP/IP network or for an RT Ethernet network.
The two plugs correspond to a twofold switch in a TCP/IP network.
LED Status

7.3.3 PROFIBUS DP (only for Device Variant CML...PN...)

X7P PROFIBUS DP interface The IndraControl L25 provides a PROFIBUS interface according to DIN EN
50170, part 2.
D-Sub female connector, 9-pin

Type RS485
Cable type Shielded, twisted pair
Transmission rate 9.6 kBit/s to 12 kBit/ss
X7P
1
2
5 1 RxD/TxD-P 3
CNTR-T 4
DGND 5
VP 100 mA 6
7
9 6 RxD/TxD-N 8
CNTR-N 9
Shield above the metallic

plug of the housing
Fig.7-14: PROFIBUS DP interface

The bus line is specified as cable type A according to EN 50170, Part 8-2. The
bus line must comply with the following cable parameters:
Surge impedance at a frequency within a range 135 to 156 ohm

from 3 to 20 MHz
Operating capacity <= 30 pF/m
Loop resistance <= 110 ohm/km
Outer diameter > 0.64 mm
Core cross-section > 0.34 mm2
Fig.7-15: Parameters for PROFIBUS DP cable

The mentioned cable parameters in fig. "" on page 38 of a standard cable of
cable type A result in the following length extensions of a bus segment for the
particular transmission rates:
Transmission rate in 9.6 19.2 45.45 93.75 187.5 500 1500 3000 6000 12000
kbits/s
Max. segment length 1200 1200 1200 1200 1000 400 200 100 100 100
in m
Fig.7-16: Maximum segment length with regard to the transmission rate

Two LEDS are located above the PROFIBUS interface that display the interface
state:
LED designation Color State Description
Stat. Green Lights permanently Communication

Lights acyclically Not configured
Lights cyclically Configured
Bus Red Lights permanently No connection
Flashes Slave diagnostics
Fig.7-17: PROFIBUS state display

per LED
7.3.4 SERCOS III (only for Device Variant CML...3N...)

X7E1 and X7E2 SERCOS interface Connect the SERCOS III devices to the optionally available X7E1 and X7E2
connectors.
Type Ethernet 100BaseT

Cable length 100 m max.
Cable type CAT5e with S/STP
Transmission rate 10 or 100 MBit/s
Ethernet
max. 100 m
Ethernet RJ45 2
ToZum
the Network
Netzwerk
L 3
8
4
5
1 6
S
7
8
LED Status

7.3.5 Ready Contact

X2R ready contact Pin 1 and pin 2 of the 3-pin male connector strip X2R are the connections of
the optionally available ready contact.
NOTICE Insufficient contact, loss of UL certification due

to inadequate wire.
Use only copper wire (cross-section AWG 22 to 16; 0.34 mm2 to 1.5 mm2) for
wiring the connection terminals.
The ready contact has a single-channel setup.
Characteristics of the relay (photo-MOS

relay)
Switching capacity DC 60 V, 1 A
UL rating AC/DC 30 V,1 A, resistive
Dropout time 0.3 ms
Bounce time None
Watchdog time (analog watchdog only) 50 ms ± 25 %
Fig.7-19: Characteristics of the ready contact

If it is in the release status, the ready contact is open. After powering up the
device, the contact is closed. The contact is opened again, if one of the states
listed below occurs:
● The DC 24 V supply voltage falls below the permissible limit.
● The internal 5 V and 3.3 V voltages fall below the permissible limit.
● The ready watchdog is elapsing.
● The reset button is actuated.
The LED arranged next to the ready contact is a red-green dual LED. This LED
can assume the following states:
LED "Ready" Meaning
Off Watchdog has not been started yet

or
Ready contact was opened by software (but the watchdog is still trig‐
gered internally)
Green Ready contact is closed; watchdogs are triggered.
Red Ready error; at least one watchdog has responded.
Fig.7-20: Ready LED
7.3.6 Interface for Compact Flash Card

Compact Flash card The IndraControl L25 features a slot for a Compact Flash card. This slot can
be used to insert the memory card containing the firmware (this memory card
has to be ordered separately). Additionally, data and programs are stored on
this card. Operation without Compact Flash card is not possible.
DANGER Uncontrolled movements caused by operation

without Compact Flash card!
Do not remove the Compact Flash card as long as the IndraControl L25 is in
operation!
7.4 Inline Bus

To its right, the IndraControl L25 can be extended by additional Rexroth Inline
terminals. The I/O unit can be extended up to 32-byte inputs and 32-byte out‐
puts by these terminals.
Max. 63 Rexroth Inline terminals can be connected.
For further information regarding Rexroth Inline terminals, please

refer to the documentation "Automation Terminals Of The Rexroth
Inline Product Range" (parts number R911317021).
7.5 Function Module Connector

To its left, the IndraControl L25 is provided with a function module connector
that can be used to connect extension modules.
This 120-pin connector is a Bosch Rexroth PC104Plus connector where the
PC104 signals as well as additional system-specific signals are applied. In other
words, only the function modules especially developed for the IndraCon‐
trol L25 can be connected to this connector.
Max. two function modules can be connected. The both function modules must
not exceed the following limit values in total:
● Current consumption from 5 V: Max. total current 1 A
● Current consumption from 3.3 V: Max. total current 2 A
● Total power consumption: Max. total of the total power consumption 10 W
For further information, please refer to the documentation "Rexroth IndraCon‐
trol L Function Modules" (parts number R911326408).
Installation and Maintenance
8 Installation and Maintenance

8.1 Mechanical Installation of IndraControl L25
8.1.1 General Information
Mount the IndraControl L25 to a mounting rail (standard top-hat rail) according
to DIN EN 50022 (3.5 mm × 7.5 mm).
Ensure that the top-hat rail is attached such that it provides appro‐
priate rigidity.
In addition to its holding function, this top-hat rail also assumes the
function of ground connection and heat removal. For that reason,
the top-hat rail must be connected to a functional earth ground.
Furthermore, the top-hat rail is provided as heat sink in connection with the
metal bottom frame of the IndraControl L25.
Ensure a well heat-dissipating connection to the rear panel of the

control cabinet.
Install the IndraControl L25 horizontally in a control cabinet or in an appropriate

housing.
If the ambient conditions are sufficient, the IndraControl L25 can be directly
installed on the plant (see also chapter 4.3 "Ambient Conditions" on page
22).
CAUTION Do not mount controls, modules, inline termi‐

nals and connectors while the unit is provided
with voltage!
Before mounting or dismounting components of the station, de-energize the
entire station.
Connect the voltage only after the entire station has been set up. Any non-
observance of this requirement may damage the components.
8.1.2 Mounting the IndraControl L25

Mounting the IndraControl L25 on Mount the IndraControl L25 by hanging it onto the top-hat rail from above and
the top-hat rail then exerting slight pressure to engage the control in the lower section of the
housing.
Adding Rexroth Inline terminals in If necessary, mount Rexroth Inline terminals in series. For further information,
series please refer to chapter 8.2 "Mechanical Installation of Rexroth Inline Termi‐
nals" on page 45.
End plate The end plate has to form the mechanical termination to the right of the station,
irrespective of whether Rexroth Inline terminals have been mounted in series
or not. The end plate does not have any electrical function. The end plate pro‐
tects the station from ESD pulses and the user from dangerous contact voltag‐
es. The end plate is included in the scope of delivery of the IndraControl L25.
Therefore it is not necessary to order the end plate separately.
Mounting function modules Thereafter, place the function modules onto the top-hat rail to the left of the
IndraControl L25, if necessary. Slide the function modules along the top-hat rail
all the way to the left side of the IndraControl L25, until a secure connection via
the PCIPLUS bus is established.
Fixing the end clamp / CLIPFIX Finally, attach end clamps to both sides of the Rexroth Inline station. These end
clamps ensure that the station is securely mounted to the top-hat rail and are
also provided as lateral termination elements. These end clamps are included
in the scope of delivery of the IndraControl L25.
8.1.3 Dismounting the IndraControl L25

Disconnecting additional modules To dismount the IndraControl L25, first disconnect the function modules moun‐
from the IndraControl L25 ted to the left of the IndraControl L25 from the latter. First remove the left-hand
end clamp (CLIPFIX) and slide the function modules along the top-hat rail to
the left until the plug connection of the PCIPLUS bus is severed.
Removing the first Rexroth Inline Thereafter, remove the first Rexroth Inline terminal that is mounted to the right
terminal of the IndraControl L25. Proceed as follows:
● Remove the labeling field, if present.
If any of the terminal is provided with more than one connector, all
these connectors have to be removed from the terminal.
● Pry out the connector of the terminal to be removed by pressing on the

rear connector shaft latch.
● Remove the connector(s).
● Remove the power connector from the IndraControl L25. This ensures that
the feathers of the voltage jumpers and of the keyway/feather key con‐
nection are prevented from damage. Moreover, the terminal can be ac‐
cessed more easily.
● Actuate the release mechanism (see ① in the following figure) and remove
the terminal perpendiculary to the top-hat rail (see ② in the following fig‐
ure).
Fig.8-1: The first Rexroth Inline terminal has to be removed before dismounting
the IndraControl L25.
Removing the IndraControl L25 Now the IndraControl L25 can be removed from the top-hat rail by loosening
from the top-hat rail the fixing claw on the bottom side by means of a tool (screwdriver) and pulling
the IndraControl L25 off the top-hat rail from below, tilting it and removing it
upwards.
8.2 Mechanical Installation of Rexroth Inline Terminals

Rexroth Inline terminals can be added in series to the right of the IndraCon‐
trol L25 as appropriate. No tool is required. On connecting these modules in
series, the potential and bus signal connection (voltage routing and data rout‐
ing) between the individual components of the station is established automati‐
cally.
The terminals are mounted perpendicularly to the top-hat rail.
Once the station has been set up, individual terminals can be replaced subse‐
quently by being pulled out or plugged in without any additional tools.
Top-hat rail The Rexroth Inline terminals are mounted to the right of the IndraControl L25
on the 35 mm standard top-hat rail.
8.2.2 Mounting the Inline Terminals

Proceed as follows to latch on a terminal (see fig. 8-2 "Latching a terminal" on
page 46):
● First latch on the terminal that is required to set up the station, perpen‐
dicularly to the top-hat rail (see figure A).
Ensure that all feather keys and keyways of neighboring terminals

are interlocked (figure B).
The keyway/feather key connection connects neighboring modules to each

other. In this way the voltage routing is set up securely.
● Then fit the connectors onto the respective terminal.
First fit the front connector shaft latch in the front release mechanism (figure
C).
Then press the connector towards the terminal until it clicks into place in the
rear release mechanism (figure D).
The keyways provided in the terminal are not continued in the con‐
nector. A terminal can only be latched on, if there is no connector
to the left of it. If necessary, the connector has to be removed.
A B
C D
Fig.8-2: Latching a terminal
8.2.3 Demounting the Inline Terminals

Proceed as follows to remove a terminal (see fig. 8-3 "Removing a terminal" on
page 47):
● Remove the labeling field, if present (A1 in figure A).
If any of the terminal is provided with more than one connector, all
these connectors have to be removed. The following sections de‐
scribe how to remove a 2-slot terminal.
Pry out the connector of the terminal to be removed by pressing on the rear
connector shaft latch (A2 in figure A).
● Remove the connector (figure B).
● Remove the adjacent connectors of the neighboring terminals (figure C).
This ensures that the feathers of the voltage jumpers and of the keyway/
feather key connection are prevented from damage. Moreover, the termi‐
nal can be accessed more easily.
● Actuate the release mechanism (D1 in figure D) and remove the terminal
perpendicularly to the top-hat rail (D2 in figure D). If you have failed to
loosen the connector of the neighboring terminal to the left, this connector
now comes loose to protect the feathers of the voltage routing and the
keyway/feather key connection.
Fig.8-3: Removing a terminal

Changing a terminal If you want to replace a terminal within the Rexroth Inline station, proceed as
described above to remove it. Do not latch on the adjacent connector of the
neighboring terminal to the left yet.
Fit the new terminal. Subsequently, refit all connectors.
8.2.4 Fuse Replacement

f segment terminals with fuse are used, the connected voltage and the state of
the fuse are monitored and indicated by diagnostic displays.
A missing fuse has to be installed; a defective fuse has to be re‐

placed.
When replacing the fuse, please observe the following instructions on the safety
of your health and the protection of your station!
1. Always use the screwdriver with care to prevent yourself and any other
person from being injured
2. Pry out the fuse at the metal contact. Do not pry the fuse out at the glass
body to prevent the latter from being broken.
3. Pry out the fuse carefully on one side and then remove it by hand. Take
care not to drop the fuse into your station.
Proceed as follows to replace the fuse. Also see the illustrations in fig. 8-4
"Fuse replacement" on page 48:
● Swing up the fuse lever (A)
● Put a screwdriver behind a metal contact of the fuse (B)
● Carefully pry out the metal contact of the fuse (C)
● Remove the fuse by hand (D)
● Latch in the new fuse (E)
● Press the fuse lever down again until it clicks into place (F)
A B
C D
E F
Fig.8-4: Fuse replacement
8.3 Electrical Installation

The following rules for setting up a system, in which the electrical equipment
like control systems are used, must be adhered to:
● DIN VDE 0100
● DIN EN 60 204-1
● DIN EN 50 178
DANGER Danger of personal injury and material dam‐

age!
Any dangerous states of the system which might cause personal injury or ma‐
terial damage must be prevented!
The rules and regulations for setting up EMERGENCY STOP equipment ac‐
cording to EN 60 204-1 must be adhered to!
Any automatic restart of machines after power return, e. g. after an EMER‐
GENCY STOP, must be excluded!
Protection for direct and indirect contact must be ensured by the measures
prescribed (connection to protective conductor, isolation, etc.).
8.3.2 External Power Supply Unit

All components of the IndraControl L25 are supplied with 24 V voltage supplies.
The power supply unit must be safety-separated according to DIN EN 50 178,
section 5.2.18.1. Transformers must be designed with safety separation ac‐
cording to DIN EN 60 742.
If these requirements are complied with, the 24 V supply voltage is rated as
safety-separated extra-low voltage according to DIN EN 50 178, section
5.2.8.1. This voltage is designed either as safety extra-low voltage (SELV)
without ground connection of the reference conductor or as protective extra-
low voltage (PELV) with ground connection of the reference conductor.
A three-phase power supply unit with simple full-bridge rectification is sufficient.
The ripple voltage content must not exceed 5 %.
All 24 V voltage supply lines have to
● be laid such that they are isolated from lines carrying higher voltages, or
● be insulated to a particularly high degree, with the insulation having to be
designed for the highest voltage present (see EN 60 204-1: 1997, section
14.1.3).
Any peripherals, e.g. digital sensors or actuators, which are connected to the
interfaces of the IndraControl L25, have to comply also with the criteria of safe‐
ty-separated circuits.
8.3.3 24 V Voltage Supply

Setup without Electrical Isolation
The most easiest connection method is the establishment without an electrical
isolation between the internal logic and the peripheral supply.
In this case, a power supply unit is appropriate to supply the IndraCon‐
trol L25. It is not permitted to use an autotransformer to ensure compliance with
overvoltage category II.
L1
L2
L3
N
PE
Overvoltage category III
400 V
Power
S
supply
SERCOS
X7E1
unit1
S1 L
Reset Stop
1.1 2.1
Overvoltage L S
ETH
X7E2
category II 1.2 2.2
S
24V X7E3
Ready
Dist. 1.3 2.3

X2R
1.4 2.4
FE
US
ULS GND UM
GND (US, UM)
Fig.8-5: Setup without electrical isolation

Setup with Electrical Isolation
According to DIN EN 60204–1, electrical isolation should be provided between
the logic of the central processing unit and the I/O interfaces of the peripheral
devices. Accordingly, the voltage ULS (24 logic voltage) is electrically isolated
from the voltages US (24 V segment voltage) and UM (24 V main voltage) in the
IndraControl L25.
The following figure shows an example of a setup with electrical isolation:
L1
L2
L3
N
PE
Overvoltage Trans- L
category III, 400 V former
S
X7E1
Power 230 V voltage
supply
unit 1 for programming S1
Reset Stop
L
device, etc.
+ L S
1.1 2.1
Overvoltage
ETH
X7E2
Overvoltage category III 400 V S 1.2 2.2
X7E3
category II, 24 V
Ready
Power Dist.
supply X2R
1.3 2.3
unit 3
1.4 2.4
Overvoltage
category I, 24 V
FE
2 2
US
ULS GND
UM
GND (US, UM)
Fig.8-6: Setup with electrical isolation

Reference Conductor Connected to the Protective Conductor
If the reference conductor (N, 0 V) is connected to the protective conductor
system, then this connection must be arranged at a central point (e. g. at the
load power supply unit or at the isolating transformer). In addition, it must be
possible to break this connection for measuring ground leakage currents.

Hence, the supply current circuit is a PELV circuit.
L1
L2
L3
N
PE
X7E1
24 V 24 V S1 L
Reset Stop
0V + 0V + L S
1.1 2.1
ETH
X7E2
S 1.2 2.2
X7E3
Ready
Dist. X2R 1.3 2.3
Disconnectable
connections 1.4 2.4
FE
US
ULS GND UM
GND (US, UM)
Fig.8-7: Reference conductor connected to the protective conductor

Reference Conductor not Connected to the Protective Conductor
If the reference conductor (N, 0 V) is not connected to the protective conductor
system, then an appropriate ground fault detector is to be used to prevent in‐
advertent power-up in case of insulation faults. Hence, the supply current circuit
is a SELV circuit. Please note that any additionally connected equipment might
also cancel the floating setup.
L1
L2
L3
N
PE
S
SERCOS
24 V 24 V X7E1
S1 L
Reset Stop
0V + 0V + 1.1 2.1
L S
ETH
X7E2
E1 S
X7E3
1.2 2.2
Ready
Dist. X2R 1.3 2.3
E2
1.4 2.4
FE
US
ULS GND UM
GND (US, UM)
Fig.8-8: Reference conductor not connected to the protective conductor

Programming Device and Grounding

Programming devices are almost always provided with a connection between
the ground and the functional earth ground. This connection might cause prob‐
lems, if the voltage supply of the IndraControl L25 is provided with a ground
fault detector and the programming device is connected to the IndraCon‐
trol L25. Owing to the non-isolated power supply unit device, the ground fault
in the programming device effects the ground fault detector via the central pro‐
cessing unit and the power supply unit device. In this case, the detector should
not deactivate the system automatically, but only indicate the ground fault.
Maintenance staff should be aware of this fact.
Dimensioning the Voltage Supply
When dimensioning the voltage supply, the maximum currents have to be ob‐
served, see DIN VDE 0100-523. A voltage between 20.4 V to 28.8 V must be
applied directly to the device.
The voltage also must be maintained if:
● There are variations in the line voltage, e.g. caused by different loads of
the power supply network.
● Different load states, e.g. short-circuit, normal load, lamp load, or no load.
The maximum line cross-section for the voltage supply is 1.5 mm2.
8.3.4 Main Switches and Fuses

Main Switches
A main switch according to DIN VDE 0100 must be provided for the IndraCon‐
trol L25 as well as for sensors and actuators.
Fuses
Fuses and circuit-breakers protect the supply lines in a network. The lines of
the voltage supply of the IndraControl L25 must be protected. The sensor sup‐
ply and the actuator supply should each be protected by a separate fuse. If the
supply lines are shorter than 3 m and are placed such that they are protected
from ground faults and short-circuits, it is not necessary to provide fuses.
Further criteria for selecting protective devices are:
● Nominal voltage
● Temperature
● Internal resistances of the fuses
● Inrush currents
● Cable lengths
● External impedance of the power supply system
● Possible fault location
● Vibration
For further information, please refer to Manual No. 32, VDE publications, Di‐
mensioning and protecting lines and cables according to DIN 57 100,
VDE 0100–430 and –523.
Appropriate information is also provided by many manufacturers of fuses and
circuit-breakers.
8.3.5 Grounding
An optimum grounding is required to keep away possible interferences from the

IndraControl L25 and the Rexroth Inline modules and to discharge them to the
ground.
Functional earth ground The top-hat rail, which is used for mounting the IndraControl L25, must be
mounted to a grounded metal carrier, e. g. the rear panel of the control cabinet.
A functional earth ground is required to ensure optimum noise immunity. The
functional earth ground has to be connected via a cable, which is as short as
possible or preferably via a ground strap.
Recommended value:
Length: 1 m max.
Cross-section: 6 mm2
The IndraControl L25 as well as the power and segment terminals are provided
with FE springs (metal clips) at their bottom side, which establish an electric
connection to the top-hat rail. To ensure a reliable ground connection even in
case of dirt or a damaged metal clip, the IndraControl L25 must be additionally
grounded via the FE terminal point, using a conductor with a cross-section of
at least 1.5 mm2.
The FE functional earth ground is used to discharge disturbances. It is not pro‐
vided as a protection against electric shock for persons.
Voltage jumper Starting at the IndraControl L25, the FE (functional earth ground) voltage jump‐
er is routed through all connected Rexroth Inline modules. This ensures that
these modules are grounded once the ground connection of the IndraCon‐
trol L25, the supply terminals and the top-hat rail has been properly established.
Potential equalization Potential equalization according to DIN VDE 0100 Part 540 must be provided
between the system parts and the voltage supply.
All components of the system have to be connected to the PE protective con‐
ductor system at the connectors that are marked accordingly.
8.3.6 Shield System

General Information
The shielding is intended to reduce any effects of interferences on the system.
The PROFIBUS line and the connection lines to modules for analog signals
must be shielded.
Observe the following when shielding:
● Fit the shield over an area as large as possible under the clip in the shield
connector.
● Ensure proper contact between the connector and the module.
● Avoid damaging or squeezing cores. Avoid stripping the lines too much.
● Connect the cores properly.
Shielding the PROFIBUS Cable
For noise immune transmission, Bosch Rexroth recommends a two-core twis‐
ted and shielded line pair, as specified as cable type A in EN 50 170, part 8-2.
Cable type B, which is also described in the above mentioned specification, is
obsolete and must not be used any longer.
The cable parameters are described in section chapter 7.3.3 "PROFIBUS DP
(only for Device Variant CML...PN...)" on page 38.
The line shield must be applied in the bus connector. In case of installation in
the control cabinet, the line shield of the connected PROFIBUS line must be
connected to a shield bus using cable clips, if possible directly behind the cable
bushing. Use an appropriate shield terminal.
8.3.7 Connecting Lines to Tension Spring Connection Points

General Information
Connect the lines for peripheral equipment and voltage supply to the tension
spring connection points.
Shielded/unshielded lines Unshielded lines are used for the digital inputs and outputs as well as for the
voltage supply. Shielded lines are connected to analog inputs and outputs.
AWG Lines with an average wire gauge of 0.2 mm2 to 1.5 mm2 (AWG 24 – 16) can
be connected. These lines can conduct signals up to 250 V AC/DC and 5 A.
Connecting Unshielded Lines
Fig.8-9: Connecting lines to tension spring connectors

Wire the connectors as required according to the application.
Proceed as follows to wire the connectors:
● Strip the line to a length of 8 mm. Wiring is provided without core end
sleeves. However, core end sleeves may be used, if desired. In this case,
do ensure that the core end sleeves are properly crimped.
● Put a screwdriver into the actuation slot of the corresponding terminal point
(figure 8-9, A), so that the core can be inserted into the opening of the
spring. Insert the core (figure 8-9, B). Pull the screwdriver out of the open‐
ing. This fixes the core. We recommend you to label the cores and terminal
points after the installation.
8.4 Maintenance
Regular maintenance Include the following measures in the maintenance schedule:
● At least once a year, check all plug and terminal connections of the com‐
ponents regarding proper tightness and possible damage. Verify that lines
and cables are not broken or squeezed. Replace damaged parts imme‐
diately.
LC display A fading readability of the display may cause that the display has to be ex‐
changed. For further information please contact the Bosch Rexroth Service.
Environmental Protection and Disposal
9 Environmental Protection and Disposal

9.1 Environmental Protection
Production Processes The products are made with energy- and resource-optimized production pro‐
cesses which allow re-using and recycling the resulting waste. We regularly try
to replace pollutant-loaded raw materials and supplies by more environment-
friendly alternatives.
No Release of Hazardous Substan‐ Our products do not contain any hazardous substances which may be released
ces in the case of appropriate use. Normally, our products will not have any negativ
influences on the environment.
Significant Components Basically, our products contain the following components:
Electronic devices Motors
∙ steel ∙ steel
∙ aluminum ∙ aluminum
∙ copper ∙ copper
∙ synthetic materials ∙ brass
∙ electronic components and modules ∙ magnetic materials
∙ electronic components and modules
9.2 Disposal
Return of Products Our products can be returned to our premises free of charge for disposal. It is
a precondition, however, that the products are free of oil, grease or other dirt.
Furthermore, the products returned for disposal must not contain any undue
foreign material or foreign components.
Send the products ”free domicile” to the following address:
Bosch Rexroth AG
Electric Drives and Controls
Buergermeister-Dr.-Nebel-Strasse 2
97816 Lohr am Main, Germany
Packaging The packaging materials consist of cardboard, wood and polystyrene. These
materials can be recycled anywhere without any problem.
For ecological reasons, please refrain from returning the empty packages to
us.
Batteries and Accumulators Batteries and accumulators can be labeled with this symbol.
The symbol indicating "separate collection" for all batteries and accu‐
mulators is the crossed-out wheeled bin.
The end user within the EU is legally obligated to return used batteries. Outside
the validity of the EU Directive 2006/66/EC keep the stipulated directives.
Used batteries can contain hazardous substances, which can harm the envi‐
ronment or the people´s health when they are improper stored or disposed of.
After use, the batteries or accumulators contained in Rexroth products have to
be properly disposed of according to the country-specific collection.
Recycling Most of the products can be recycled due to their high content of metal. In order
to recycle the metal in the best possible way, the products must be disassem‐
bled into individual modules.
Environmental Protection and Disposal
Metals contained in electric and electronic modules can also be recycled by

means of special separation processes.
Products made of plastics can contain flame retardants. These plastic parts are
labeled according to EN ISO 1043. They have to be recycled separately or
disposed of according to the valid legal requirements.
Ordering Information
10 Ordering Information
10.1 Type Designation Code
The IndraControl L25 is available in various versions according to the following
type codes.
10.1.2 IndraControl L25

Abbrev. 1 2
column 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7
Example: C M L 2 5 . 1 - 3 N - 4 0 0 - N N - N N N N - N W
Product
Main unit . . . . = CM
Housing design
Inline. . . . . . . . . . . . = L
Line
SH4 . . . . . . . . . . . . . . = 25
Design
1......................=1
Communication interface
Interface 1 Abbr. Interface 2 Abbr.
column column
9 10
Not equipped N Not equipped N
SERCOS III 3 - -
PROFIBUS
Profibus P - -
System configuration
DRAM (MB) Abbr. NvRAM (kB) Abbr. SRAM (MB) Abbr.
column column column
12 13 14
128 4 Without 0 Without 0
Fan
Without . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = N
Digital inputs / outputs

Without . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . = N
Additional design
None. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNNN
With connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NNC1
Firmware
Without firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = NW
Fig.10-1: Type designation code L25

10.2 Accessories
10.2.1 Spare Part (Power Connector)
General Information
The connector for connecting the operating voltage is included in the scope of
delivery. As spare part the following connector is available:
Order code Parts number Description
R-IB IL SCN-PWR IN R911171765 Connector for connecting the operating

PWR 7261 voltage
10.2.2 Further Accessories (Rexroth Inline Terminals, Function Modules and

Interface Cables)
Rexroth Inline Terminals
The current Rexroth Inline terminals are listed in the Bosch Rexroth product
catalog on the Internet http://www.boschrexroth.com/dcc/Vornavigation/Vor‐
Navi.cfm?PageID=g97568&Language=en
Rexroth Function Modules
CFL01.1-E2 R911170365 Fast I/O

CFL01.1-N1 R911170012 Programmable limit switch
CFL01.1-R3 R911170008 SERCOS III
CFL01.1-Q2 R911170009 SERCOS 2 / cross-communication
CFL01.1-TP R911170832 PROFIBUS DP + RT-Ethernet
CFL01.1-G1 R911171044 EnDat interface (in preparation)
CFL01.1-Y1 R911170007 SRAM
Fig.10-2: Function modules
The function module support depends on the firmware used! Please

refer to the relevant documentation!
EMI shielding If the "programmable limit switch" function module (CFL01.1-N1 R911170012)
is used in noisy environment, this EMI shielding is to be mounted. This recom‐
mendation applies to programmable limit switch modules that are plugged in
the 3rd or 4th slot at the left side of the function module bus.
CAL04.1-SH R911172216 EMI shielding
Fig.10-3: EMI shielding

Interface Cables
Ethernet interface Order code Parts number Description
RKB0007/00,15 R911170146 Ethernet cable, 100Base-TX, CAT.5, cross‐

link, ready-made, with RJ45 connector on both
sides, 0.15 m
sides, 2.5 m
sides, 5.0 m
sides, 10.0 m
sides, 25.0 m
RKB0008/002,5 R911170151 Ethernet cable, 100Base-TX, CAT.5, ready-
made, with RJ45 connector on both sides, 2.5
m
m
m
m
Fig.10-4: Interface cables - Ethernet interface

PROFIBUS DP Order code Parts number Description
REB0001 R911170134 PROFIBUS cable, Fast Connect, standard

REB0002 R911170136 PROFIBUS cable, Fast Connect, cable
carrier, tensile force 100 N
REB0003 R911170135 PROFIBUS cable, cable carrier, tensile
force 20 N
RBS0010/K02 R911170137 PROFIBUS connector 12 Mbaud
RBS0011/K02 R911170138 PROFIBUS connector 12 Mbaud, with PG
female connector
RBS0012/K02 R911170139 PROFIBUS connector 12 Mbaud, 180° an‐
gular
RBS0013/F03 R911170140 PROFIBUS connector 12 Mbaud, 90° an‐
gular, Fast Connect

RBS0014/F03 R911170141 PROFIBUS connector 12 Mbaud, 90°an‐
gular, Fast Connect, with PG female con‐
nector
RBS0015/F03 R911170142 PROFIBUS connector 12 Mbaud, 180° an‐
gular, Fast Connect
Fig.10-5: Interface cables – PROFIBUS DP

SERCOS III Ethernet Order code Parts num‐ Description
ber
RKB0007/00 R911171947 Bus cable, 1.0 m

1,0
RKB0007/00 R911170147 Bus cable, 2.5 m
2,5
RKB0007/00 R911170148 Bus cable, 5.0 m
5,0
RKB0007/01 R911170149 Bus cable, 10.0 m
0,0
RKB0007/02 R911170150 Bus cable, 25.0 m
5,0
RKB0007/03 R911171471 Bus cable, 30.0 m
0,0
RKB0007/03 R911171243 Bus cable, 35.0 m
5,0
RKB0008/00 R911171484 Bus cable, 0.5 m
0,5
RKB0008/00 R911171485 Bus cable, 1.0 m
1,0
RKB0008/00 R911170151 Bus cable, 2.5 m
2,5
RKB0008/00 R911170152 Bus cable, 5.0 m
5,0
RKB0008/01 R911170153 Bus cable, 10.0 m
0,0
RKB0008/01 R911171183 Bus cable, 15.0 m
5,0
RKB0008/02 R911171184 Bus cable, 20.0 m
0,0
RKB0008/02 R911170154 Bus cable, 25.0 m
5,0
RKB0008/03 R911171381 Bus cable, 30.0 m
0,0
RKB0008/03 R911171369 Bus cable, 35.0 m
5,0
RKB0008/04 R911171382 Bus cable, 40.0 m
0,0
Order code Parts num‐ Description

ber
RKB0008/05 R911171383 Bus cable, 50.0 m
0,0
RKB0011/ R911316888 Bus cable, variable length
xxx,x (var.)
RKB0011/00 R911321548 Bus cable, 5.0 m
5,0
RKB0013/00, R911329741 Bus cable, 19.0 m
19
RKB0013/00, R911317797 Bus cable, 25.0 m
25
RKB0013/00, R911317800 Bus cable, 35.0 m
35
RKB0013/00, R911317801 Bus cable, 55.00 m
55
RBS0016 R911315797 RJ45 Ethernet connector for self-assembly, angular, IP
20
Fig.10-6: Interface cables – SERCOS III Ethernet

Cap for CF slot Order code Parts number Description
CAL02.1-S1 R911171617 Cap for CF slot
Fig.10-7: Cap for CF slot

Tools for PROFIBUS cable Order code Parts number Description
WERKZ-ABISOLI‐ R911170143 Stripping tool for PROFIBUS Fast Con‐

ERER-FC-KABEL nect cable
WERKZ-ABISOLI‐ R911170144 Spare knife for stripping tool (packaging
ERER-FC-KABEL- seize: 5 pieces)
ERSATZMESSER
Fig.10-8: Tools for PROFIBUS cables

Service and Support
11 Service and Support

Our service helpdesk at our headquarters in Lohr, Germany and our worldwide
service will assist you with all kinds of enquiries. You can reach us around the
clock - even on weekend and on holidays.
Service Hotline
Helpdesk
Worldwide
Phone +49 (0) 9352 40 50 60 Outwith Germany please con‐
tact our sales/service office in
Fax +49 (0) 9352 40 49 41
your area first.
service.svc@boschrex‐ For hotline numbers refer to

E-mail the sales office addresses on
roth.de
the Internet.
http://www.boschrexroth.com
Internet You will also find additional notes regarding service, mainte‐
nance (e.g. delivery addresses) and training.
Preparing 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.
Index
Index
A F
Accessories......................................................... 60 Fuse.................................................................... 52
Accumulators...................................................... 57 Fuse replacement............................................... 47
Ambient conditions
Ambient conditions ....................................... 22
Analog supply (UANA)........................................... 36
G
Generation UM..................................................... 34
Appropriate use
Introduction .................................................... 7 Generation US..................................................... 35
Use ................................................................. 7 Grounding........................................................... 52
Grounding
............................................................................ 53
B
Batteries.............................................................. 57
H
Hazardous substances....................................... 57
C Housing dimensions............................................ 25
Cap for CF slot.................................................... 63
Compact Flash card............................................ 41
Compatibility test................................................. 23 I
Connections........................................................ 29 Inappropriate use.................................................. 8
Overview ...................................................... 29 Consequences, exclusion of liability .............. 7
Voltage supply .............................................. 31 Inline bus............................................................. 41
Contained substances Inline supply and analog circuit........................... 36
see "Significant components" ....................... 57 Inline terminals
CSA certified....................................................... 23 Demounting .................................................. 46
Fuse replacement ........................................ 47
Mounting ...................................................... 45
D Removing a terminal .................................... 47
Device variants..................................................... 5 Installation........................................................... 43
Dimensioning the voltage supply........................ 52 Electric ......................................................... 48
Dimensions......................................................... 25 Installation, mechanical....................................... 43
Bottom view .................................................. 25 Installation notes................................................. 26
Front view ..................................................... 25 Installing Inline terminals..................................... 45
Side view ...................................................... 26 Instructions on use................................................ 7
Dismounting........................................................ 44 Interface cables................................................... 61
Display................................................................ 27 Interfaces...................................................... 29, 36
Display and operating components..................... 27 Ethernet X7E3, X7E4 ................................... 37
Disposal.............................................................. 57 Overview ...................................................... 29
Documentation...................................................... 6 PROFIBUS ................................................... 38
Drive system......................................................... 9 SERCOS III .................................................. 39
Internally generated voltages.............................. 36
E
Electrical Installation........................................... 48 K
Electrical isolation......................................... 49, 50 Keys.................................................................... 27
Electric drive system............................................. 9
EMI shielding...................................................... 60
Environmental protection.................................... 57 L
Ethernet interface.......................................... 36, 61 LC display........................................................... 55
Ethernet X7E3, X7E4.......................................... 37 Logic circuit......................................................... 36
F M
Front view........................................................... 25 Main circuit.......................................................... 34
Functional earth ground...................................... 53 Main switches..................................................... 52
Function module connector................................. 41 Maintenance................................................. 43, 54
Function modules................................................ 60 Mechanical installation........................................ 43
Memory card....................................................... 41
Index
M S
Minimum distances............................................. 26 Shield system...................................................... 53
Mounting............................................................. 43 Side view............................................................. 26
Significant components....................................... 57
Spare part (connector)........................................ 60
O Standards............................................................ 22
Operating components........................................ 27 Stop LED............................................................. 27
Operating keys.................................................... 27 Support
Ordering information........................................... 59 see Service Hotline ...................................... 65
System presentation............................................. 5
P Brief description ............................................. 5
Packaging........................................................... 57 View ............................................................... 5
PELV................................................................... 14
Potential equalization.......................................... 53 T
Power connector................................................. 60 Technical data............................................... 21, 22
Power supply unit................................................ 49 Equipment .................................................... 21
Production processes......................................... 57 Used standards ............................................ 22
PROFIBUS cable Voltage supply .............................................. 21
Shielding ...................................................... 53 Tension spring connection point......................... 54
PROFIBUS DP.................................................... 61 Tools for PROFIBUS cable................................. 63
PROFIBUS DP connection................................. 38 Type designation code........................................ 59
Programming device........................................... 52
Protective conductor........................................... 50
Protective extra-low voltage................................ 14 U
UL and CSA certified.......................................... 23
Unshielded lines.................................................. 54
R Used standards................................................... 22
Ready contact..................................................... 40
Recycling............................................................ 57
Reference conductor........................................... 50 V
Reset Button....................................................... 27 View CML...3N... device variant.......................... 30
Return of products.............................................. 57 View CML...PN... device variant......................... 31
Rexroth Inline terminals...................................... 60 Voltage jumper FE.............................................. 53
Voltages, internally.............................................. 36
Voltage supply.............................................. 21, 31
S 24 V .............................................................. 49
Safety instructions for electric drives and con‐ Dimensioning ............................................... 52
trols....................................................................... 9 Voltage supply ULS........................................ 33, 34
Segment circuit................................................... 35
Segment circuit US.............................................. 34
SERCOS III......................................................... 39 W
SERCOS III Ethernet.......................................... 62 Wear parts.......................................................... 24
Shielding the PROFIBUS cabIe.......................... 53
Notes
Bosch Rexroth AG
Electric Drives and Controls
P.O. Box 13 57
97803 Lohr, Germany
Bgm.-Dr.-Nebel-Str. 2
97816 Lohr, Germany
Tel. +49 (0)93 52-40-0
Fax +49 (0)93 52-48 85
www.boschrexroth.com/electrics
Printed in Germany
R911328474 DOK-CONTRL-IC*L25*****-PR03-EN-P

Rexroth Indracontrol L25: Project Planning Manual

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Electric Drives Linear Motion and

and Controls Hydraulics Assembly Technologies Pneumatics Service

Rexroth IndraControl R911328474

Project Planning Manual

Title Rexroth IndraControl

Type of Documentation Project Planning Manual

Document Typecode DOK-CONTRL-IC*L25*****-PR03-EN-P

Internal File Reference RS-7395430658d72e230a6846a00141db89-3-en-US-4

Purpose of Documentation This documentation describes the IndraControl L25 controls.

Record of Revision Edition Release Date Notes

Copyright © Bosch Rexroth AG 2009

2 Important Instructions on Use........................................................................................ 7

3 Safety Instructions for Electric Drives and Controls....................................................... 9

6 Display and Operating Components............................................................................ 27

7 Connections and Interfaces......................................................................................... 29

8 Installation and Maintenance....................................................................................... 43

9 Environmental Protection and Disposal ...................................................................... 57

11 Service and Support.................................................................................................... 65

1.2 Device Variants

Connection Connection type Device variant

X7E1 and X7E2 Ethernet (SERCOS III) CML...3N...

Fig.1-1: Device variants

Fig.1-2: View of a typical IndraControl L25

1.4 Further Documentation

PLC Programming with Rexroth DOK-CONTRL-IL**PRO*V01- R911305036

RECO Inline PROFIBUS DP Ter‐ DOK-CONTRL-R-IL-PB*-BK- R911289587

Automation Terminals of the DOK-CONTRL-ILSYSINS***- R911317021

Fig.1-3: Further documentation

Important Instructions on Use

2 Important Instructions on Use

Bosch Rexroth disclaims as manufacturer any warranty, liability or

2.1.2 Areas of Use and Application

Typical fields of use of the IndraControl L25 are:

Important Instructions on Use

2.2 Inappropriate Use

Safety Instructions for Electric Drives and Controls

3 Safety Instructions for Electric Drives and Controls

Safety Instructions for Electric Drives and Controls

1) to be trained, instructed or authorized to switch electric circuits and devices

3.2 General Information

3.2.2 Requirements for Safe Use

Safety Instructions for Electric Drives and Controls

concept in which measures of risk reduction for personal safety depend

3.2.3 Hazards by Improper Use

Safety Instructions for Electric Drives and Controls

● Risk of injury by improper handling! Injury by crushing, shearing, cutting,

Safety Instructions for Electric Drives and Controls

3.3 Instructions with Regard to Specific Dangers

Safety Instructions for Electric Drives and Controls

● Connect the equipment grounding conductor of the components of the

1.5 mm2 (16 AWG) 2 × 1.5 mm2 (16 AWG)

6 mm2 (10 AWG) 2 × 6 mm2 (10 AWG)

25 mm2 (4 AWG) 16 mm2 (6 AWG) -

50 mm2 (1/0 AWG) 25 mm2 (4 AWG) -

70 mm2 (2/0 AWG) 35 mm2 (2 AWG) -

Fig.3-1: Minimum Cross Section of the Equipment Grounding Connection

3.3.2 Protective Extra-Low Voltage as Protection Against Electric Shock

3.3.3 Protection Against Dangerous Movements

Safety Instructions for Electric Drives and Controls