Antriebs- und Steuerungstechnik

Typ3 osa

Connectivity Requirements

Edition

103
Typ3 osa

Connectivity Requirements

1070 073 736-103 (99.05) GB

E 1995 – 1999

by Robert Bosch GmbH, Erbach / Germany

All rights reserved, including applications for protective rights.
Reproduction or handing over to third parties are subject to our written permission.

Discretionary charge 20.00 DM

 Contents V

Contents
Page

1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

1.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.2 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
1.3 Safety markings on products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
1.4 Safety instructions in this manual . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
1.5 Safety instructions concerning the product described . . . . . . . . 1–6
1.6 Documentation, software release and trademarks . . . . . . . . . . . 1–9

2 Typ3 osa System Overview . . . . . . . . . . . . . . . . . . . . 2–1

2.1 Typ3 osa-compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
2.2 Typ3 osa-modular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.3 Standards applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.4 Conditions of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8

3 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1 osa master L, osa master XL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
3.1.1 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.1.2 S1 Rotary Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
3.1.3 H1 Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
3.1.4 PC Card (PCMCIA Card) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
3.2 osa plc (ICL 700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13
3.2.1 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
3.3 osa profibus fms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
3.4 osa dc interface / osa dc interface ana . . . . . . . . . . . . . . . . . . . . . 3–18
3.4.1 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19
3.4.2 RESET Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
3.4.3 LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
3.4.4 F1 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
3.4.5 Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26

4 PC Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

4.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.2 osa display (display unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.2 Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7
4.3.2 Serial interfaces COM1 and COM2 . . . . . . . . . . . . . . . . . . . . . . . 4–8
4.3.3 LPT1 parallel port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12
4.3.4 3.5” Floppy disk drive interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
4.3.5 Ethernet interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
4.3.6 SVGA interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
4.3.7 MF2 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
4.3.8 Free ISA slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–17
4.4 osa keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19
4.5 osa switch (Machine Control Panel) . . . . . . . . . . . . . . . . . . . . . . 4–21
4.5.1 Connection to osa master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22
4.5.2 Connection of EMERGENCY-STOP mushroom striker . . . . . . . 4–23
4.5.3 Connection of digital handwheel/manual operating unit . . . . . . . 4–24
4.5.4 Connection of additional external keys . . . . . . . . . . . . . . . . . . . . . 4–25
4.5.5 Front-sided interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26

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VI Contents

5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1 osa rack 2 for Typ3 osa-compact . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.2 osa rack 2 for Typ3 osa-modular . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.3 osa rack 4 for Typ3 osa-modular . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.4 PC Control Panels ”osa display pc” and ”typ3 compact pc” . . . 5–5
5.5 osa switch (machine control panel) . . . . . . . . . . . . . . . . . . . . . . . . 5–9

6 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

6.1 Notes on Protective Earth (PE) Connectors and Screening . . . 6–2
6.2 Interference Suppression Information . . . . . . . . . . . . . . . . . . . . . . 6–3
6.3 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.3.1 24 VDC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.3.2 230/115 VAC supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
6.4 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7

7 3.5” Floppy Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . 7–1

7.1 Control elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
7.2 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.4 Installation cut-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.6 Software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5

8 Maintenance and Spare Parts List . . . . . . . . . . . . . 8–1

8.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
8.2 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
8.2.1 osa rack for Typ3 osa-modular . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
8.2.2 osa rack for Typ3 osa-compact . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
8.2.3 Plug-in modules for osa rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
8.2.4 PC Control Panels (with integrated PC) . . . . . . . . . . . . . . . . . . . . 8–3
8.2.5 osa keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
8.2.6 Floppy disk drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
8.2.7 Software for modular PC Control Panel . . . . . . . . . . . . . . . . . . . . 8–4
8.2.8 Machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
8.2.9 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
8.2.10 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6

A Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
A.1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
A.2 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2

1070 073 736-103 (99.05) GB

 Safety Instructions 1–1

1 Safety Instructions

Please read this manual before commissioning the Typ3 osa. Store this
manual in a place to which all users have access at any time.

1.1 Proper use

This manual contains all information required for the proper use of the con-
trol unit. For reasons of clarity, however, it cannot contain each and every
detail about each and all combinations of functions. Likewise, as the control
unit is usually part of a larger installation or system, it is impossible to con-
sider each and any aspect of integration or operation.

The Typ3 osa is used to

D activate feed drives, spindles and auxiliary axes of a machine tool via
SERCOS interface for the purpose of guiding a processing tool along a
programmed path to process a workpiece (CNC). Furthermore, a PLC is
required with appropriate I/O components which – in communication with
the actual CNC – controls the machine processing cycles holistically and
acts as a technical safety monitor.
D program contours and the processing technology (path feedrate, spindle
speed, tool change) of a workpiece.

Any other application is deemed improper use!

The products described

D have been developed, manufactured, tested and documented in com-
pliance with the safety standards. These products pose no danger to per-
sons or property if they are used in accordance with the handling
stipulations and safety notes prescribed for their configuration, mount-
ing, and proper operation.
D comply with the requirements of
D the EMC Directives (89/336/EEC, 93/68/EEC and 93/44/EEC)
D the Low-Voltage Directive (73/23/EEC)
D the harmonized standards EN 50081-2 and EN 50082-2
D are designed for operation in industrial environments (emission class A),
i.e.
D no direct connection to public low-voltage power supply,
D connection to the medium- or high-voltage system via a transformer.
In residential environments, in trade and commerce as well as small en-
terprises class A equipment may only be used if it does not inadmissibly
interfere with other equipment.

. This is a class A device which may cause radio interference in residen-

tial environments. In this case, the operator may be required to take
suitable countermeasures and to bear the cost of the same.

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1–2 Safety Instructions

The faultless, safe functioning of the product requires proper transport, stor-
age, erection and installation as well as careful operation.

CAUTION
This product was examined by us for ”Year 2000 Compliance”
using our operating, programming, visualization and control soft-
ware, and passed the relevant tests.

We should like to point out that the ”Year 2000 Compliance” may get
lost if additional software packages are installed, for which the cus-
tomer is responsible.

Examples of a possible loss of ”Year 2000 Compliance” known to us

include:
1. If other software packages are installed, parts of the software
supplied by us may be overwritten (e.g. DLL’s).
2. The additionally installed software reads the date directly from
the BIOS or even the date/time module. In order to correct the
date after the millennium change, it will be sufficient to restart the
unit.
3. Some components of Microsoft products (e.g. the File Manager
and the Explorer) are limited as to ”Year 2000 Compliance”. For
more information, please refer to the Microsoft web pages at
http://www.eu.microsoft.com/ithome/topics/year2k/product/
product.htm .

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 Safety Instructions 1–3

1.2 Qualified personnel

The requirements as to qualified personnel depend on the qualification pro-

files described by ZVEI (central association of the electrical industry) and
VDMA (association of German machine and plant builders) in:
Weiterbildung in der Automatisierungstechnik
edited by: ZVEI and VDMA
MaschinenbauVerlag
Postfach 71 08 64
D-60498 Frankfurt.

The present manual is designed for NC project engineers and NC special-

ists.

Programming, start and operation as well as the modification of program

parameters is reserved to properly trained personnel! This personnel must
be able to judge potential hazards arising from programming, program
changes and in general from the mechanical, electrical, or electronic equip-
ment.

Interventions in the hardware and software of our products, unless de-

scribed otherwise in this manual, are reserved to our specialized personnel.

Tampering with the hardware or software, ignoring warning signs attached to

the components, or non-compliance with the warning notes given in this
manual can result in serious bodily injury or property damage.

Only electrotechnicians as recognized under VDE 1000-10 who are familiar

with the contents of this manual may install and service the products descri-
bed.

Such personnel are

D those who, being well trained and experienced in their field and familiar
with the relevant norms, are able to analyze the jobs being carried out
and recognize any hazards which may have arisen.
D those who have acquired the same amount of expert knowledge through
years of experience that would normally be acquired through formal tech-
nical training.

Please note our comprehensive range of training courses.

Our training center will be pleased to provide you with further information,
telephone: +49 (0) 6062 78-258.

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1–4 Safety Instructions

1.3 Safety markings on products

Warning of dangerous electrical voltage!

Warning of danger caused by batteries!

Components sensitive to electrostatic discharge!

Warning of hazardous light emissions (optical fiber cable

emissions)

Disconnect from mains before opening!

Pin for connecting PE conductor only!

Connection of shield conductor only

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 Safety Instructions 1–5

1.4 Safety instructions in this manual

DANGEROUS ELECTRICAL VOLTAGE

This symbol is used to warn of a dangerous electrical voltage. The fail-
ure to observe the instructions in this manual in whole or in part may result
in personal injuries.

DANGER
This symbol will be used if the failure to observe the instructions in this
manual in whole or in part may result in personal injuries.

CAUTION
This symbol will be used if the failure to observe the instructions in this
manual in whole or in part may result in damages to equipment or data
files.

. This symbol will be used to draw the user’s attention to special circumstan-
ces.

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1–6 Safety Instructions

1.5 Safety instructions concerning the product described

DANGER
Retrofits or modifications may adversely affect the safety of the
products described!

The consequences may include severe injuries, damage to equip-

ment, or environmental hazards. Possible retrofits or modifications
to the system using third-party equipment therefore have to be ap-
proved by Bosch.

DANGER
Danger of life through inadequate EMERGENCY-STOP devices!
EMERGENCY-STOP devices must be active and within reach in all
system modes. Releasing an EMERGENCY-STOP device must not
result in an uncontrolled restart of the system! First check the
EMERGENCY-STOP circuit, then switch the system on!

DANGER
Danger for persons and equipment!
First every new program should be thoroughly tested without axis
movement! In the ”Automatic” group operating mode, the control
offers the opportunity to inhibit axis movements and/or the output
of auxiliary functions by pressing certain softkeys.

DANGEROUS ELECTRICAL VOLTAGE

Unless described otherwise, maintenance works must be performed
on inactive systems! The system must be protected against unau-
thorized or accidental reclosing.

Measuring or test activities on the live system are reserved to quali-

fied electrical personnel!

DANGER
Tool or axis movements!
Feed and spindle motors generate very powerful mechanical forces
and can accelerate very quickly due to their high dynamics.
D Always stay outside the danger area of the machine when it is
running!
D Do not ever deactivate the safety-relevant functions of the unit!
D Report any malfunction of the unit to your servicing and repairs
department immediately!

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 Safety Instructions 1–7

DANGER
Getting caught by moving parts of machinery!
During careless handling of machines with moving parts, clothes or
long hair may get caught in the mechanics, pulling operators into
the machine!
D Wear a hair net!
D Wear a protective suit!
D Take off protective gloves before working near moving parts!
D Take off any jewelry and wristwatches!

DANGER
Remember that chippings may be cast out during operation of the
machine!
They can cause eye injuries and burns.
D Wear protective goggles!
D Wear a protective suit !

DANGER
Sharp edges on workpieces and tools!
D Wear protective gloves!

CAUTION
Only spare parts approved by Bosch may be used!

CAUTION
Observe all precautions for ESD protection when handling modules
and components! Avoid electrostatic discharge!

The following protective measures must be observed for modules and com-
ponents sensitive to electrostatic discharge (ESD)!
D The personnel resposible for storage, transport, and handling must have
been trained for ESD protection.
D ESD-sensitive components must be stored and transported in their pre-
scribed protective packaging.
D ESD-sensitive components may only be handled at special ESD-work-
places.
D Personnel, working surfaces, as well as all equipment and tools which
get in contact with ESD-sensitive components must have the same po-
tential (e.g., by grounding).
D Wear an approved grounding bracelet. The grounding bracelet must be
connected with the working surface through a cable with an integrated
resistor of 1 MW.

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1–8 Safety Instructions

D ESD-sensitive components must by no means get in contact with

chargeable objects, including most plastic materials.
D When ESD-sensitive components are installed in or removed from
equipment, the equipment must be de-energized.

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 Safety Instructions 1–9

1.6 Documentation, software release and trademarks

Documentation
The present manual provides information on operating conditions and hard-
ware components of the Typ3 osa.

Overview of available documentation Part no.

German English
Interface conditions 1070 073 704 1070 073 736
for project engineering and maintenance
Operating instructions 1070 073 726 1070 073 739
Standard operator interface
Operating instructions – Diagnostics 1070 073 779 1070 073 780
DIN programming instructions 1070 073 725 1070 073 738
for programming to DIN 66025
CPL programming instructions 1070 073 727 1070 073 740
ICL700 system description, program 1070 073 706 1070 073 737
structure of the integrated PLC
ICL700 project planning manual, 1070 073 728 1070 073 741
software interfaces and CNC interface
signals of the integrated PLC
MACODA 1070 073 705 1070 073 742
operation and configuration of the ma-
chine parameters
Tool Management Parameter Setting 1070 073 782 –
Software PLC 1070 073 783 1070 073 792
Development Environment for
Windows NT
Measuring Cycles 1070 073 788 1070 073 789
for Touch-Trigger Switching Probes

. In the present manual, the floppy disk drive is always drive A, the fixed
disk is drive C.

Special keys or combinations of keys are represented by pointed brackets:

D Special keys: e.g. <enter>, <pgup>, <del>
D Key combinations (pressed simultaneously): e.g. <ctrl> + <pgup>

L This asterisk symbol refers to an activity to be performed by the user.

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1–10 Safety Instructions

Version

. This description refers to version:

Software: 4.3

. The current release number of the individual software modules can be

viewed by selecting the ”Control-Diagnostics” softkey in the
”Diagnostics” group operating mode.

. The software version of Windows95 or WindowsNT is displayed by

selecting the ”My Computer” icon on the Start screen and then the
HELP menu, item ”About Windows95” or ”About WindowsNT”.

Modifications
Modifications in the present manual as compared to the previous edition are
marked by black vertical bars on the margin.

Trademarks
All trademarks for software installed on Bosch products upon delivery are
the property of the respective manufacturers.

Upon delivery, all installed software is copyright-protected. The software

may only be reproduced with the approval of Bosch or in accordance with the
license agreement of the respective manufacturer.

MS-DOSr and Windowst are registered trademarks of Microsoft Corp.

PROFIBUSr is a registered trademark of PROFIBUS Nutzerorganisation

e. V.

SERCOS interfacer is a registered trademark of Interessengemeinschaft

SERCOS interface e.V.

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 Typ3 osa System Overview 2–1

2 Typ3 osa System Overview

Two system variants of Typ3 osa are available:

D Typ3 osa-compact:
The system unit of Typ3 osa is completely coupled to the PC Control
Panel (osa display PC).

D Typ3 osa-modular:
The system unit is installed as an independent rack in the switch cabinet.
The PC Control Panel is located on the machine.

Each system variant is a combination of the following modules and PC Con-

trol Panels (for part numbers, refer to section 8):

Baugruppen
D osa master L
Computer module for NC core and system coordination. Functions:
D Management of the entire data traffic on the system bus of the control
unit and of the entire Typ3 osa file system
D Block processing of part programs, plus interpolation
D Communicating with the drives via SERCOS interface.
Connection of 1 optical fiber cable ring.
D Communicating with the PC Control Panel via 10-Base-T Ethernet
D Communicating with external devices (e.g. PC) via V24 interface
D Debugging via 2nd V24 interface
(only in conjunction with the ”osa dc interface” module)
D Accepting a PCMCIA Card (portable memory medium, e.g. for cus-
tomer programs, program cycles or even system software).

D osa master XL
Computer module similar to osa master L, but with additional 2nd optical
fiber cable ring for drives with SERCOS interface.

D osa plc
High-performance PLC controller. Functions:
D Processing / linking of digital signals
D Communicating with external programming device
D Connecting a PLC expansion unit with I/O periphery via CMOS bus.
For available PLC components, refer to ”CL500 control manual”. Fur-
thermore, the plug-in PLC module ”E24V/DC, 95-fold” is available.
. The osa plc module can only be used together with the
”Typ3 osa-modular” variant. For a description of the functional
scope and performance, refer to the ”ICL700 system descrip-
tion” manual.

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2–2 Typ3 osa System Overview

D osa profibus fms

Interface module comprising 1 x RS 485 and 1 x optical fiber cable. Func-
tions:
D Communicating with external devices via Profibus FMS to DIN 19245
Parts 1 and 2

D osa dc interface
24 V power supply with peripheral interfaces. Functions:
D Power supply to Typ3 osa components
(except PC Control Panel in ”Typ3 osa-modular” system variant)
D Buffering of all Typ3 osa RAM areas via backup battery
D Capture of max. 8 digitale high-speed input signals
D Generating max. 6 digital high-speed output signals
D Communicating with external devices via Profibus DP interface
D Controlling the READY2 contact (readiness signalling)
D Typ3 osa RESET function
D Controlling RESET-Out contact.

D osa dc interface ana

24 V power supply with peripheral interfaces. Additional functions
compared to osa dc interface:
D D/A conversion for 4 analog output signals
D A/D conversion for 8 analog input signals
D Communication with external devices va Bitbus OFC interface

PC Control Panels
D osa display pc
The PC Control Panel comprises the following individual components:
D osa display with TFT flat screen
D PC, coupled to osa display
D osa keyboard
(the ”osa switch” machine control panel may be optionally used)

Functions:
D Communicating between Typ3 osa and the user via the standard op-
erator interface
D Connecting a digital handwheel (to osa switch)
D other functions can be performed via the integrated PC (e.g. WOP
programming, management of part programs, CNC data backup,
printer control, etc.)

D typ3 compact pc
The PC Control Panel comprises the following individual components:
D osa display with TFT flat screen
D PC, coupled to osa display
D osa keyboard
(the ”osa switch” machine control panel may be optionally used)
D osa rack 2

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 Typ3 osa System Overview 2–3

Functions:
D Accommodating the Typ3 osa modules in the osa rack 2
D Communication between Typ3 osa and the user via the standard op-
erator interface
D Connecting a digital hand wheel (to osa switch)
D other functions can be performed via the integrated PC (e.g. WOP
programming, management of part programs, CNC data backup,
printer control, etc.)

2.1 Typ3 osa-compact

All CNC components are accommodated within the operating range of the
machine. In the event that the PC Control Panel “typ3 compact pc” with
24VDC power supply is used, the “osa dc interface” module will also power
the integrated PC.

Components:
D PC Control Panel ”typ3 compact pc”
D osa master L/XL
D osa dc interface or osa dc interface ana
D osa rack 2
D Software PLC for PLC functions

Typ3 osa-compact PC Control Panel

Slot assignment
in housing behind the PC ”typ3 compact pc” with osa rack 2
osa rack 2 osa rack 2
Control Panel

1 2
osa
keyboard

osa
switch
1 2
osa master L osa dc interface
or or
osa master XL osa dc interface ana osa rack 2

Typ3 osa-compact with ”typ3 compact pc” PC Control Panel

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 2–4 Typ3 osa System Overview

Linking components
All connections between the system components can be made using ready-
made cables (for part no., refer to section 8). For more information on cable
lengths and pin assignments, refer to section 3.

CAUTION
Damages to system components may result from making or remov-
ing plug-in connections during system operation!
You should always shut off the system before you connect the com-
ponents.

osa rack 2
Drives ....

OFC ring 1

SERCOS interface X71 (ring 1, in)

e.g. PC X72 (ring 1, out)

Ethernet X52

V24 X35

X51 X10
typ3 kompact pc 24 VDC
Connection to PC (X52)
Power supply

osa rack 2

Connection to PC (X1)
230 VAC
or 24 VDC
Power supply
X1

osa keyboard

osa switch
osa master connection

Establishing connections: Typ3 osa-compact with ”typ3 compact pc” PC Control Panel

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 Typ3 osa System Overview 2–5

2.2 Typ3 osa-modular

Only the PC Control Panel is located in the operating area of the machine.
The system unit of Typ3 osa is installed in the separate osa rack 2 or osa
rack 4 inside the switch cabinet.
The osa dc interface module ensures the power supply to all Typ3 osa com-
ponents. For this purpose, it requires an external 24 VDC power source.

Typ3 osa-modular with osa rack 4

(components and possible module equipment):
D PC Control Panel ”osa display pc”
D osa master L/XL
D osa plc
D osa dc interface or osa dc interface ana
D osa rack 4

Optionally:
D osa profibus fms
for communication with external units.

Typ3 osa-modular PC Control Panel

Slot assignment installed in switch cabinet ”osa display pc”
osa rack 4

1 2 3 4 osa
keyboard

osa
switch

1 2 3 4
osa master L e.g. osa dc interface
or osa profibus
e.g.
or
Switch
osa plc Machine
osa master XL fms osa dc interface ana cabinet

Slots 2 and 3 can be used for any other modules

(e.g. osa plc, osa profibus fms).

Typ3 osa-modular in osa rack 4 with ”osa display pc” PC Control Panel

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 2–6 Typ3 osa System Overview

Typ3 osa-modular with osa rack 2

(components and possible module equipment):
D PC Control Panel ”osa display pc”
D osa master L/XL
D osa dc interface or osa dc interface ana
D osa rack 2

PC Control Panel
Slot assignment Typ3 osa-modular ”osa display pc”
osa rack 2 installed in switch cabinet

osa
display

osa
display
PC

1 2 osa
keyboard

osa
switch

1 2
osa master L osa dc interface
or or
Switch
Machine
osa master XL osa dc interface ana cabinet

Typ3 osa-modular in osa rack 2 with ”osa display pc” PC Control Panel

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 Typ3 osa System Overview 2–7

Linking components
All connections between the system components can be made using ready-
made cables (for part no., refer to section 8). For more information on cable
lengths and pin assignments, refer to section 3.

CAUTION
Damages to system components may result from making or remov-
ing plug-in connections during system operation!
You should always shut off the system before you connect the com-
ponents.

osa rack 4

Drives ....

OFC ring 1

SERCOS interface X71 (ring 1, in)

X72 (ring 1, out)

Ethernet X52
e.g. PC
V24 X35

X51
X10
24 VDC
Ethernet Power supply
connection

Connection to PC (X52) X61 (to ICL)

osa display pc
CMOS bus

PLC Expansion Unit

ËËËËËËËË PLCI/O
Connection to PC (X1)
230 VAC
Power
X1 supply

AG/Z-S (can be positioned in slot 1 or

osa keyboard last slot in expansion unit)

osa switch
osa master connection

Establishing connections: Typ3 osa-modular with ”osa display pc” PC Control Panel

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2–8 Typ3 osa System Overview

2.3 Standards applied

The Typ3 osa system components comply with the following standards:
D EN 60 204–1 Electrical equipment of machines
D EN 50187 Electronic equipment for use in power installa-
tions (with respect to VDE160)
D EN 50 081–2 Generic emission standard for industrial envi-
ronments
D EN 50 082–2 Generic immunity standard for industrial envi-
ronments
D EN 60 742 Isolating transformers and safety isolating
transformers (transformer for 24V power
supply, safe isolation)
D EN 61 131–2 EMC requirements for programmable control-
lers (requirements on 24V power supply)
D EN 418 Safety of machinery; emergency stop equip-
ment
D EN 60 529 Degrees of protection provided by enclosures
D EN 60 068–2–6 Environmental testing – Part 2: Vibration
D EN 60 068–2–27 Basic environmental testing procedures –
Part 2: Shock

Exception:
For PC Control Panels, standard EN 50 187 is not applicable, but rather:
D EN 60 950 Overvoltage category II

2.4 Conditions of application

Unless described otherwise in the individual sections, the following data
applies to the system components:

Temperatures
Storage temperature:
D PC Control panels: –20°C up to +60°C
D all other components: –25_C up to +70_C

Ambient temperature:
D Modular control panels: +5°C up to +45°C
D 3.5” Floppy Disk drive: +5_C up to +45_C
D all other components +5_C up to +55_C

The ambient temperatures are applicable for the installation instructions de-
scribed in section 5.
Temperature changes over time are admissible up to 3_C per minute.

Humidity
Climatic category 3K3 to EN 60 529, condensation is not permitted.

Air pressure
For operation up to 1000 m above m.s.l.: to DIN 60204

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 Typ3 osa System Overview 2–9

Protection standards
The switch cabinets and installation rooms for Typ3 osa must at least comply
with protection standard IP54 (dust filter in front of air inlet and outlet).

D PC Control Panels: Front covers IP65, otherwise IP00

min. designed for installation to IP54
D All card racks: IP20
min. designed for installation to IP54
D osa switch: IP00
min. designed for installation to IP54
D 3.5” Floppy Disk drive: With protective cover IP54, otherwise IP00
min. designed for installation to IP54

CAUTION
Danger for product!
The ambient air must be free from conductive contaminations
(acids, alkalis, corrosive agents, salts, metal vapors, etc.).
Filters in the air inlet and outlet must be regularly serviced.

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 2–10 Typ3 osa System Overview

Your notes:

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 Modules 3–1

3 Modules

This chapter provides – sorted by module types – the following information:

D Module illustrations / diagrams

D Explanations of control and display elements where applicable
D Interface pin assignments and specifications

. For information on the installation of a module, refer to section 5.

CAUTION
Improper pin assignment of connecting cables may result in de-
struction of interfaces!
Therefore use only cables with suitable pin assignmemnts, and la-
bel the cables accordingly.

3.1 osa master L, osa master XL

Central system module of Typ3 osa which is available in two versions and is
always required.

D osa master L (SNCI_2/12/8 with 1 SERCOS ring)

D osa master XL (SNCI_2/X with 2 SERCOS rings)

The osa master L/XL module is equipped with a gold capacitor which buffers
the RAM data for at least 10...60 min even if the board has been removed.

CAUTION
Data loss through discharged capacitor!
Do not place any modules on conductive surfaces. Reinstall the
modules in the rack after approx. 5 min.

When the card is plugged in, but the mains voltage is interrupted, the data
will be buffered by the battery of osa interface dc/ana (refer to section 3.4.5).

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3–2 Modules

PC Card EJECT button

Standard PC Card slot

S1 Rotary switch

H1 Diagnostic display

Connectors for digital drives, SERCOS ring 1

(X71: In; X72: Out)

NC System connection to PC Control Panel

osa display pc:
Ethernet-10-Base-T
(female X52, RJ45, 8-pin)

1 V24 and 1 Debugging interface

(male X35, D-SUB, 9-pin)

Connector for machine control panel

osa switch
(female X51, D-SUB, 9-pin)

Front view of osa master L

CAUTION
Take all precautions necessary for ESD protection when handling
modules and components! Avoid electrostatic discharge!

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 Modules 3–3

PC Card EJECT button

Standard PC Card slot

S1 Rotary switch

H1 Diagnostic display

Connectors for digital drives, SERCOS ring 1

(X71: In; X72: Out)

Connectors for digital drives, SERCOS ring 2

(X73: In; X74: Out) –> only for osa master XL

NC System connection to PC Control Panel

osa display pc:
Ethernet-10-Base-T
(female X52, RJ45, 8-pin)

1 V24 and 1 Debugging interface

(male X35, D-SUB, 9-pin)

Connector for machine control panel

osa switch
(female X51, D-SUB, 9-pin)

Front view of osa master XL

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3–4 Modules

3.1.1 Connectors

X71...X74 SERCOS interface connectors

Connection of digital drives with SERCOS interface via optical fiber cables.
Depending on the module, 1 or 2 SERCOS interface rings may be con-
nected:
X71: Ring1, In
X72: Ring 1, Out
X73: Ring 2, In
X74: Ring 2, Out

The connectors used comply with the F-SMA standard to IEC 874-2.
Prefabricated optical fiber cables with connectors and strain reliefs at both
ends are available 2 m, 5 m and 10 m long. They are made of plastic material
and equipped with a step-index profile.
For part numbers, refer to section 8.2.

The number of drives per SERCOS interface depends upon the required
cycle time and the data volume occurring on each drive (max. 4 Mbaud per
OFC ring).

DANGER
The high power of the LED’s in the optical fiber conductors may en-
danger your eyesight when looking straight at the LED’s. When the
inverter is switched on, do not look into the LED or the open end of
a short connected line.

. Measuring systems are connected to the drive modules.

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 Modules 3–5

X35 V.24/Debugging interface

Maximum of 2 serial V.24 interfaces. While the interface labelled ”V.24” in the
following illustration is always available for connecting external periphery,
the interface labelled ”Debugger” can be used for debugging only.

X35 (osa master )

max. 15 m

1
RxD_D
2
RxD
3
TxD V.24
4

5
GND
6
562 Ohm
7
+12V

8
Debugger
9
TxD_D

Shield is connected to metal shell of

the plug-in connection

X35 pin assignment (osa master)

D-SUB connector, 9-pin

Level: HIGH:+3V ... +9V
LOW: –3 V... –9V
Transmission max. 19200 Baud (fixed speed of 9600 baud for
speed: Debugger interface)
Handshake: Software (XON, XOFF)

Tx Transmit Data line of CNC

Rx Receive Data line of CNC
GND Signal Ground
Line length: max. 15 m,
for longer lines, suitable repeaters with a metal
housing must be interconnected.
Cable type: Shielded cable, conductor cross-section 0.14 mm2

. For interface test units, Typ3 osa outputs a permanent HIGH signal at
pins 4 and 7.
Please note that hardware handshake signals of a connected unit
(CTS/RTS or DTR/DSR) will not be evaluated!

CAUTION
Malfunctions caused by inadequate screening!
Always use only metal and/or conductive male and female connec-
tor/coupling shells with a large-area shield conductor surface.

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3–6 Modules

X51 Connection to osa switch

X51 (osa master )

max. 30 m

1
CTX0
2 CAN bus to osa switch
CTX1
3

5
+12V power supply
6 from osa master
GND to osa switch

Shield is connected to metal shell of

the plug-in connection

X51 pin assignment (osa master)

D-SUB connector, 9-pin

Connection type: CAN bus
Line length: max. 30m
Cable type: preassembled cable, shielded,
conductor area 2 x 2 x 0.25 mm2

X52 NC System Connection with PC Control Panel ”osa display pc”

X52 (osa master )

max. 100 m

1
ETT_TXOP
2
ETT_TXOM J14
3
ETT_RXIP
4

6
ETT_RXIM
7

Shield is connected to
metal shell of connector

X52 pin assignment (osa master)

RJ45, female, 8-pin.

Connection type: Ethernet 10-Base-T
Line length: max. 100 m
Cable type: preassembled, shielded twisted Pair

CAUTION
Malfunctions caused by incompatible cables!
Use only preassembled original cables for connecting the modular
Control Panel.

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 Modules 3–7

3.1.2 S1 Rotary Switch

CAUTION
Loss of Data or possible malfunction!
The position of the rotary switch influences the start sequence of the
Typ3 osa Numerical Control.

For this reason, setting the S1 switch to positions other than ”0” is
authorized for service purposes only, and is restricted to specially
trained service technicians!

Position ”0”: Switch position for standard operation (”Normal mode”).

The file systems are retained and will be checked for
consistency during run-up.
If the FEPROM file system is defective, the unit cannot
be run up. In this case, the control must be reloaded.
If a root file system is defective and cannot be automati-
cally repaired, the control will not run up. A critical sys-
tem error will be displayed. During the next run-up a
new, empty file system will be automatically generated.
If a defective usrfep file system is detected, the control
will try to link the file system to the ”!usrfep!” directory
reserved for this purpose (mounting). The user can then
copy the still readable files to another file system (e.g.
root file system).
After having run up in switch position ”7”, the recovered
files can be copied back to the new usrfep file system.
The PLC systems software is retained and will not be
loaded again to the osa plc.
The base monitor activates the Ethernet interface. The
debugging interface is activated by the base monitor
only if the osa dc interface module is available.
Position ”1”: The osa plc remains in STOP condition when the con-
trol has run up. The PLC user program is not executed.
Otherwise as position ”0”.
Position ”2”: Debugging mode with and without osa dc interface;
otherwise as position ”1” (only for osa master L/XL).
Position ”3”: Guaranteed run-up. The control runs up with a minimal
configuration, independent of the machine parameter
settings. Thus, a false configuration of the machine pa-
rameters, which prevents a run-up in normal mode
(position ”1”), can be circumvented; otherwise as posi-
tion ”1” (only for osa master L/XL).
Position ”4”: as position ”2”. (only for osa master L/XL).
Position ”5”: as position ”2”, but without ”power fail handling” (only
for osa master L/XL).

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3–8 Modules

Position ”6”: Initial program loading. Used for the first start-up of a
newly installed NC control. First, a new Root file system
is generated. The hardware configuration of the part
program memory (e.g. with/without PC card) is deter-
mined. The PLC system firmware and PLC application
program are loaded for the first time. The Typ3 osa then
copies, from the ”usrfep” FEPRPOM file system, all
data required for the start-up. In the event that such
data does not exist in that location, the control software
proceeds by generating the factory-preset basic config-
uration with the use of data from the ”feprom” FEPROM
file system.
The PLC application program is then started.

CAUTION
Loss of Data!
Switch position ”6” causes all data of the old file system to be de-
leted. You are cautioned to use this setting only when you have com-
pleted the backup of all important data (such as MACODA parame-
ters, SERCOS files, etc.) in the ”usrfep” FEPROM file system. Other-
wise you will have to perform a complete new software installation!

Position ”7”: Initial loading of basic data. Used for starting up a con-
trol, the ”usrfep” FEPROM file system of which has
been destroyed or contains inconsistent data, making
the start-odf the Typ3 osa Numerical Control impossi-
ble. In contrast to the consequences of switch Position
”6”, the old ”usrfep” FEPROM file system is also deleted
entirely, and newly generated. The data of the root file
system is retained. Otherwise as ”Normal mode”.

CAUTION
Loss of Data!
Switch position ”7” causes all data of the ”ursfep” FEPROM file sys-
tem to be deleted. The root file system remains intact.

You are cautioned to use this setting only when you have completed
the backup of all important data (such as MACODA parameters,
SERCOS files, etc.) to an external data storage medium. Otherwise
you will have to perform a complete new software installation!

Position ”8”: Similar to Position ”9” (applies exclusively to osa master

L/XL)
Position ”9”: Debugging mode. The hardware is initialized, and the
entire software is loaded into the individual modules. All
modules – with the exception of the CL – are initialized,
assume the monitor mode and stand by for degugging
instructions. The osa plc delay both loading and starting
the PLC application program until all other modules
have been started.

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 Modules 3–9

Position ”A”: Debugging mode. The hardware is initialized without

loading the software into the individual modules. From
this point onward, fucntions are the same as with Posi-
tion ”F.” This position is intended for loading software
into RAM via Ethernet.
Position ”B”: Initial loading of basic data or software swap from PC
Card. The PC Card must have been specially prepared
for this purpose. If this is not the case, the system, will
not start up.
The Typ3 osa copies, from an appropriately prepared
PC Card, all data into its internal boot and/or data FE-
PROM’s. This way, any Typ3 software can be
introduced to the NC Control (even into a new, com-
pletely “empty” control).
Please keep in mind that the destination areas on the
control will be overwritten: In the event that the PC Card
contains, for example, the ”usrfep” and ”feprom”
FEPROM file sytems, the data of all preexisting ”usrfep”
and/or ”feprom” FEPROM file systems on the control
will be deleted!
Position ”C”: For backing up the osa plc system software to the FE-
PROM of the NC control. The backup procedure must
be started from a programming device connected to the
osa plc. The osa plc then copies the system software
into the FEPROM range of the NC control.
Position ”D”: Debugging mode. Deletes all subsequently loaded soft-
ware, if any, in the RAM reload mode.
Deletes the root parameters in the FEPROM (PC card
extension of the root file system, etc.)
Position ”E”: Debugging mode. The position is designated for the
display of the Ethernet address and the debugging bau-
drate on the H1 display. All characters are displayed in
succession.
In the event that the switch position is changed while
the Ethernet address is displayed, the contol discontin-
ues the Ethernet address display and commences with
the display of the debugging baudrate. In the event that
switch S1 is no longer positioned at ”E” subsequent to
displaying the last figure, the Typ3 osa Control will ini-
tialize its debugging interface at a speed of 9600 Baud.
The remaining functions are as with Position ”F,” below.

Example:
Display – on H1 – of Ethernet Address (e.g. 00 06 34 00 12 13),
and of debugging baudrate (e.g. 9600 baud).

' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' '

' ' ' ' '

Ethernet address display on H1

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 3–10 Modules

Position ”F”: Debugging mode. Activates the base monitor. The Typ3
osa communicates with the debugging computer via the
second V24 interface on X35 (default baudrate is 9600).
The pin assignment of the X35 interface connector is
specified on page 3–5.

. While in the debugger window, the command Ctrl Y can be generated

by entering the ”nmi” character string.

3.1.3 H1 Diagnostic Display

The H1 diagnostic display is used – at different times and by different soft-

ware functions (e.g. basis monitor, PC Card bootloader, start-up software) –
for displaying status information and fault messages.

Display readings during standard operation, NC control running

”–”: If ”–” is not displayed although S1 rotary switch is set
to ”0” position, please contact our customer service.
Decimal point: Illuminates for at least 0.2 sec with each data packet
transmitted via Ethernet.

Displays during debugging operating

. In the event that the Typ3 osa is booted with the S1 switch set to ”E,” it
will initially return different configuration data on H1. The explanation
of displays appears in Section 3.1.2, ”Position E”.

”8”, ”A”: The system is in basis monitor mode. If ”A” is dis-

played, the monitor expects data from the debugging
interface and/or from the Ethernet interface.
”L”: Loading via Ethernet. The control is currently process-
ing a data packet.
”d”: Loading via Ethernet. The control is currently deleting
FEPROM ranges.
Decimal point: Illuminates for at least 0.2 sec with each verfied data
packet transmitted via Ethernet.

Displays during the boot process (faults)

Any faults occurring during the boot process of the Typ3 osa cannot immedi-
ately be returned to the H1 display. For this reason, bootloader and start-up
software are using the H1 as a diagnostic display. In this case, a complete
fault message is formed by characters that are displayed in succession on a
timeline.
Faults occurring in the bootloader area are identified by the starting se-
quence ”P” and ”E” (Panic Error), and in the software area by ”F” and ”E”
(Fatal Error). The timed succession of the fault messages are depicted in the
illustration below. For example, ”PE 0 86” and/or ”FE 1 56”:

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 Modules 3–11

0.5 s 0.5 s 2s 1s 1s 0.5 s 0.5 s 1s 2s 1s 1s

' ' ' ' ' ... ' ' ... ' ' ' ' ...

Module no. 0 Number of module on

which fault has oc-
Fault message Fault code Fault message curred. The last digit Fault code
from bootloader from start-up SW appears for 2 sec.

Error displays during the boot process

Displays during “osa plc software backup to Typ3 osa FEPROM” (S1 Position: ”C”)
”C”: FEPROM range is currently being de-
leted.
Decimal point and rotating Now programming FEPROM area.
through 1 segment each time:

Example:

' ' ' ' '

Display during FEPROM programming

”E”: Fault detected during deleting or programming FEPROM

area. Process was aborted.
”8”: Verifies complete and fault-free data transfer to control me-
mory.

Displays during “initial data loading or SW swap from PC Card” (S1 Position: ”B”)
”C”: Now programming a range of 32 kB in boot FEPROM. See
also ”0” and ”L.”
”d”: Now programming a range of 8 kB in data FEPROM. See
also ”0” and ”L.”
”0”: Display alternates between ”C” and ”d.” Now progarmming
corresponding FEPROM range with value ”0.”
”L”: Display alternates between ”C” and ”d.” Now programming
the corresponding FEPROM range with data from PC Card.
”F”: Now clearing FEPROM’s.
”P”: Now verifying the checksum of the data to be programmed
(in blocks of 64 kB). In case of fault, refer to ”E.”
”E”: Fault detected during programming FEPROM’s. Program-
ming was aborted.
”U”: Switch S1 not in Position ”B.”
”A”: The PC Card was filled with data, the destination addresses
of which are outside the FEPROM range of the NC control.
Programming is aborted.
”S”: Faulty data on PC Card. Programming is aborted.
”2”: ZWS RAM cannot be written to, or insufficient capacity
(<256 kB).
”8.”: Verifies fault-free data copy from PC Card to NC control.

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3–12 Modules

3.1.4 PC Card (PCMCIA Card)

PC cards are available with different memory sizes and storage media. For
Typ3 osa, you may use Flash-EPROM and SRAM PC cards.

D For example, the PC card may be used to load or store user programs,
cycles, or even system software.

D SRAM PC cards may be used to expand the part program memory of the
osa master.
. Typ3 osa must be run up in switch position 6 for this purpose.

PC Card Slot: 68-pin, as per PCMCIA/JEIDA standard

Memory address max. 64 MByte
range:
Bus width: 16 Bit
Access time: < 250 ns

CAUTION
The PC card may be damaged by ejecting or inserting it while the
card slot is powered!
Data contained in the card could be destroyed.
Therefore, activate the mechanical write-protection switch of the
card before you insert or eject it!

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 Modules 3–13

3.2 osa plc (ICL 700)

High-performance PLC for the ”Typ3 osa-modular” system variant. It pro-
cesses the input/output signals generated by the peripheral devices of the
PLC.

The osa plc board contains a gold capacitor which buffers the RAM data for
at least 10...60 min even if the board has been unplugged.

CAUTION
Data loss through discharged capacitor!
Do not place any modules on conductive surfaces. Reinstall the
modules in the rack after approx. 5 min.

When the board is plugged in and the power supply is interrupted, the data
will be buffered by the battery of the osa interface dc/ana (cf. section 3.4.5).

Disable Outputs switch

Connection for programming device

(female X31, D-SUB, 25-pin)

CMOS bus for connecting a PLC

expansion unit via the ”AG/Z-S”
PLC module
(female X61, HD D-SUB, 50-pin)

CAN bus interface

(female X51, D-SUB, 9-pin)

osa plc (front view)

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 3–14 Modules

CAUTION
Take all precautions necessary for ESD protection when handling
modules and components! Avoid electrostatic discharge!

3.2.1 Connectors

X31 Programming device connection

X31

1
2
TXD24
3
RXD24
4

5
6
DSR24
7

8
to pro-
9 gramming
V12INN
device
10
P12VN
11
1 13 DSR
12
RX#
14 25 13
TX#
14
DSR#
15
TXD24_2
16
RDRCTL#
17
RXD24_2
18

19
RDRCTL
20
DTR24
21
22
RX
23
TX
24

25
GND

Shield is connected to metal shell of

connector

Connector X31 (osa plc)

Female D-SUB connector, 25-pin

Cable type: preassembled cable, part no. 1070 054 956

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 Modules 3–15

X61 CMOS bus for AG/ZS (PLC expansion unit)

X61
max. 0.55 m
1
12V GND
2
+12V
3
4
IRD
RM# 5
CLKI 6
7
D11
D14 8
9
D17
10
AD10
11
AD13
12
AD16
13
DO0
DO3 14

DO6 15
16
17
18

IWR
19 to AG/ZS
20
CLBP
CLKO 21
1 15
D12 22
16 30 23
D15
31 44 24
EASTATE#
25
AD11
26
AD14
27
AD17
28
DO1
29
DO4
30
DO7
31
32
33
WAITPER#
34
CLAB*
35
IO_INIT#
36
D10
37
D13
38
D16
39
40
AD12
41
AD15
42
IS#
43
DO2
44
DO5

Shield is connected to metal shell of

connector

Connector X61 (osa plc)

Female D-SUB connector, 44-pin

Connection type: CMOS bus
Line length: max. 0.55 m
Cable type: preassembled, part no. 1070 070 755

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3–16 Modules

X51 Connection to osa switch

X51 (osa master )

max. 30 m

1
CTX0
2 CAN bus to osa switch
CTX1
3

5
+12V power supply from osa
6 master to osa switch
GND

Shield is connected to metal shell of

connector

Connector X51 (osa master)

Male D-SUB connector, 9-pin

Connection type: CAN bus
Line length: max. 30m

CAUTION
Malfunctions caused by incompatible cables!
Use only preassembled original cables for all connections.

1070 073 736-103 (99.05) GB

 Modules 3–17

3.3 osa profibus fms

Connection module enabling the Typ3 osa Numerical Control to interface
with the PROFIBUS FMS.
Current consumption of osa profibus fms: 0.3 A/24VDC

CAUTION
Take all precautions necessary for ESD protection when handling
modules and components! Avoid electrostatic discharge!

Display: ISA bus issues interrupt request

Display: ISA bus OK

Display: Module holds the token

in Profibus FMS Protocol

Profibus FMS via OFC

(X75 connector)

Profibus FMS via D-SUB

(female X51, D-SUB, 9-pin)

osa profibus fms (front view)

. This module can only be used for the ”Typ3 osa-modular” system vari-
ant.

CAUTION
Malfunctions caused by incompatible cables!
Use only preassembled original cables for all connections.

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3–18 Modules

3.4 osa dc interface / osa dc interface ana

Central power supply and interface module of Typ3 osa. Two versions of this
module, which is always required, are available.

D osa dc interface (DCIO_1/MK) with Profibus-DP and digital I/O inter-

faces
D osa dc interface ana (DCIO_1) additionally with analog I/O and bit bus
interfaces

The description refers to osa dc interface ana.

Display PI: Profibus DP Active

Display PE: Profibus DP Fault

Digital I/O Interface

(female X12, D-SUB, 15-pin)

Profibus DP Interface
(female X51, D-SUB, 9-pin)

Battery Compartment

”READY”, ”VOUT” Indicators, and RESET key

READY2, RESET Out, RESET In

(X71 connector)
Fuse F1
VIN Input Power Indicator
External 24VDC Power Supply
(X10 connector)

osa dc interface (front view)

CAUTION
Take all precautions necessary for ESD protection when handling
modules and components! Avoid electrostatic discharge!

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 Modules 3–19

Display BI: Bitbus is Polling

Display BE: Bitbus Fault

Connectors for Bitbus

(X72: In; X73: Out)

Analog I/O Interface

(female X11, D-SUB, 25-pin)

Display PI: Profibus DP Active

Display PE: Profibus DP Fault

Digital I/O Interface

(female X12, D-SUB, 15-pin)

Profibus DP Interface
(female X51, D-SUB, 9-pin)

Battery Compartment

”READY”, ”VOUT” Indicators, and RESET key

READY2, RESET Out, RESET In

(X71 connector)
Fuse F1
VIN Input Power Indicator
External 24VDC Power Supply
(X10 connector)

osa dc interface ana (front view)

3.4.1 Connectors

X72, X73 Bitbus Connectors

Optical fiber connectors for OFC connecting cables (mfg. Hewlett Packard,
Type HFBR-PNS x; x = cable length).

X72: In
X73: Out

Minimum cable length: 3m

Maximum cable length: 20 m

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3–20 Modules

X11 Analog I/O Interface

X11 (osa dc interface)

max. 100 m

IN1
1 pos.
2 neg.

IN2
3 pos.
4 neg.

IN3
5 pos.
6 neg.

IN4
7 pos.
8 neg.
9

OUT1
10 –10 to +10V
11 GND

OUT2
12 –10 to +10V
13 GND

IN5
14 pos.
15 neg.

IN6
16 pos.
17 neg.

IN7
18 pos.
19 neg.

IN8
20 pos.
21 neg.

OUT3
22 –10 to +10V
23 GND

OUT4
24 –10 to +10V
25 GND

Shield is connected to metal shell of

connector

Connector X11 (osa dc interface)

Female D-SUB connector, 25-pole

Line length: max. 100m
Cable type: Shielded, twisted-pair

CAUTION
Malfunctions caused by inadequate shielding!
Always use only metal and/or conductive male and female connec-
tor/coupling shells with a large-area shield conductor surface.

Specifications – Inputs
Input type: Differential inputs
Input measuring range: "10 V
Resolution: 12 Bit
Conversion accuracy: "2 LSB
Conversion interval: 10 ms per channel
Input resistance: typ. 1G W
Input frequency: max. 10 kHz

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 Modules 3–21

Specifications – Outputs
Output type: Ground-referenced
Outpult voltage range: +10 V
Resolution: 12 Bit
Conversion accuracy: "2 LSB
Conversion interval: max. 50 ms
Input resistance of connected
input: min. 10 kW

. RESET resets all digital outputs to ”logic 0” (see section 3.4.2).

X12 Digital I/O Interface (High-speed Inputs/outputs)

X12 (osa dc interface)

OUT1 1
OUT2 2
OUT3 3
IN1 4
IN2 5
IN3 6
IN4 7
IN5 8
OUT4 9
OUT5 10
OUT6 11
12
IN6 13
IN7 14
IN8 15

Shield is connected to metal shell of

connector

Connector X12 (osa dc interface)

Female D-SUB connector, 15-pin

Specifications – Inputs
Galvanic isolation: via optocoupler
Voltage ranges: LOW level: –3 to +5V
HIGH level: +15 to +30V
Input current: 0.14 mA / V of input voltage
Input delay: max. 0.2ms

Specifications – Outputs
Concurrence: 100%
Nominal ratings: 24VDC, 0.5A
Max. current at max. voltage: 0.6A
Internal voltage drop: 1V
Max. leakage current, LOW level: 0.5mA
Max. short-circuit current: 1.7A, electronically limited

1070 073 736-103 (99.05) GB

3–22 Modules

ON delay: 0.2ms
OFF delay: 0.05ms

. RESET resets all digital outputs to ”logic 0” (see page 3–23).

CAUTION
The output stages may get damaged!
Do not connect capacitive loads. Inductive loads must be suffi-
ciently protected against interference. Note the information in sec-
tion 6.2 in this respect.

X51 Profibus DP Interface

X51 (osa dc interface)

1
2
Data P 3 RS485 Signal +
Repeater P 4 TTL Signal for Repeater Control
0V 5 ISO-GND
+5V 6 Repeater Power Supply
7 (+5V; 100mA)
Data N 8 RS485 Signal –
Repeater N 9 GND for Repeater P

Shield is connected to metal shell of

connector

Female D-SUB connector, 9-pole

The maximum permissible line lengths are dependent upon the baudrate
being used (as per DIN E 19245, part 3):

Baudrate (kBits/s) max. line length (m)

500 400
1500 200
3000 100
6000 100
12000 100

For longer lines, suitable repeaters with a metal housing must be intercon-
nected.

CAUTION
Malfunctions caused by inadequate shielding!
Always use only metal and/or conductive male and female connec-
tor/coupling shells with a large-area shield conductor surface.

1070 073 736-103 (99.05) GB

 Modules 3–23

X71 READY2, RESET Out, RESET In

In-line plug-in connector MSTB, 1.5, 6-pin, mfg. Weidmüller

X71 (osa dc interface)

READY2

RESET Out

RESET In

Connector X71 (osa dc interface)

Specifications – READY2:
Function: Announces the operational readi-
ness of the Typ3 osa Numerical
Controller by closing the floating
contact.
Switching current: max. 1 A
Switching voltage: max. 40 VDC
Switching load: max. 40 W
Response time: 3 ms
Contact release time: 2 ms
Bounce time: 0.5 ms
Conductor area (max.): 1.5 mm2

DANGER
Integrate the READY2 contact into the EMERGENCY-STOP loop of
the system!
Make sure that all hazardous machine functions immediately enter
a safe condition when the contact is opened.

Specifications – RESET Out

Function: Announces the proper operating
status of the internal power gener-
ation of the osa dc interface by
closing the floating contact.

Switching current: max. 0.5 A

Switching voltage: max. 40 VDC
Switching load: max. 15 W
Response time: 3 ms
Contact release time: 2 ms
Bounce time: 1 ms
Conductor area (max.): 1.5 mm2

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3–24 Modules

Specification – RESET In:

Function: As RESET key (cf. page 3–23).
Initiates a RESET when high level
is present.
Input characteristic: 24 VDC, floating
Voltage ranges: LOW: –3 ... +5 V
HIGH: +15 ... +30 V
Conductor area (max.): 1.5 mm2

X10 24 VDC External Power Supply

Power supply via a DC/DC converter for generating all voltages required in-
ternally and for power supply to the digital I/O interface X12 (see page 3–21).

X10 (osa dc interface)

24V from 24 V external power supply

24V to 24 V rack fan, Typ3 osa - modular
0V from 24 V external power supply
to 24 V rack fan, Typ3 osa - modular
0V

Connector X10 (osa dc interface)

In-line plug-in connector MSTB, 1.5, 4-pin, mfg. Weidmüller

Input voltage: 24 VDC, +20 %, –15 %
Permitted ripple voltage: max. 1.2 Vpp
Current draw: depending on system variant;
max. 3.5 A
osa rack 2: 1.22 A
osa rack 4: 1.58 A
(with osa master and osa plc)
Fuse protection: Fuse F1, M6.3A
Conductor area (max.): 1.5 mm2

DANGEROUS ELECTRICAL VOLTAGE

The 24 VDC input voltage must satisfy the requirements of ”Safety
separation”!

CAUTION
Risk of damage to machine or workpieces!
During the power-down sequence of the machine ensure that all
drives and actuators are electrically disabled before the input power
to X10 is switched OFF!

1070 073 736-103 (99.05) GB

 Modules 3–25

3.4.2 RESET Key

Initiates a restart of the control unit (hardware Reset).

For safety reasons, the key is concealed. It may be operated with a screw-
driver or a similar instrument.

CAUTION
Loss of data and damage to the machine!
Upon detection of a RESET command, the READY2 contact opens
immediately, the microprocessor of the Typ3 osa interrupts all cur-
rent processes and proceeds with a restart of the control unit. This
causes all unsecured data (e.g. a part program that has not yet been
saved) to be lost.
Press the RESET key only if no processing operation is active and
all data has been saved.

3.4.3 LED’s

VOut Output voltage indicator

Led illuminates when the internal supply voltages for the Typ3 osa control
are being properly generated, and as long as no overtemperature is de-
tected (>55_C).

VIn Input voltage indicator

LED illuminates when voltage is present at X10.

Ready Ready indicator

LED illuminates when the READY2 contact is closed. This indicates that the
control is operational.

3.4.4 F1 Fuse
Fuse, M 6.3 A, for protection of X10

In the presence of excessive power consumption or in the case of input volt-

age polarity reversal at X10, fuse F1 will blow to protect the Typ3 osa mod-
ules.

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3–26 Modules

3.4.5 Battery Compartment

Accommodates a Lithium battery (Type Li-SL-760/S, 3.6 V, 1.8 Ah, AA size;
order no. 1070 914 446).
The battery backs up the RAM memory ranges of all modules (osa master
and osa plc). Accordingly, the data held in RAM and in the internal system
clock is retained even if power to the unit is switched OFF.

The control unit permanently checks the battery charge level and, in the
event that the battery must be replaced, returns an appropriate message via
the display unit.
D NC hardware: ... is ”empty” or ”wrong polarity”

The battery can be replaced during operation because the gold capacitors
on the osa master and osa plc modules provide for short-time power supply
back-up.

CAUTION
Risk of data loss if battery is empty, or if the control unit is switched
off when the battery is empty.
Replace a discharged battery immediately with a fresh battery of the
same type.

CAUTION
Risk of health hazards caused by lithium-containing battery!
The empty battery must be disposed of as hazardous waste with the
waste key code number 35 325. It may be returned to Bosch.

1070 073 736-103 (99.05) GB

 PC Control Panels 4–1

4 PC Control Panels

The PC Control Panels are available in the following designs:

D osa display pc, consisting of
D ”osa display” display unit
D PC connected to osa display
D osa keyboard, optionally osa switch

D typ3 compact pc, consisting of

D ”osa display” display unit
D PC connected to osa display
D osa rack 2, connected to PC
D osa keyboard, optionally osa switch

Every PC Control Panel is connected to the osa master module via

10BaseT-Ethernet. Using this link and suitable PC software the PC displays
the operator interface information of Typ3 osa on the display unit and vice
versa, it feeds back all keyboard events to Typ3 osa (NC mode). File transfer
between Typ3 osa and the PC is also effected via the Ethernet link.

You may change between the NC mode and the PC mode at any time via the
keyboard. If the PC display is active, keyboard entries are not transmitted to
Typ3 osa, in this case, the PC behaves like a standard PC.

1070 073 736-103 (99.05) GB

 4–2 PC Control Panels

4.1 Technical data

PC Control Panels are available with different technical specifications:

Display unit – DSTN

– TFT
Power supply – 230 VAC
– 24 VDC
CPU power – AMD
– Intel Pentium
DRAM on-board – 16, 32, 64 MB

4.1.1 Overview

PC Control Panel
Control Panel osa display pc (DSTN) osa display pc (TFT) typ3
variant compact
pc
Designation 486A PENA PENA 486A PENA PENA TFT color
DSTN DSTN DSTN TFT color TFT color TFT color 24V
230V 230V 24V 230V 230V 24V
PCPLN PCPLN PCPLN PCPLN PCPLN PCPLN PCPNL
486A PENA PENA 486A PENA PENA PENA

32TF1 32DS1 32DS1 32TF1 32TF1 32TF1 32TF1

ISA2A2 ISA2A ISA2D ISA2A ISA2A ISA2D ISA2KS
Part no. 1070080135 1070079816 1070079815 1070080984 1070079814 1070079813 1070079525
CPU AMD/DX5 D – – D – – D
133 MHz
Pentium 133 MHz – D D – D D –
Main memory 32 MB DRAM D D D D D D D
onboard
Hard disk > 840 MB IDE – – – – – – D
> 1.6 GB IDE D D D D D D –
Graphics con- for TFT color: – – – D D D D
troller max. resolution
640x480
for DSTN color: D D D – – – –
max. resolution
640x480
ext. CRT monitor D D D D D D D
connection;
max. resolution
1024x768 pixels
(256 colors)
Free slots ISA bus (2/3 slot) 2 2 2 2 2 2 2

Power supply Characteristics osa display pc (DSTN) osa display pc (TFT) typ3
compact
pc
PC 85–264VAC In X20 X20 – X20 X20 – –
24VDC In – – X10 – – X10 X10
3.5” Floppy Disk +5VDC, +12VDC X70 X70 X70 X70 X70 X70 X70

D= available
–= not available

1070 073 736-103 (99.05) GB

 PC Control Panels 4–3

Interfaces Characteristics Connector designation

(all PC variants)
1x COM1 (serial) RS232 (UART 16550) X34
1x COM2 (serial) RS232 or RS485 X35
(UART 16550)
1x LPT1 (parallel) in SPP, EPP or ECP mode X61
1x floppy disk drive for 3.5” floppy disk drive; X71
(data) formatting: (720kB; 1.44MB; 2.88MB)
Keyboard MF2 X1
1x SVGA for ext. CRT monitor connection; max. resolution 1024x768 pixels X11
1x Ethernet 10 Base T X52

Basic System Operating system software PC Typ3 osa-modular

Typ3 osa-compact
PC Windows95 (US version) Option –
Windows95 (German version) D –
WindowsNT (US version) Option –
WindowsNT (German version) Option –
Typ3 osa Typ3 osa Version 3.x – D
(German version)
Typ3 osa Version 4.x – D
(German version)
Typ3 osa Version x.x – in preparation
(export version)

D= available
–= not available

4.1.2 osa display (display unit)

The display unit is available in two designs:

D 10.4 inch LCD colour flat display, passive
D 10.4 inch TFT colour flat display, active

All flat display types provide a resolution of 640x480 pixels.

Higher resolutions (800x600 and/or 1024x768) can be obtained with a sep-
arate CRT monitor. An SVGA signal output connector is provided for this
purpose at the rear panel of the PC Control Panel.

1070 073 736-103 (99.05) GB

4–4 PC Control Panels

4.2 Power connections

Overview
Depending on the design, the supply voltage is
D 85–264 VAC In (connector X20) or
D 24 VDC In (connector X10)

It is used for power supply to

D osa display and keyboard
D integrated PC
D 3.5” floppy disc drive

PC rear view

PE conductor bolt

Flat display (back side)

Interface:
Power supply
85–264 VAC In

osa display Power supply to floppy Power supply

disk drive (X70) 85–264 VAC In (X20)

Interface:
Power supply 24 VDC In

osa display Power supply to floppy Power supply

disk drive (X70) 24 VDC In (X10)

. The 24 VDC power connector is identical for typ3 compact pc and osa
display pc.

1070 073 736-103 (99.05) GB

 PC Control Panels 4–5

X20 85–264 VAC power connector

Available as an alternative to the 24 VDC power connector for:
D osa display pc

All voltages required internally are generated by the internal power supply
unit.

Supply: 85...264 VAC, 47–63 Hz

Max. conductor area: 1.5 mm2
Current consumption with 0.7 A
Unom = 230VAC: 0.2 A (only for 80135 and 80984)
Current consumption with 1.4 A
Unom = 115VAC: 0.4 A (only for 80135 and 80984)

X20

Assignment

PE N1
PE
U2

X10 24 VDC power connector

Available for:
D osa display pc (alternative to 85–264 VAC power connector)
D typ3 compact pc

Supply via a DC/DC converter for generating all voltages required internally.

Supply: 24 VDC, 3.5 A

Max. conductor area: 1.5 mm2 (cf. section 6.4 ”Power supply”)
Weidmüller plug-in terminal, MSTB 1.5, 4-pin

24 VDC connector X10

Pin Assignment
1
1 24V
2
2 24V
3 3 0V
4 0V
4

DANGEROUS ELECTRICAL VOLTAGE

The 24 VDC input voltage must satisfy the requirements of ”Safety
separation”!

CAUTION
Risk of damage to machine or workpieces!
During the power-down sequence of the machine ensure that all
drives and actuators are electrically disabled before the input power
to X10 is switched OFF!

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4–6 PC Control Panels

X70 3.5” floppy disk drive power supply

Power supply to an optionally connected 3.5” floppy disk drive.

Supply: +5V, +12V, 0.9A max.

Female plug-in connector,
4-pin

Connector (X70) Pin Assignment

1 2 3 4 1 +5V
2 GND
3 GND
4 +12V

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 PC Control Panels 4–7

4.3 Interfaces

4.3.1 Overview

The following table describes the built-in connector types of the PC Control
Panels and their mating connectors.

Connector Connection Connector type (built-in) Mating connector or cable

X34 COM1 9-pin male Cannon connector 9-pin female Cannon connector (V24)
X35 COM2 9-pin male Cannon connector 9-pin female Cannon connector (V24)
X61 LPT1 25-pin female Cannon connector 25-pin Cannon connector
(e.g. from printer cable)
X71 Floppy data interface 34-pin male connector (IDC) 34-pin socket connector (IDC)
(floppy disk drive data cable)
X52 Ethernet Female RJ45 connector Male RJ45 connector (twisted-pair, 8 cores)
X11 SVGA 15-pin SVGA socket 15-pin SVGA connector
(from ext. monitor)
X1 Keyboard 5-pin MF2 socket MF2 keyboard, MF2 plug

osa display plc PC Control Panel as 230 VAC variant (for 24VDC variant,
cf. section 4.2):

View from below Floppy data interface

(230 VAC variant) COM1 (X34) Ethernet (X52) (X71)
2 free ISA
slots
COM2 (X35) LPT1 (X61) Keyboard: MF2 (X1)

PC cover

TFT display SVGA (ext.) Power supply Power supply

(X11) (floppy) (X70) PC 85-264VAC In (X20)

1070 073 736-103 (99.05) GB

4–8 PC Control Panels

typ3 compact pc PC Control Panel with Typ3 compact connected:

View from below Typ3 osa compact

(24 VDC variant)

PC cover TFT display Power supply

24VDC In (X10)

4.3.2 Serial interfaces COM1 and COM2

X34 COM1 as RS232 interface

9-pin male Cannon
connector
Type: RS232
Cable length: max. 15 m
Cable type: shielded, min. conductor cross-section 0.14 mm2
Transmission rate: max. 115,200 bits/s
Handshake: hardware and software handshake (XON, XOFF)

COM1 X34
max. 15 m
1
DCD
2
RX to peripheral
3
TX units
4
1 5 DTR
5
GND
6 9 6
DSR
7
RTS
CTS 8

9
RI

Shield connected to connector

metal housing

For pin assignment, cf. page 4–11.

. If special hardware is to be connected to COM1, it may be necessary to

adjust the communication parameters of COM1. For this purpose, call
up the Windows 95/NT ”System control” and select the appropriate
COM1 parameter settings.

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 PC Control Panels 4–9

CAUTION
Malfunctions caused by inadequate screening!
Always use only metal and/or conductive male and female connec-
tor/coupling shells with a large-area shield conductor surface.

COM1 used as V.24 interface

If COM1 is used as a V.24 interface, other peripherals (e.g. an external PC)
may be linked to the PC Control Panel.

The cable, part no. 1070 077 753 (length 5 m) facilitates data transmission
between the PC Control Panel and an external PC with a suitable V.24 inter-
face. Use a special transmission program, e.g. ”Windows Terminal Pro-
gram” for data transfer.

Cable type: 5 x 0.14 mm2

Cable length: 5 m (standard)
Connector: 9-pin female D-SUB

Peripheral units

PC V.24 connection PC V.24 connection PC Control Panel

male Cannon con- male Cannon con- COM 1, 2 (X34, X35)
nector 25-pin COM X nector 9-pin COM X

TX 2 TX 3 Data 2 RX
RX 3 RX 2 Data 3 TX
DTR 20 DTR 4 Status 6 DSR
DSR 6 DSR 6 Status 4 DTR
GND 7 GND 5 5 GND

Shield Shield Shield on housing Shield

on both sides of the

connector metal housing

Data communication with serial peripherals

. A cable with a 25-pin female connector is not included in the Bosch

delivery. 9-pin female to 25-pin female adapters are commercially avai-
lable.

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4–10 PC Control Panels

X35 COM2 used as RS232 or RS485 interface

9-pin male D-SUB connector
Type: RS232 or RS485; default setting depends on
order
Cable length: RS232: max. 15 m;
RS485: max. 100 m
Cable type: shielded cable, min. conductor cross-section
0.14 mm2
Transmission rate: max. 115,200 bits/s (RS232)
Handshake: hardware and software handshake (XON, XOFF)

COM2 X35 (D-Sub)

RS485 RS232 max. 15 m,
or 100m
1
DCD DCD
2
RXD- RX
3
1 TXD- TX to peripheral
5 4
DTR DTR units
6 9 GND GND 5
6
DSR DSR
7
RXD+ RTS
TXD+ CTS 8
9
RI RI

Shield connected to connector

metal housing

COM2 must be configured as RS232 or RS485 interface by setting an ap-

propriate jumper (default setting depends on order):

LPT 1

Jumper
J18
COM1

COM2
Battery

Jumper J18 settings

for COM2:
5
3
1

CPU RS232:
6
4
2
5
3
1

RS485:

Motherboard of osa display PC

6
4
2

Motherboard jumper settings for COM2

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 PC Control Panels 4–11

Pin assignment for RS232 interface:

DCD Data Carrier Detect; receive line used, for example, by a con-
nected modem to signal to the PC that it is receiving a carrier
signal (connection established).
RX Receive Data; receive line for data.
TX Transmit Data; transmit line for data to peripheral device.
DTR Data Terminal Ready; transmit line used by the PC to signal to
a connected peripheral device that its interface is enabled and
initialized.
DSR Data Set Ready; receive line used by the connected peripheral
device to signal to the PC that it is powered up and initialized.
GND Signal Ground
RTS Request to Send; receive line used by the connected periph-
eral device to signal to the PC that it requests permission to
send data.
CTS Clear to Send; transmit line used by the PC to inform the con-
nected peripheral that it is clear to send, i.e., that is has per-
mission to send data.
RI Ring Indicator; receive line used by a connected modem to
signal to the PC that an incoming call is waiting.
Shield Contact to metal frame of hardware module via connector
metal housing of the D-SUB plug-in connector.

Pin assignment for RS485 interface:

DCD identical to RS232
RXD–, RXD+ Receive Data; receive lines for data.
TXD–, TXD+ Transmit Data; transmit lines, data to peripheral device.
DTR identical to RS232
DSR identical to RS232
GND identical to RS232
RI identical to RS232
Shield identical to RS232

In order to use COM2 as RS485, the cable between the motherboard and
the D-SUB connector of COM2 inside the PC must be replaced (part
no.: 1070078881, 14-core ribbon cable).
It replaces the line inserted if COM2 is used as RS232.

CAUTION
Malfunctions caused by inadequate screening!
Always use only metal and/or conductive male and female connec-
tor/coupling shells with a large-area shield conductor surface.

. If special hardware is to be connected to COM2, it may be necessary to

adjust the communication parameters of COM2. For this purpose, call
up the Windows 95/NT ”System control” and select the appropriate
COM2 parameter settings.

COM2 used as V.24 interface

If used as a V.24 interface, other peripherals (e.g. an external PC) may be
linked to COM2 as well as COM1 (cf. page 4–9).

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4–12 PC Control Panels

4.3.3 LPT1 parallel port

X61 LPT1 printer port

All printers equipped with a parallel port can be connected using a commer-
cially available printer cable.

Male D-SUB connector, 25-pin

Type: SPP (bidirectional), EPP or ECP
Cable length: max. 3 m
Cable type: shielded cable, min. conductor
cross-section 0.14 mm2

LPT1 X61

Interfaces mode max. 3m

ECP EPP SPP

1
Strobe Write Strobe
2
D0 D0 D0
3
D1 D1 D1
4
D2 D2 D2
5
D3 D3 D3
6
D4 D4 D4
7
D5 D5 D5
8
D6 D6 D6
9 to Peripheral
D7 D7 D7
10 Devices
ACK Intr ACK
11
1 13 Busy Wait Busy
12
PError n.u. PE
14 25 13
Select n.u. Select
14
Autofd Datastb Autofd
15
Fault n.u. Error
16
Init n.u. Init
17
SelectIn Addrstrb SelectIn
18
GND GND GND
19
GND GND GND
20
GND GND GND
21
GND GND GND
22
GND GND GND
23
GND GND GND
GND GND GND 24

25
GND GND GND Shield connected to
connector metal
housing

The parallel port is usually operated in SPP standard mode. It may also be
used in EPP (Enhanced Parallel Port) or ECP (Extended Capabilities Port)
modes if suitable peripherals are available. The settings in the PC BIOS
must be changed accordingly. For more information please contact Bosch.

CAUTION
Malfunctions caused by inadequate screening!
Always use only metal and/or conductive male and female connec-
tor/coupling shells with a large-area shield conductor surface.

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 PC Control Panels 4–13

4.3.4 3.5” Floppy disk drive interface

X71 Connection of drive ”A”

For connecting a floppy disk drive. The onboard floppy controller supports
the following drive types:
D 5.25 and/or 3.5 inch
D Single-Density (360 kB and/or 720 kB)
D Double-Density (1.2 MB and/or 1.44 MB)
D Enhanced Floppy Mode (2.88 MB)

Only one drive type can be connected using a 34-pin floppy disk ribbon
cable. For recommended floppy disk drives, refer to section 7.

shielded ribbon cable Line no. 1

1

Floppy ”A”
X71 bootdrive
on PC Control Panel connector

39

Installation
D Connect the Floppy ”A” bootdrive end of the ribbon cable to the floppy
disk drive. The other end of the cable should be plugged into the X71
floppy disk drive connector of the PC Control Panel. Note the line with the
red marking on the ribbon cable, which always has to connect to PIN 1 of
the equipment connectors to be linked.
In most cases, connector notches prevent incorrect connections.
D Furthermore, the floppy disk drive has to be connected to the power sup-
ply. For this purpose, connect the cable (4-pin male connector) coming
from the floppy disk drive to X70 of the PC Control Panel.

. If the floppy disk drive is permanently installed, both connections

(X70, X71) must be shielded, and the shield conductor must be con-
nected to frame potential at both ends.

Subsequent to the installation, you must register the installed drives by

means of the PC’s AMIBIOS setup program. Proceed as follows:
D Switch ON the PC Control Panel again.
D When you see the “Hit <DEL> if you want to run SETUP” user prompt,
press the DEL key. This starts the setup program.
D Begin by selecting the Standard symbol, followed by Floppy A.
D Select the value matching the drive’s capacity (360 kB, 720 kB, 1.2 MB,
1.44 MB or 2.88 MB).
D Return to the Main Menu of the setup program, and select the Peripheral
symbol. There, the OnBoard FDC parameter must be set to Enabled.
If this is not the case, you should first set the Programming Mode para-
meter to manual. Conclude by setting the OnBoard parameter to
enabled.

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4–14 PC Control Panels

D Save the new settings by pressing the ESC key while in the Main Menu,
and then selecting Save changes and Exit.
D Once the PC has booted up again, you should be able to access drive A.
If this is not the case, switch OFF the PC Control Panel and check that
controller cable and floppy disk drive wiring are properly seated in their
sockets. Reboot the PC.

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 PC Control Panels 4–15

4.3.5 Ethernet interface

X52 Ethernet
The Ethernet interface is used to connect the PC Control Panel to Typ3 osa.
This connection can also be made via a network (cf. figure).

Femal RJ45 connector, 8-pin

Type: Ethernet 10-Base-T
Cable length: max. 100 m
Cable type: Shielded twisted-pair
Transmission speed: 10 Mbit/s
100 Mbit/s (in preparation)

Ethernet X52
max. 100 m Ethernet connector
Female RJ45 1 on Typ3 osa
TXD+
connector 2
TXD–
RXD+ 3
4
5
6
RXD–
7
8

Network wiring

Administration Application

PC Control Panel

File server
HUB Ethernet
connector
Application server, (X52)
e.g.
Ethernet
– program transfer
– file transfer
– backup e.g. Windows NT
network
Ethernet
connector
(X52)

Typ3 osa

CAUTION
Malfunctions caused by incompatible cables!
Use only preassembled original cables for all connections.

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4–16 PC Control Panels

4.3.6 SVGA interface

X11 Screen connector

SVGA output for connecting a CRT monitor to obtain a higher screen resolu-
tion.

Female HD connector, 15-pin

Max. resolution: 1024 x 768 pixels (at 256 colors)

Pin Signal (Color)

1 RED
2 GREEN
SVGA X11 3 BLUE
4 –
5 GND
1 6 RED GND
7 GREEN GND
8 BLUE GND
15 9 –
10 Digital GND
11 –
12 –
13 Hsync
14 Vsync
15 –

4.3.7 MF2 interface

X1 MF2 keyboard connector

Female DIN connector, 5-pin
Cable length: max. 1.5 m
Cable type: shielded cable, min. conductor cross-section
0.14 mm2

MF2 X1
max. 1.5 m

1
Keyboard Clock
2 osa keyboard
3 1 Keyboard Data
5 24 3

4
GND
5
+5V

Shield connected to connector

metal housing

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 PC Control Panels 4–17

4.3.8 Free ISA slots

The PC Control Panel can accommodate 2 additional expansion boards.

The dimensions of the expansion board may be approx. 180x100 cm
(2/3 board), and the board must be suitable for the ISA bus.

There are no limitations as to the selection of the expansion board, provided

that it satisfies the technical requirements of the Windows 95 and/or Win-
dows NT operating system and is operational in this environment.

Rear view

ISA slot

optional ISA slot

expansion boards

DRAM memory PE lug

slots

Dummy cover ISA slots:

View from below (for empty
slots) Slot A1 Expansion slot
Slot A2 fastener

Installation of an ISA expansion card

L Disconnect the unit from power (if necessary, remove plug from connector
X20/X10).

L Remove the PC cover and blanking plate (dummy cover) of the slot

L Press the contact side of the expansion board into one of the slots at the side
of the board.

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 4–18 PC Control Panels

L Fasten the mounting frame of the expansion board to the PC enclosure

(original fastening of dummy cover) and reinstall the PC enclosure to the PC-
Modular. Keep the dummy cover in case the expansion board is removed
later.

L Reconnect the power supply to the PC (connector X20).

L When the PC operating system has been rebooted, you may configure the
driver software and the associated expansion board software as described
by the manufacturer.

Software installation
Normally, the ISA expansion board is accompanied by the driver software for
the PC. Make sure that the card is accompanied by the driver software re-
quired for Windows95 and/or WindowsNT (depending on the operating
system installed on your PC when delivered). For more details on the instal-
lation, please refer to the manufacturer’s manual for the board.

Application example:
Internal modem for data transmission through the telephone network:

Customer
service Application

PC Control Panel
modem con-
Service nected to ISA
computer board

Service
application, modem
e.g. connection Transmission
– remote diagnostics network (e.g.
– remote access Telecoms)
– file transfer
Ethernet
connector
(X52)

Typ3 osa

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 PC Control Panels 4–19

4.4 osa keyboard

The osa keyboard is an integral component of the PC Control Panel. It in-

cludes:
D CNC-specific keys, including Softkeys.
D QWERTY keyboard
D Separate numeric keypad

The keyboard is used to operate both the Typ3 osa Numerical Control and
the integrated PC. An additional PC keyboard is therefore not required.

The keyboard is shipped from the factory with a 1.5-metre connecting cable
and connector to match the keyboard interface (X1) of the integrated PC.

. In the event that you are not using the standard keyboard cable sup-
plied by Bosch, please ensure that the maximum permissible length of
2.5 m between keyboard and PC is not exceeded.

Keyboard setting options

On the back side of the keyboard, there are DIP switches for adjusting the
keyboard to the PC.
The DIP switch positions are set to default settings for standard applications
in the factory.

Explanation of DIP Switches

Switch Position: OFF Position: ON

S1 Automatic match to XT / AT XT

S2 Reserved. / Pass-through enabled Reserved. / Pass-through disabled

S3 Auto repeat normal Auto repeat OFF

S4 Key click ON Key click OFF

S5 n-key rollover 2-key rollover

S6 not used not used

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4–20 PC Control Panels

S1 DIP switches for

approx. 1.5 m S6 keyboard settings

Factory presets:
on off S1–S4 and S6: OFF
MF2 Con- S5: ON
necting
plug for
PC Control
Panel

Back side of osa keyboard

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 PC Control Panels 4–21

4.5 osa switch (Machine Control Panel)

The osa switch is available as an optional accessory. With regard to design

and dimensions, it is designed to match PC Control Panel.
Connection to X51 of the osa master module.

32 illuminated keys 2 key-operated switches

osa switch
front view

optional interface feedrate selector digital override poten-

digital override poten- EMERGENCY-STOP
(sealed with cover switch tiometer for feedratetiometer for spindle
against front side) speed
digital handwheel osa master (CAN bus) e.g. connection for V.24
osa switch
rear view

13 1
St3
25 14
digital handwheel
EMERGENCY STOP
St5 1 2 St2
discrete keys St4

12 22
5

14 24
EMERGENCY-STOP 13 23
6
1

11 21

Control elements and interface connectors:

D 32 illuminated keys
D Key switches
D Feedrate selector switch (max. 11 steps)
D Digital stepping switch for feedrate in % (max. 28 steps)
Although ranges and increment sizes can be modified by means of
MACODA parameter 103000004, key labeling will no longer correspond
to actual settings.
Total range: from 0 to 120%,
subdivided into individual ranges: 0 to 10% (increment size: 2.5%)
10 to 80% (increment size:10%)
80 to 120% (increment size:
2.5%).

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4–22 PC Control Panels

D Digital stepping switch for spindle speed in % (max. 31 steps)

Although ranges and increment sizes can be modified by means of
MACODA parameter 107000018, key labeling will no longer correspond
to actual settings.
Total range: from 0 to 150% in 5 % increments

D EMERGENCY-STOP, 2-channel, max. load: 24 V, 2 A (safe to EN 418)

D Interface for digital handwheel (female D-SUB connector, 25-pin)
D Male D-SUB connector, 9-pin, for connection to X51 of the osa master
module
D D-SUB 9-pin male/male coupling. Used, for example, to bring out the V24
interface X35 from the osa master to the front panel of the osa switch.
The logical statuses of all keys, switches and potentiometers – as well as the
data of a connected handwheel – are cyclically transferred to the Typ3 osa
via CAN bus, and mapped onto markers. Furthermore, markers can be set
for the purpose of switching On or Off the function and illumination of individ-
ual keys. The functionality of individual control elements must be imple-
mented by means of the appropriate interpretation of markers through the
PLC software.

. For additional information (i.e., assignment of control elements and

marker addresses), please refer to the “Typ3 osa Project Planning
Manual ICL700”, cf. page 1–9.

4.5.1 Connection to osa master

St2 CAN bus
Osa switch is connected to X51 of the osa master module via St2

Female D-SUB connector, 9-pin

Type: CAN bus
Cable length: max. 30 m

St2
max. 30 m

1 to osa master
CTX0
2 CAN bus
CTX1
1 5 3

4
6 9
5 Power supply
+12V
from osa master
6
GND

Shield connected to connector

metal housing

CAUTION
Malfunctions caused by incompatible cables!
Use only preassembled original cables for all connections.

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 PC Control Panels 4–23

4.5.2 Connection of EMERGENCY-STOP mushroom striker

The EMERGENCY-STOP mushroom striker must be connected to the

EMERGENCY-STOP loop. It is tamper-proof to EN 418.

Male connector, 8-pin

Type: two-channel: 2 ncc’s, 2 noc’s
Max. load: 24 V, 2 A

osa switch EMERGENCY-STOP mushroom striker

11

12 to EMERGENCY-
STOP loop
noc 13
21 11
ncc 14
23 13

24 14 23
ncc
22 12 24
noc
21

22

DANGER
Danger of life through inadequate EMERGENCY-STOP devices!
EMERGENCY-STOP devices must be active and within reach in all
system modes. Releasing an EMERGENCY-STOP device must not
result in an uncontrolled restart of the system! First check the
EMERGENCY-STOP circuit, then switch the system on!

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4–24 PC Control Panels

4.5.3 Connection of digital handwheel/manual operating unit

St3 Data lines

The following pin assignment of St3 on the osa switch is shown as an exam-
ple of a connection configuration for a handwheel or manual operating unit
made by Messrs. Euchner:

Female D-SUB connector,

25-pin
Connection type: iaw RS422 A
Line length: max. 3.5 m, extendible spiral cable
Supply voltage: 5V

Handwheel/Manual
St3
operating unit

(connection to St4) EMERGENCY-STOP 1 EMERGENCY-STOP

D7 2 M8.0
D5 3 M8.2
GND 4
Scan9 5 (for marker M9.xx
D6 6 M9.1
D4 7 M9.3
D2 8 M9.5
1 13 D0 9 M9.7
14 25
A* 10 Handwheel A*
B* 11 Handwheel B*
12V 12
GND 13
(connection to St4) EMERGENCY-STOP 14 EMERGENCY-STOP
D6 15 M8.1
Scan8 16 (for marker M8.xx)
Scan9 17 (for marker 9.xx)
D7 18 M9.0
D5 19 M9.2
D3 20 M9.4
D1 21 M9.6
A 22 Handwheel A
B 23 Handwheel B
5V 24 Handwheel 5V
GND 25 Handwheel 0V

Shield Shield Shield

Connected to metal shell

of both connectors

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 PC Control Panels 4–25

St4 EMERGENCY-STOP connection

The St4 EMERGENCY-STOP connection may be used if a manual operat-
ing unit is equipped with an EMERGENCY-STOP button which is to be con-
nected to the EMERGENCY-STOP loop.
The EMERGENCY-STOP signal is supplied by connector St3 and con-
nected to St4 via the circuit board. The contacts of St4 are linked to the
EMERGENCY-STOP circuit.

St4

(from St3, pin 1) 1 EMERGENCY-STOP

loop
(from St3, pin 14) 2

4.5.4 Connection of additional external keys

St5 additional discrete keys

Male Weidmüller connectors,
6-pin

St5 discrete keys

Scan8 1 (for marker M8.xx)

D0 2 M8.7
D1 3 M8.6
D2 4 M8.5

1 2 3 4 5 6 D3 5 M8.4
D4 6 M8.3

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4–26 PC Control Panels

4.5.5 Front-sided interface

The front side of the osa switch accommodates an interface connector
which can be alternatively assigned as:
D V.24 interface to osa master (X35) or
D COM1/2 port for connection to PC Control Panel

A detachable cap is fitted to the interface connector to protect it against

moisture.

V.24 interface X35 of osa master:

The interface designated V.24 in the figure below is always available as a
data port for linking external peripherals. The interface named Debugging
can only be used for debugging purposes.

. The Debugging interface can only be used if the ”osa dc interface”

module has been inserted.

Front-sided interface used as X35

max. 15 m
1
RxD_D
2
RxD
to peripherals
3
TxD V.24
4
1 5
5
GND
6 9
6
562 Ohm
7
+12V
8
Debugging
9
TxD_D

Shield connected to connector

metal housing

. The pin assignment is identical to X35 of the osa master, cf. page 3–5.

RS232 interface COM1 of PC Control Panel

Frontsided interface used as COM1

max. 15 m
1
DCD
2
RX
3
TX to peripherals
4
1 DTR
5
GND 5
6 9 6
DSR
7
RTS
CTS 8
9
RI
Shield connected to connector
metal housing

. The pin assignment is identical to COM1 of the PC Control Panel, cf.

page 4–8.

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 Installation 5–1

5 Installation

The following installation instructions refer to the PC Control Panel variants

”osa display pc” and ”typ3 compact pc”, osa keyboard, and osa switch, as
well as the control unit versions Typ3 osa-compact and Typ3 osa-modular.
For applicable standards and conditions of use, refer to sections 2.3 and 2.4.

CAUTION
Danger for product!
The ambient air must be free from conductive contaminations
(acids, alkalis, corrosive agents, salts, metal vapors, etc.).
Filters in the air inlet and outlet must be regularly serviced.

DANGER
The operational reliability of components designed to be installed
in housings or switch cabinets is considerably impaired if these
units are operated or handled while not being installed in such en-
closures.
Therefore, you should operate and handle the Typ3 osa components
only when installed in an enclosure.

. A maintenance-friendly installation, i.e. easy access to the connection

leads and fuses, is of great importance.

. Prior to installation, you should note down the data on the name-
plates. In case nameplates are no longer visible or legible after instal-
lation, you may access this data quickly at any time.

5.1 osa rack 2 for Typ3 osa-compact

Weight: approx. 4 kg when fully equipped

Orientation: 0_ to max. 45_ slanted position; fastened to back
side of the osa display PC
Installation type: in console or swivel frame, sealed in accordance with
IP54

D In order to ensure adequate ventilation and cable access, provide a mini-

mum top and bottom clearance of 50 mm.
D The maximum distance between the osa rack and a PLC expansion rack
is limited by the length of the available connecting cables between ICL
and AG/Z-S. Cable length is 0.55 m.
D Maintain as much distance as possible from sources of interference.

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5–2 Installation

For installation, push the osa rack 2 into the holding slots of the PC cover.

268.8

osa rack 2 – rear view

190.1
osa rack 2

min. 50 mm card insertion opening min. 50 mm

clearance clearance

Typ3 osa-compact
– rear view
osa rack 2

PC Control Panel
(typ3 compact pc)

Holding slots in PC
housing

integrated PC

86.5
78
side view
osa rack 2

integrated PC

4 holding brackets on housing

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 Installation 5–3

5.2 osa rack 2 for Typ3 osa-modular

Weight: approx. 9 kg when fully equipped

Orientation: vertically; fastened to back side
Installation type: in switch cabinet, sealed in accordance with IP54

D In order to ensure adequate ventilation and cable access, provide a mini-

mum top and bottom clearance of 50 mm.
D The maximum distance between the osa rack and a PLC expansion rack
is limited by the length of the available connecting cables between ICL
and AG/Z-S. Cable length is 0.55 m.
D Maintain as much distance as possible from sources of interference.
D Fasten the osa rack 2 with 2 hexagon head approx. screws size M6 on an
even metallic surface.
D Hang the osa rack onto the screws and tighten the screws. A conductive
connection to the mounting surface must be established via the screws.

min. 50 mm clearance
7.5

78
13
6.5 207
314.2

329.2
315.5

Ground lug
(PE connection)
10.8

6.5
Ground lug
(PE connection)
min. 50 mm clearance

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5–4 Installation

5.3 osa rack 4 for Typ3 osa-modular

Weight: approx. 10 kg when fully equipped

Orientation: vertically; fastened to back side
Installation type: in switch cabinet, sealed in accordance with IP54

D In order to ensure adequate ventilation and cable access, provide a mini-

mum top and bottom clearance of 50 mm.
D The maximum distance between the osa rack and a PLC expansion rack
is limited by the length of the available connecting cables between ICL
and AG/Z-S. Cable length is 0.55 m.
D Maintain as much distance as possible from sources of interference.
D Fasten the osa rack 4 with 2 hexagon head approx. screws size M6 on an
even metallic surface.
D Hang the osa rack onto the screws and tighten the screws. A conductive
connection to the mounting surface must be established via the screws.

min. 50 mm clearance
7.5

125
13
6.5 207
314.2

329.2
315.5

Ground lug
(PE connection)
10.8

6.5
Ground lug
(PE connection)
min. 50 mm clearance

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 Installation 5–5

5.4 PC Control Panels ”osa display pc” and ”typ3 compact pc”
Weight: osa display pc: approx. 4 kg
typ3 compact pc: approx. 8 kg (including Typ3 osa-compact)
osa keyboard: approx. 1 kg
Orientation: osa display: 0_ to max. 45_ slanted position.
osa keyboard: 0_ to max. 90_ slanted position, centered below
the osa display.
Max. distance from osa display: 100 mm.
Installation in console or swivel frame, sealed in accordance with IP54
type:

. Please consider that the front of the control panel may get contami-
nated more quickly if installed in slanted or horizontal orientation.

Minimum all-round
osa display clearance 50 mm

max. 100 mm

osa keyboard

max. 45°

max. 90° (osa keyboard)

D Install the PC Control Panel in a way that facilitates the most ergonomic
operator access and operation. Also, the operator must always have a
clear line of sight toward all moving machine components!
D Avoid installation locations exposed to direct sunlight (reduction of dis-
play readability, additional thermal load).
D In order to ensure adequate ventilation and cable access, provide a mini-
mum all-round clearance of 50 mm.
D Route all connecting cables in loops, and provide strain reliefs for all
cables.
D Maintain as much distance as possible from sources of interference.
D Use only silicone-free sealing compounds, adhesives or insulating
media.

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5–6 Installation

PC Control Panel osa display pc

Distance to rear wall of installation enclosure: min. 50 mm All-around panel seal (at rear)
130

238.5
250
3 120.5

OK for osa keyboard to 338.5

butt on panel Ğ 4.5
350

198.5
osa keyboard

210

11 all around edge

OK to butt-mount
osa switch here. All-around
panel seal
(at rear)

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 Installation 5–7

PC Control Panel typ3 compact pc including Typ3 osa-compact

Distance to rear wall of installation enclosure: min. 50 mm

All-around panel seal (at rear)
min 248.5 mm

238.5
250
Typ3 osa-compact

3
120.5 338.5
198.5 Ğ 4.5
350

OK for osa keyboard to

butt on panel

198.5
210
osa keyboard

11 all around edge

OK to butt-mount
35 osa switch here.
All-around panel seal (at rear)

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 5–8 Installation

Installation cut-outs
PC Control Panel osa display pc

338.5
M4 or 5mm in
diameter

230 238
330

PC Control Panel typ3 compact pc incl. Typ3 osa-compact

338.5 M4 or 5mm in
diameter

190 198

330

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 Installation 5–9

5.5 osa switch (machine control panel)

Weight: approx. 1,7 kg
Orientation: 0_ to max. 90_ slanted position.
centered under osa keyboard.
Max. distance from osa display: 300 mm.
Installation type: in console or swivel frame, sealed in accordance with IP54

. Please consider that the front of the control panel may get contami-
nated more quickly if installed in slanted or horizontal orientation.

Minimum all-round
clearance 50 mm

osa display

max. 100 mm
max. 45°
osa keyboard max. 300 mm

osa switch
max. 90°

D Install the osa switch in a way that facilitates the most ergonomic opera-
tor access and operation. Also, the operator must have a clear line of
sight toward all moving machine components!
D Avoid installation locations exposed to direct sunlight (illuminated keys
are harder to differentiate, additional thermal load).
D In order to ensure adequate ventilation and cable access, provide a mini-
mum all-round clearance of 50 mm.
D Route all connecting cables in loops, and provide strain reliefs for all
cables.
D Maintain as much distance as possible from sources of interference.
D Use only silicone-free sealing compounds, adhesives or insulating
media.

1070 073 736-103 (99.05) GB

 5–10 Installation

40
All-around panel seal (at rear)
5

OK for osa
keyboard to
butt on panel

175
163
338.5
3

350

50 mm
clearance

Installation cut-out

338.5 M4 or 5mm in
diameter

155 163
330

1070 073 736-103 (99.05) GB

 Electrical Connection 6–1

6 Electrical Connection

The present chapter describes only the principles guiding the electrical con-
nection of the Typ3 osa Numerical Control. It contains information that is of
concern mainly to the system planner/designer.

It is the responsibility of the system planner to provide for, and incorporate,

required components, such as EMERGENCY-OFF control circuits, mains
switches, etc., in accordance with accepted industry practice, while ensur-
ing the highest degree of safety.

. Therefore, with regard to electrical connections, the connection dia-

grams and installation instructions supplied by the machine
manufacturer shall always be binding!

CAUTION
Damages to system components may result from making or remov-
ing plug-in connections during system operation!
You should always shut off the system before you connect the com-
ponents.

1070 073 736-103 (99.04) GB

6–2 Electrical Connection

6.1 Notes on Protective Earth (PE) Connectors and Screening

DANGER
Hazardous conditions, functional failures and physical system
damage through insufficient potential equalization or poor screen-
ing between individual components!

Equipotential bonding currents must not flow through the screen-

ing of interface cables.

L Ground wiring must be structured in a meshed arrangement. All compo-

nents, switch cabinet housings/doors and the mounting plate must be
grounded.

L Equipotential bonding lines/PE lines of all plant sections should be as short

and as low-resistance as possible.

L Install PE rails, preferably with full conductance, on the mounting plate in the
switching cabinet. In the case of isolated PE rails, both ends of the rail must
be connected to the mounting plate by means of sufficiently dimensioned
copper grounding straps not exceeding 20 cm in length.
Position PE rails in such a way that the length of PE conductors connecting
individual modules in the switching cabinet does not exceed 1 meter.

L Ensure that a sufficient conductor area (cross-section) is always used

throughout the PE system. Refer also to EN 60204 Part 1 (max. electrical
resistance and testing of PE wiring installations).

L If at all possible, connect the screening at both ends.

L Ensure that potential equalization currents do not flow through the screening
conductors of interface cables. Therefore, always provide proper equipoten-
tial bonding between the devices to be connected already prior to the first
system start-up. In doing so, also take into account such types of interfaces
that are used to connect devices in different locations – regardless of dis-
tance or mains power supply.

DANGER
Danger of electric shock through insufficient PE conductor connec-
tion!
PE conductor connections must not be negatively affected by me-
chanical, chemical, or electro-chemical influences. The connection
must be lasting.

1070 073 736-103 (99.04) GB

 Electrical Connection 6–3

6.2 Interference Suppression Information

When planning the system, and to improve operational system safety, you
are advised to take into account all interference suppression regulation
guidelines and statutes governing the interference clearing of individual
components.

DANGER
Hazardous conditions, functional failures and physical system
damage through EMC or conducted interference!
Inadequate line routing, insufficient cable shielding or inappropri-
ate PE system designs may introduce interference into electronic
equipment.
Therefore, signal voltage lines should be laid at appropriate dis-
tances from power cables (e.g. motor cables). If this is not possible,
separate metal cable ducts must be used.

The following sections endeavour to provide you with a brief overview of op-
tional interference suppression measures in the switching cabinet. They in-
clude, for example:
D Filters
D Spark quenching circuits
D Attenuation of inductive switching surges
D Limiting the switching impulse voltage of fast semiconductors
D Screening
To provide effective interference suppression, all of the above components
must be considered because only in combination will they produce optimum
efficiency. The principle applying to interference suppression is summarized
as follows:
D Interference suppression as close as possible to the interferer
D Use of components restricted to those identified as having interference-
suppressing properties
D Limiting leakage currents in accordance with safety regulations
D Providing protective insulation
D Ensuring sufficient mechanical support to prevent vibration breakage.
When using pin-point precision in the application of interference suppres-
sion measures, the question of symmetry or asmmetry is an essential one.
Besides symmetrical interference voltage components occurring between
mains connecting lines, asymmetrical interference voltages are produced
as well. They are caused, for example, by capacitive coupling between the
source of interference and the mains network.
A commonly used interference suppression circuit is shown in the diagram
below. The asymmetrical interference voltages are dispersed across Cy to-
wards the housing. Cx effects an attenuation ofd the symmetrical interfer-
ence voltages.

L Cy

L Cx Mains

Cy

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 6–4 Electrical Connection

Interference Suppression Examples:

Suppression example – Contacts:
(Alternating current, Direct current, offset DC current)

a) b) c)

R R
VDR
Rp U

C C

to b) for sensitive contact points; residual current on open contact!

to c) voltage-dependent resistance, residual current on open con-
tact!

Suppression example – Inductive load:

(Motors, solenoid, relay and contactor coils)

a) b) c) d) e)
-

R D R
VDR
D
U
VDR
C ZD C
+

to c) with relay, cut-off delay

to d) with relay, defined cut-off delay
to e) must be optimized for inductance!

Suppression example – Mains input:

L1

L1
L2 M
Cx Cy 3
M ~
L3
Cx
~
N Cy
Cx Cx Cx

PE PE

1070 073 736-103 (99.04) GB

 Electrical Connection 6–5

6.3 Power Supply

In normal circumstances the entire system draws its power from the 3-phase
rotary current mains network. All internal voltages required by the system
are derived from this power supply.

DANGER
Hazardous system conditions and functional failures of electrical
modules through wrong power supply voltages!

D All required supply voltages must be within specified voltage

ranges.
D Fluctuations or deviations from nominal values must neither ex-
ceed nor fall short of specified tolerances.
D The required electrical fuse protection must be provided on the
mains side!

6.3.1 24 VDC Power Supply

Rated voltage UN: 24VDC ; +20%,–15%
Residual ripple at UN: see diagram below
Interference resistance and Umax= 35V (for t < 100ms)
surge immunity:
Consumption at UN: max. 3.5A (Typ3 osa-compact)
max. 3.5A (Typ3 osa-modular)
Input fuse, Typ3 osa: M4A (5x20) medium slow-blow
Polarization: through decoupling diode; reversal of
polarity triggers input fuse.

DANGEROUS ELECTRICAL VOLTAGE

The 24 VDC input voltage must satisfy the requirements of ”Safety
separation”!

Safety transformer pursuant to EN 60742

L1 L2 L3
400V +5%
400V
400V -5%

PE

0V + 24V

1070 073 736-103 (99.04) GB

6–6 Electrical Connection

Offset AC voltage components of the type produced by an unregulated

rotary current bridge circuit without smoothing, at a ripple factor of 5%, are
permissible (refer to DIN 40110/10.75, Sect. 1.2).
This produces, as the upper voltage limit, the highest absolute value of
30.2 V, and the smallest absolute value of 18.5 V as the lower voltage limit.

U
1.05 . 28.8 V = 30.2 V

Upper limit 28.8 V

0.866 . 30.2 = 26.1 V

300 el

cos (30 0) = 0.866

1.05 . 20.4 = 21.4 V
Lower limit 20.4 V

0.866 . 21.4 = 18.5 V

t
0

6.3.2 230/115 VAC supply

The 230/115 VAC supply is used for the ”osa display pc” and ”typ3 compact
pc” PC Control Panels.

Rated voltage: 85VAC ... 264VAC;

long-range input
Current consumption 0.7 A
at Unom =230VAC: 0.2 A (only for 80135 and 80984)
Current consumption 1.4 A
at Unom =115VAC: 0.4 A (only for 80135 and 80984)
Making current at 230VAC: 30A cold start 25_C
at 115VAC: 15A cold start 25_C
Input fuse: 4A (5x20)

1070 073 736-103 (99.04) GB

 Electrical Connection 6–7

6.4 Power Connections

The following block diagrams describe only the essential principles of mak-
ing the various power connections. The information thus provided expressly
addresses the system planner/designer.

It is the responsibility of the system planner to provide for, and incorporate,

required components, such as EMERGENCY-OFF control circuits, mains
switches, etc., in accordance with accepted industry practice, while ensur-
ing the highest degree of safety.

. Therefore, with regard to electrical connections, the connection dia-

grams and installation instructions supplied by the machine
manufacturer shall always be binding!

DANGEROUS ELECTRICAL VOLTAGE

Possible Danger to life and severe equipment damage through
faulty or improperly configured EMERGENCY-OFF circuit!

Also, integrate the EMERGENCY-OFF pushbutton on the osa switch

into the EMERGENCY-OFF circuit!

DANGER
Uncontrolled traversing movements as a result of improper system
shut-down procedure!

Therefore, configure the system control circuits in a way that en-

sures that a shut-down procedure automatically includes powering
down the drives prior to disconnection the power supply voltages.

Please note the following in order to avoid functional system faults:

D Ensure that the installation of the terminal strips for 24 VDC and 0 V po-
tentials in the switching cabinet provides for isolation. Maintain a mini-
mum distance of 10 cm from power lines when routing signal cables.
D Configure the system control circuits in a way that ensures that control
panels, CNC and PLC are always powered up simultaneously.

1070 073 736-103 (99.04) GB

6–8 Electrical Connection

Fig. 1: Mains Connection

Mains IN
min.162 (green/yellow)
to switching cabinet enclosure
162 (green/yellow)
L1 to machine
L2
L3

PE
N
62 (green/yellow)
all component PE (GND lugs)
102 (green/yellow) Earth rail for 0V wiring
(see Fig. 2)
PE Connect Hub
W1
U1
V1

PE
PE
PE
PE
PE
N

162 (green/yellow)

Fuses, motor protection switch preferred

400V 42 (green/yellow)
N-conductor to Transformer as
be used only per EN 60742
with permission 230V
of operator!
42 (green/yellow)
PE N1 U2 PE

42 (green/yellow)

PE conductor area greater

PE
N1
U2

or equal to that of mains IN

of device to be grounded
If required, service outlets for one or (color: green/yellow)
more 230 V ventilation fans
230 V supply
(PC Control Panel 230VAC version),
PLC programming units
(see Fig. 3ff.)
Conductor areas depend : terminals
upon current draw, but no with isolated
less than 1.52 mm installation
L1.1
L2.1
L3.1

L1.1
L2.1
L3.1
PE

PE
N

Drives 24 V power supply

(see Fig. 2)

1070 073 736-103 (99.04) GB

 Electrical Connection 6–9

Fig. 2: Generation of 24 VDC Power

from 24 V power
supply connection from PE Connect Hub
(see Fig. 1) (see Fig. 1)
Conductor areas depend
on current draw, but no
less than 1.5 mm2

L2.1
L1.1

L3.1

PE
102 (green/yellow)

Power supply with

safety transformer
pursuant to EN
60742 and up-
stream motor
protection switch
400 VAC
24 VDC

Conductor areas depend

on current draw, but no
less than 4 mm2. With
higher power draw,
2 x 4 mm2
62 (1)(blue)
Length max. 4m

A A B

102 (green/yellow)(2)
24 V External 0 V External Earth rail

A = Terminal strip 42
B = Terminal strip 102
: terminals w/ isolated installation

24 VDC Power supply for Typ3 osa (X10),

PLC (power supply for I/O modules),
ventilation fans 24 VDC,
PC Control Panel 24VDC version
Load distribution bars (24V/0V) for drives
(see Fig. 4ff)

(1) In plain view and easily removed

(2) Preferred installation of PE rails is fully conductive on the mounting
base plate. If isolated, both ends of PE rails must be connected to base
plate via copper grounding straps not exceeding 20 cm in length.
Conductor area of copper straps must be no less than that of incoming
power supply line.

1070 073 736-103 (99.04) GB

6–10 Electrical Connection

Fig. 3a: Using Typ3 osa with PC Control Panel (230 VAC supply)

From 230 V supply From 24 V power supply

(see Fig. 1) connection (see Fig. 2)

Conductor areas depend on

current draw, but no less
than 0.75 mm2 Conductor areas depend
Conductor area depends
on current draw, but no
PE
N1
U2

on current draw (*)

less than 0.5 mm2 (*)

PLC Expansion Unit

(The voltages for the logical circuits of the PLC modules (*) 0.5 mm@, up to 4 m;
are generated by the CNC power supply (osa dc inter- 0.75 mm@, up to 6 m;
face): max. current load 700 mA!) 1.5 mm@, up to 10 m.
Distances larger than 10 m
require separate power supply
on consumer!
AG/Z–S

E
E
E
A
A
A

X61

PE
24V
24V=
0.8A max.
0.5A typ. 0V

CMOS cable, max. 0.55m Possible Typ3 variant:

Typ3 osa-modular

osa master L/XL

osa dc interface
PC Control Panel
(230 VAC version) osa fms

osa display and X61 osa pcl

osa display PC
U2 10-Base-T Ethernet X10
N1 system interconnecting cable, max. 100m
X51 X52

X20
PE X52

PE X1
CAN bus
max. 1.5m
system interconnecting cable, max. 30m PE
osa keyboard

PE X1

osa switch

PE osa master

1070 073 736-103 (99.04) GB

 Electrical Connection 6–11

Fig. 3b: Using Typ3 osa with PC Control Panel (24 VDC supply)

From 230 V supply From 24 V power supply

(see Fig. 1) connection (see Fig. 2)

Conductor areas depend

on current draw, but no
less than 0.75 mm2 Conductor areas depend on
Conductor area depends
current draw, but no less
PE
N1
U2

on current draw (*)

than 0.5 mm2 (*)

PLC Expansion Unit (*) 0.5 mm@, up to 4 m;

(The voltages for the logical circuits of the PLC modules 0.75 mm@, up to 6 m;
are generated by the CNC power supply (osa dc inter- 1.5 mm@, up to 10 m.
Distances larger than 10 m
face): max. current load 700 mA!) require separate power supply
on consumer!
AG/Z–S

E
E
E
A
A
A

X61

PE
24V
24V=
0.8A max.
0.5A typ. 0V

CMOS cable, max. 0.55m Possible Typ3 variant:

Typ3 osa-modular

osa master L/XL

osa dc interface
PC Control Panel
(24 VDC version) osa fms

X61 osa pcl

osa display and 24VDC supply
osa display PC
X20
X10
X51 X52

X52
10-Base-T Ethernet
PE X1 system interconnecting cable,
max. 1.5m
max. 100m
PE
osa keyboard

PE X1

osa switch

PE osa master
CAN bus
system interconnecting cable,
max. 30m

1070 073 736-103 (99.04) GB

6–12 Electrical Connection

Fig. 3c: Using Typ3 osa-compact with PC Control Panel (230 VAC supply)
From 230 V supply From 24 V power supply
(see Fig. 1) connection (see Fig. 2)

Conductor areas depend

on current draw, but no
less than 0.75 mm2 Conductor areas depend
Conductor area depends
on current draw, but no
PE
N1
U2 less than 0.5 mm2 (*)
on current draw (*)

(*) 0.5 mm@, up to 4 m;

0.75 mm@, up to 6 m;
PLC Expansion Unit 1.5 mm@, up to 10 m.
Distances larger than 10 m
(The voltages for the logical circuits of the PLC modules require separate power supply
are generated by the CNC power supply (osa dc inter- on consumer!
face): max. current load 700 mA!)
AG/Z–S

E
E
E
A
A
A
X61

PE
24V
24V=
0.8A max.
0.5A typ. 0V

CMOS cable, max. 0.55m

Modular PC Control Panel

with Typ3 osa-compact
osa display and
osa display PC
U2
N1 X1
X20
PE 10-Base-T Ethernet
X52
PE system interconnecting
cable, max. 100m
Typ3 osa-compact

osa master L/XL X52

X51
PE
osa dc interface X10

max. 1.5m

osa keyboard

PE X1
CAN bus
system interconnecting
osa switch cable, max. 30m

PE osa master

1070 073 736-103 (99.04) GB

 Electrical Connection 6–13

Fig. 3d: Using Typ3 osa-compact with PC Control Panel (24 VDC supply)
From 230 V supply From 24 V power supply
(see Fig. 1) connection (see Fig. 2)

Conductor areas depend on

current draw, but no less
than 0.75 mm2 Conductor areas depend
Conductor area depends
PE
on current draw, but no
N1
U2
on current draw (*)
less than 0.5 mm2 (*)
(*) 0.5 mm@, up to 4 m;
0.75 mm@, up to 6 m;
PLC Expansion Unit 1.5 mm@, up to 10 m.
Distances larger than 10 m
(The voltages for the logical circuits of the PLC modules require separate power supply
are generated by the CNC power supply (osa dc inter- on consumer!
face): max. current load 700 mA!)
AG/Z–S

E
E
E
A
A
A
X61

PE
24V
24V=
0.8A max.
0.5A typ. 0V

CMOS cable, max. 0.55m

PC Control Panel
with Typ3 osa-compact
osa display and 24VDC supply
osa display PC
X20

X1
X52
PE
10-Base-T Ethernet
Typ3 osa-compact system interconnecting
cable, max. 100m
osa master L/XL X52
X51
PE
osa dc interface X10

max. 1.5m

osa keyboard

PE X1
CAN bus
system interconnecting
osa switch cable, max. 30m

PE osa master

1070 073 736-103 (99.04) GB

 6–14 Electrical Connection

Your notes:

1070 073 736-103 (99.04) GB

 3.5” Floppy Disk Drive 7–1

7 3.5” Floppy Disk Drive

A 3.5” floppy disk drive for 1.44 MB or 720 kB floppy disks is available for
saving data.
It is supplied as an assembly with a mounting frame open at the back side
and connection cables for control panel installation.
Its front side is protected against dust and liquids by a hinged cover (IP54).

7.1 Control elements

To insert the 3.5” floppy disk, first open the protective cover and then insert
the disk with the sliding element first into the drive slot until the disk is en-
gaged in the drive (clicking sound). When the control LED flickers, the PC
accesses the floppy disk.

To remove the floppy disk press the eject key.

3.5” floppy disk drive drive slot protective cover

(hinged, not transparent)

control LED eject key installation frame

1070 073 736-103 (99.05) GB

7–2 3.5” Floppy Disk Drive

7.2 Connectors
The rear side of the floppy disk drive accommodates the connectors for data
transmission (K1) and power supply (K2):

4 1
2 34
K1
1 33 K2

K1 data connection K2 power supply

Data transmission
Data transmission between the drive and the PC Control Panel is facilitated
by the 34-wire ribbon cable included in the delivery of the 3.5” floppy disk
drive.
If a 34-pole standard ribbon cable is used, cores 10...16 must be reversed
(cf. section 4.3.4).

K1 on 3.5” floppy disk drive

34
1

approx.
750 mm 17–34 10–16 1–9

open cable from 10–16

34 and turn conductors
1 line no. 1 (red)

to PC Control Panel X71

Power supply
Power supply to the 3.5” floppy disk drive is achieved by connecting the sup-
plied cable to connector K2.

K2 (Floppy Disk)
approx.
800 mm
4 1 1
+5V
2
GND
K2
3
GND
4
+12V to PC Control Panel
connector X70

1070 073 736-103 (99.05) GB

 3.5” Floppy Disk Drive 7–3

7.3 Installation

For more instructions on the 3.5” floppy disk drive, please refer to the sec-
tions ”standards applied” and ”conditions of use”.

Weight: approx. 0.7–1 kg

Orientation: horizontally, vertically
Place of installation: with protective cover IP54, otherwise IP00
designed for installation at least to IP54
Display: indicator LED for floppy disk access
Control elements: eject key for floppy disk, dust hood with in-
terlock
Installation elements: Installation frame and mounting frame for
front-sided and rear-sided fastening of the
floppy disk drive.
Power supply: +5VDC; +10%, –10%
Power consumption: 0.9A max.
Power input: 1.5W; (30mW in stand-by mode)

CAUTION
Take all precautions necessary for ESD protection when handling
modules and components! Avoid electrostatic discharge!

Permitted orientations of the 3.5” floppy disk drive:

horizontal installation vertical installation

eject key

eject key

CAUTION
When installed horizontally, the eject key of the 3.5” floppy disk
drive must not point upward.

1070 073 736-103 (99.05) GB

7–4 3.5” Floppy Disk Drive

7.4 Installation cut-out

The supplied installation frame is fixed and aligned in the installation area
shown below. Afterwards, insert the floppy disk drive into the rear mounting
frame and fasten it to the installation frame.
Fastening M3
max. depth of engagement: 4mm
133.8

3.6 42
R3
25 32 38.7
112

118
130

7.5 Dimensions

Front view

50

Side view
Cover
(with approx. 130
degrees hinge)

36

49 168 30

Mounting frame
Clearance for
cable routing

Rear view

Floppy disk drive

Installation frame

Connector and cable for

power supply
Cover Floppy data connector (approx. 800 mm)
110 with ribbon cable
145 (approx. 750 mm) Mounting frame

1070 073 736-103 (99.05) GB

 3.5” Floppy Disk Drive 7–5

7.6 Software installation

When you have installed and connected the 3.5” floppy disk drive, you
should boot the PC. While booting, press the <DEL> key on the osa key-
board.

When the AMIBIOS setup screen is displayed (may also be a setup routine
of a different manufacturer), select ”Standard setup”.
Select Floppy A from the ”Standard setup” menu. In the ”Floppy A” menu
select the type of floppy disk drive connected (e.g. 1.44 MB 3.5” for floppy
disk or osa disc). Then press the ESC key several times until you reach the
”Exit Setup” menu.

To accept the settings, select ”Save changes and exit”. If you do not want to
accept the settings, select the ”Do not save changes and Exit” option from
the ”Exit Setup” menu. You thereby quit the AMIBIOS setup, and the PC is
automatically booted.

CAUTION
Avoid incorrect booting. Do not change any other entries in the
AMIBIOS setup!

Note the relevant instructions contained in this manual, the docu-

mentation for the integrated PC and the documentation of your
floppy disk supplier.

Backup your hard disk data before you start! Note down the original
settings before making any changes. Thus, you can always restore
the original condition. Record all changes to the PC settings. Incor-
rect BOOT processes caused by your changes may thus be reverted,
if necessary. Incorrect BOOT process may possibly have the effect
that your system is not started up properly, or even not started up
at all!

1070 073 736-103 (99.05) GB

 7–6 3.5” Floppy Disk Drive

Your notes:

1070 073 736-103 (99.05) GB

 Maintenance and Spare Parts List 8–1

8 Maintenance and Spare Parts List

8.1 Maintenance

DANGER
Dangerous System Conditions or Possible Component Damage!
Please observe the ”Maintenance and Repairs” section in the chap-
ter on ”Safety Instructions.”

Add the following tasks to your maintenance schedule:

D Clean the screen surface at least once a week with an antistatic cloth
or with an alcohol-based window cleaner.

CAUTION
Solvents may dissolve the film surface and display sealing of the
osa display!
Do not use any solvents (e.g. thinner)!

D Replace the backlights in the display units at least every 2 years. Based
on the functional principle of these units, a gradual loss of brightness will
be noted over time, causing a deterioration of screen readability.
D Check all plug-in and terminal connections at least once a year for
proper tightness and possible damage. Inspect cables for cracks, pinch-
ing damage or other signs of mechanical distress!
Have damaged parts replaced immediately!
D Check fans and fan filter mats at least once a year.
Contaminated filter mats block the air volume throughput required for de-
vice ventilation and cooling. Therefore, wash contamined filter mats in
soapy suds, or replace them with new ones. Subsequent to washing filter
mats, ensure that tey are fully dried before reinserting them intio the filter
frame!

DANGER
Risk of injury by rotating air impeller!
Keep hands out of the air impeller, and do not insinuate any other
items.

D Replace the Lithium battery in the osa dc I/O module immediately upon
the appearance of the fault message in the display. For replacement,
use a new battery of the same type (type Li-SL-760/S, 3.6 V, 1.8 Ah, AA
size; order no.: 1070 914 446).

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8–2 Maintenance and Spare Parts List

8.2 Spare Parts List

8.2.1 osa rack for Typ3 osa-modular

osa rack 2 1070 079 596
NC cardrack 3-C2 (including fan)
2 slots for
– osa master and
– osa dc interface

osa rack 4 1070 078 280

NC cardrack 3-C4 (including fan)
4 slots for
– osa master,
– osa dc interface
– osa plc,
– osa profibus fms

osa cover
(for covering a slot in osa rack 2/4) 1070 075 608

8.2.2 osa rack for Typ3 osa-compact

Included in PC Control Panel typ3 compact pc.

8.2.3 Plug-in modules for osa rack

osa master L
(module SNCI_2/12/8) 1070 080 399

osa master XL
(module SNCI_2/X) 1070 080 397

osa dc interface
(module DCIO_1/MK) 1070 077 995

osa dc interface ana

(module DCIO_1) 1070 077 994

osa plc
(module ICL700_1/C/!/.5) 1070 681 97

osa profibus fms

(module ISA_2_Profi) on request 1070 080 312

1070 073 736-103 (99.04) GB

 Maintenance and Spare Parts List 8–3

8.2.4 PC Control Panels (with integrated PC)

osa display pc 486A DSTN, 230V 1070 080 135
(PCPNL 486A32TF1ISA2A2)

Display unit with integrated industry-standard PC:

Equipment front IP65, DSTN Color LCD,
AMD/DX5 133 MHz CPU, 32MB DRAM, >1.6 MB hard disk 2,5”,
1x RS232, 1x RS485/RS232, LPT1, Ethernet 10BaseT,
2 free ISA slots,
230V mains connection

osa display pc PENA DSTN, 230V 1070 079 816

(PCPNL PENA32DS1ISA2A)

Display unit with integrated industry-standard PC:

Equipment front IP65, DSTN Color LCD,
Pentium 133 MHz CPU, 32MB DRAM, >1.6 GB hard disk 2,5”,
1x RS232, 1x RS485/RS232, LPT1, Ethernet 10BaseT,
2 free ISA slots,
230V mains connection

osa display pc PENA DSTN, 24V 1070 079 815

(PCPNL PENA32DS1ISA2D)

Display unit with integrated industry-standard PC:

Equipment front IP65, DSTN Color LCD,
Pentium 133 MHz CPU, 32MB DRAM, >1.6 GB hard disk 2,5”,
1x RS232, 1x RS485/RS232, LPT1, Ethernet 10BaseT,
2 free ISA slots,
24V mains connection

osa display pc 486A TFT color, 230V 1070 080 984

(PCPNL 486A32TF1ISA2A)

Display unit with integrated industry-standard PC:

Equipment front IP65, TFT Color LCD,
AMD/DX5 133 MHz CPU,32MB DRAM, >1.6 MB hard disk 2,5”,
1x RS232, 1x RS485/RS232, LPT1, Ethernet 10BaseT,
2 free ISA slots,
230V mains connection

osa display pc PENA TFT color, 230V 1070 079 814

(PCPNL PENA32TF1ISA2A)

Display unit with integrated industry-standard PC:

Equipment front IP65, DSTN Color LCD,
Pentium 133 MHz CPU, 32MB DRAM, >1.6 GB hard disk 2,5”,
1x RS232, 1x RS485/RS232, LPT1, Ethernet 10BaseT,
2 free ISA slots,
230V mains connection

osa display pc PENA TFT color, 24V 1070 079 813

(PCPNL PENA32TF1ISA2D)

Display unit with integrated industry-standard PC:

Equipment front IP65, DSTN Color LCD,
Pentium 133 MHz CPU, 32MB DRAM, >1.6 GB hard disk 2,5”,
1x RS232, 1x RS485/RS232, LPT1, Ethernet 10BaseT,
2 free ISA slots,
24V mains connection

1070 073 736-103 (99.04) GB

8–4 Maintenance and Spare Parts List

typ3 compact pc 486A TFT color, 24V 1070 079 525

(PCPNL PENA32TF1ISA2KS)

Display unit with integrated industry-standard PC:

Equipment front IP65, TFT Color LCD,
AMD/DX5 133 MHz CPU,32MB DRAM, >840 MB hard disk 2,5”,
1x RS232, 1x RS485/RS232, LPT1, Ethernet 10BaseT,
2 free ISA slots,
24V mains connection
and integrated osa rack 2 (no modules included in price!)

8.2.5 osa keyboard

osa keyboard 1070 917 943
ASCII keyboard with special keys, IP65
MF2 connector, only suitable for osa display PC

8.2.6 Floppy disk drive

Floppy disk drive 1.44 MB 1070 081 360
ext. 3.5” floppy disk drive with mounting frame
for installation in switch cabinet, front side IP54,
connection cable (data, power supply) to osa display PC

8.2.7 Software for modular PC Control Panel

Operating system:
(pre-installed on PC Control Panel)

Windows95 (German license, OEM version OSR 2.1) 1070 079 966
with data carrier

Windows95 (English license, OEM version OSR 2.1) 1070 079 783
with data carrier

WindowsNT 4.0 (German license) with data carrier 1070 079 964
Precondition: min. 32 MB DRAM on-board of osa display PC

WindowsNT 4.0 (English license) with data carrier 1070 079 965
Precondition: min. 32 MB DRAM on-board of osa display PC

X Server:
(pre-installed on PC Control Panel)

X Server for osa display PC under Windows95/NT 1070 079 784

Hummingbird eXeed V5.1 required for
operator interface on osa display PC,
installed on osa display PC,
without data carrier, with software license agreement

1070 073 736-103 (99.04) GB

 Maintenance and Spare Parts List 8–5

Operating system:
(software supplied for installation of the operating system on the PC
Control Panel by the user):

Windows95 (German license, OEM version OSR 2.1) 1070 919 148
with data carrier,
only available in connection with osa display PC

Windows95 (English license, OEM version OSR 2.1) 1070 919 000
with data carrier,
only available in connection with osa display PC

WindowsNT 4.0 (German license) with data carrier 1070 919 163
Precondition: min. 32 MB DRAM on-board of osa display PC
only available in connection with osa display PC

WindowsNT 4.0 (English license) with data carrier 1070 919 164
Precondition: min. 32 MB DRAM on-board of osa display PC,
only available in connection with osa display PC

X Server:
(software supplied for installation of the operating system on the PC
Control Panel by the user):

X Server for osa display PC under Windows95/NT 1070 918 999

Hummingbird eXeed V5.1 required for
operator interface on osa display PC,
installed on osa display PC,
without data carrier, with software license agreement,
only available in connection with osa display PC

Bosch operating system:

(pre-installed on Typ3 osa-modular or Typ3 osa-compact)

Typ3 osa software version 3.x 1070 079 727

Typ3 osa software version 4.x 1070 080 180

Typ3 osa software export version x.x in preparation

8.2.8 Machine control panel

osa switch 1070 077 735
standard machine control panel
30 push buttons with control lamp
2 x key switches
2 x override,
connector for electronic handwheel,
connector for 8 additional push buttons,
machine keys

1070 073 736-103 (99.04) GB

8–6 Maintenance and Spare Parts List

8.2.9 Cables
Cable / Connector Part no.
Power cable for PC Control Panel 1070 048 937
Optical fiber cable for SERCOS interface, pre-assembled
2m 1070 917 885
5m 1070 917 887
10 m 1070 918 956
CAN bus (osa master L/XL ´ osa switch)
SDH 2.5 m 1070 917 673
SDH 5.0 m 1070 918 954
SDH 10 m 1070 917 177
SDH 25 m 1070 918 955
Ethernet cable 10-Base-T, shielded, twisted pair, crossed
(osa master L/XL ´ PC Control Panel)
2.5 m 1070 919 188
5.0 m 1070 919 257
10 m 1070 919 795
25 m 1070 919 797
Connection (osa plc ´ AG/Z-S) 0.55 m 1070 070 755
Connection (osa plc ´ programming unit), 0.55 m 1070 054 956
Bus cable Commnet DP (traction cable) 1070 917 201
V.24 cable (PC Control Panel ´ external PC), 5 m 1070 077 753
Internal ribbon cable for RS485, 14-pole
1070 078 881
(Motherboard ´ COM2)
Special cable for digital handwheel 1070 908 558
Adapter cable for serial interface/D-SUB male, 9-pin 1070 079 801
D-SUB male connector, 9-pin 1070 910 258
D-SUB female connector, 9-pin 1070 912 981
Metal shell for D-SUB connector, 9-pin 1070 913 723

8.2.10 Accessories
Accessories Part no.
osa mbf interface 1070 075 062
(interface module for connecting machine keys and elec-
tronic handwheel)
PCMCIA card (PC card) 1 MB SRAM, 1070 918 722
for expanding the osa master L/XL part program memory
Lithium battery for osa dc I/O and osa dc I/O ana, 1070 914 446
type Li-SL-760/S, 3.6 V, 1.8 Ah, AA size
Digital handwheel 1070 096 167
Profibus card (plug-in card for PC) 1070 917 151
Ethernet cable 10-Base-T, shielded, twisted pair
(osa master L/XL ´ HUB, PC Control Panel ´ HUB)
2.5 m 1070 918 793
5.0 m 1070 919 258
HUB (Ethernet distribution for 4 x 10-Base-T, on request
1 x 10-Base-2)
HUB interface adapter for 10-Base-T, 10-Base-2 on request

1070 073 736-103 (99.04) GB

 Appendix A–1

A Appendix

A.1 Abbreviations

Abbreviation Description
C: Drive name, in this case drive C (hard
disk drive)
ESD Electro-Static Discharge
Abbreviation for all terms relating to elec-
tro-static discharge, e.g. ESD protection,
ESD hazards, etc.
Fx Function key with number x
GB Gigabyte
GOM Group Operating Mode
HP Main Program (’Hauptprogramm’)
LSEC Lead Screw Error Compensation
MB Megabyte
MCP Machine Control Panel
MDI Mode “Manual Data Input“
MP Machine parameter
MSD Machine-Status Display
MTB Machine-Tool Builder
NC, CNC Control Unit
OFC Optical Fiber Cable
OI Operator Interface
OM Operating Mode
PC Personal Computer
PLC Programmable Logic Controller
SDH Serial Digital High-Speed interface
SK Softkey
SP Subprogram

1070 073 736-103 (99.04) GB

 A–2 Appendix

A.2 Index

Numbers E
24V Power supply, 3–24 Electrical connection
230/115 VAC supply, 6–6
A 24VDC supply, 6–5
AG/ZS connection (osa plc), 3–15 EMC Directive, 1–1
Ambient temperature, 2–8 EMERGENCY–STOP connection of digital handwheel, osa
Analog I/O interface (osa dc interface), 3–20 switch, 4–25
EMERGENCY–STOP devices, 1–6 , 4–23
B EMERGENCY–STOP mushroom striker, osa switch, 4–23
Battery, 3–26 ESD, Electrostatic discharge, 1–7
Bitbus connection (osa dc interface), 3–19 ESD–sensitive components, 1–7
Ethernet connection, osa display PC, 4–15
C
CAN bus (osa Master L/XL), 3–6 F
CAN bus (osa master L/XL), 3–16 F1 Fuse (osa dc interface), 3–25
CAN bus (osa switch), 4–22 Fixed disk, 1–9
CMOS bus (osa plc), 3–15 Floppy disk
COM1, 4–8 Assignment of connecting cable, 7–2
COM2, 4–10 Control elements, 7–1
Components, Connections overview, 2–4 , 2–7 Disk drive, 7–1
Connection, electrical, 6–1 Installation dimensions, 7–4
Connection for programming device (osa plc), 3–14 Installation instructions, 7–3
Connection of digital drives, 3–4 Orientations, 7–3
Connection of PC Control Panel, 3–6 Software installation, 7–5
Connector types and cables, 4–7 Floppy disk drive, 1–9
Connection, 4–13
D
Debugging interface (osa master L/XL), 3–5 H
Debugging mode, 3–8 H1 H1 Diagnostic Display (osa master L/XL), 3–10
Deleting USFREP File system, 3–8 High–speed I/O (osa dc interface), 3–21
Diagnostic Display H1 (osa master L/XL), 3–10 Humidity, relative, 2–8
Digital handwheel (St3), osa switch, 4–24
Digital I/O interface (osa dc interface), 3–21 I
Dimensioned drawings Initial program loading, 3–8
Floppy disk, 7–4 Installation, 5–1
osa rack 2 for Typ3 osa–compact, 5–1 Floppy disk, 7–3
osa rack 2 for Typ3 osa–modular, 5–3 ISA expansion card, 4–17
osa rack 4 for Typ3 osa–modular, 5–4 Installation cut–out, Floppy disk, 7–4
osa switch, 5–9 Interfaces overview, osa display PC, 4–7
PC Control Panel Interference suppression, 6–3
osa display pc, 5–6 ISA slot, 4–17
typ3 compact pc, 5–7 Application, 4–18
Discrete keys (St5), osa switch, 4–25 Driver installation, 4–18
Disk drive, Floppy disk, 7–1 Expansion board selection, 4–17
Display unit, osa display, 4–3 Installation of expansion cards, 4–17
Documentation, 1–9 ISA bus, 4–17

J
Jumper settings for COM2, RS232, RS485, 4–10

K
Keyboard (osa keyboard), PC Control Panel, 4–19

L
Linking components overview, 2–4 , 2–7
Loading basic program, 3–8
Low–Voltage Directive, 1–1
LPT1, 4–12

1070 073 736-103 (99.04) GB

 Appendix A–3

M Power connector
Machine Control Panel osa switch, Machine Control Panel, 230 V AC, 4–5
4–21 24 V DC, 4–5
Maintenance, 8–1 Power supply, 6–5
Measuring activities, 1–6 Power supply (osa dc interface), 3–24
MF2 keyboard connector, osa display PC, 4–16 Profibus DP interface (osa dc interface), 3–22
Modifications, 1–10 Profibus FMS, 3–17
Modules Proper use, 1–1
Overview, 2–1 Protective earthing system, 6–2
Typ3 osa, 3–1
Modules sensitive to electrostatic discharge. See ESD–sen- Q
sitive components Qualified personnel, 1–3

O R
Operational readiness of the Typ3 osa, 3–23 READY indicator, 3–25
osa dc interface, 3–18 READY2 contact (osa dc interface), 3–23
osa display (display unit), 4–3 RESET In input (osa dc interface), 3–24
osa display pc, Dimensioned drawing, 5–6 RESET key (osa dc interface), 3–25
osa keyboard, PC Control Panel, 4–19 RESET Out contact (osa dc interface), 3–23
osa master L/XL, 3–1 RS232 interface
osa plc, PLC, 3–13 COM1, 4–8
osa rack 2, Dimensioned drawing, 5–1 , 5–3 COM2, 4–10
osa rack 4, Dimensioned drawing, 5–4 RS485 interface, COM2, 4–10
osa switch, 4–21 , 4–22
Digital handwheel (St3), 4–24 S
Dimensioned drawing, 5–9 S1 Rotary Switch (osa master), 3–7
discrete keys (St5), 4–25 Safety instructions, 1–5
EMERGENCY–STOP connection of digital handwheel, Safety markings, 1–4
4–25 Safety transformer, 6–5
EMERGENCY–STOP mushroom striker, 4–23 Screening, 6–2
SDH signals (osa master L/XL), 3–6 , 3–16
P SERCOS interface connectors, 3–4
PC card (osa master L/XL), 3–12 Serial interfaces, osa display PC, 4–8
PC Control Panel, 4–1 Software swap with PC Card, 3–9
230VAC In power connector, 4–5 Spare parts, 1–7
24 VDC power connector, 4–5 Spare parts list, 8–2
COM1, 4–8 Storage temperature, 2–8
COM2, 4–10 Supply voltages, 6–5
Connection of floppy disk drive, 4–13 SVGA connector, 4–16
Connection to osa master L/XL, 3–6 System variants, Overview, 2–1
Connector types and cables, 4–7
Ethernet connection, 4–15 T
Floppy disk DC power supply, 4–6 Technical data, PC Control Panel, 4–2
Interfaces overview, 4–7 Temparature
ISA slot, 4–17 during operation, 2–8
LPT1, 4–12 when stored, 2–8
MF2 keyboard connector, 4–16 Terminal software, 4–9
osa keyboard, 4–19 Trademarks, 1–10
Overview, 2–2 typ3 compact pc, Dimensioned drawing, 5–7
Power connections, 4–4 Typ3 osa, Modules, 3–1
Serial interfaces, 4–8 Typ3 osa run–up sequence, 3–7
SVGA connector, 4–16 Typ3 osa–compact
Technical data, 4–2 Installation in osa rack 2, 5–1
PE connectors, 6–2 Overview, 2–3
Pin assignment for V.24 interface, 4–11 Typ3 osa–modular
PLC, osa plc, 3–13 Connections overview, 2–4 , 2–7
Port, parallel, LPT1, 4–12 Installation in osa rack 2, 5–3
Power connections, Overview, 4–4 Installation in osa rack 4, 5–4
Overview, 2–5

1070 073 736-103 (99.04) GB

 A–4 Appendix

V X31 (osa plc), 3–14

V.24 interface, Pin assignment, 4–9 X34: RS232 interface, COM1, 4–8
V24 interface (osa master L/XL), 3–5 X35 (osa master L/XL), 3–5
Version, 1–10 X35: RS232 interface (osa display PC), COM2, 4–10
Video data signals (osa master L/XL), 3–6 , 3–16 X35: RS485 interface, COM2, 4–10
Vin Input voltage indicator, 3–25 X51 (osa dc interface), 3–22
Vout output voltage indicator, 3–25 X51 (osa master L/XL), 3–6 , 3–16
X52 (osa masterL/XL), 3–6
X X52: Ethernet connection, 4–15
X1: MF2 keyboard connector, 4–16 X61 (osa plc), 3–15
X10: 24 VDC External power supply (osa dc interface), X61: Port, parallel, LPT1, 4–12
3–24 X70: Floppy disk DC power supply, 4–6
X10: 24 VDC power connector, 4–5 X71 (osa dc interface), 3–23
X11 (osa dc interface), 3–20 X71 to X74 (SERCOS connectors), 3–4
X11: SVGA connector, 4–16 X71: Connection of floppy disk drive, 4–13
X12 (osa dc interface), 3–21 X72 (osa dc interface), 3–19
X20: 230VAC In power connector, osa display PC, 4–5 X73 (osa dc interface), 3–19

1070 073 736-103 (99.04) GB

Bosch-Automationstechnik

Robert Bosch GmbH Robert Bosch GmbH Robert Bosch GmbH

Geschäftsbereich Geschäftsbereich Geschäftsbereich
Automationstechnik Automationstechnik Automationstechnik
Industriehydraulik Montagetechnik Schulung AT/VSZ
Postfach 30 02 40 Postfach 30 02 07 Berliner Straße 25
D-70442 Stuttgart D-70442 Stuttgart D-64711 Erbach
Telefax (07 11) 8 11-18 57 Telefax (07 11) 8 11-77 77 Telefax (0 60 62) 78-8 33

Robert Bosch GmbH Robert Bosch GmbH

Geschäftsbereich Geschäftsbereich
Automationstechnik Automationstechnik
Fahrzeughydraulik Antriebs- und Steuerungstechnik
Postfach 30 02 40 Postfach 11 62
D-70442 Stuttgart D-64701 Erbach
Telefax (07 11) 8 11-17 98 Telefax (0 60 62) 78-4 28

Robert Bosch GmbH Robert Bosch GmbH

Geschäftsbereich Geschäftsbereich
Automationstechnik Automationstechnik
Pneumatik Schraub- und Einpreßsysteme
Postfach 30 02 40 Postfach 11 61
D-70442 Stuttgart D-71534 Murrhardt
Telefax (07 11) 8 11-89 17 Telefax (0 71 92) 22-1 81

Robert Bosch GmbH

Geschäftsbereich
Automationstechnik
Entgrattechnik
Postfach 30 02 07
D-70442 Stuttgart
Telefax (07 11) 8 11-34 75

Technische Änderungen vorbehalten

Ihr Ansprechpartner

Robert Bosch GmbH

Geschäftsbereich
Automationstechnik
Antriebs- und Steuerungstechnik
Postfach 11 62
D-64701 Erbach
Telefax (0 60 62) 78-4 28
1070 073 736-103 (99.05) GB · HB NC· AT/PLS · Printed in Germany