Rexroth IndraMotion for Metal Forming Rollfeed Standard 04VRS

Transcription

1 Electric Drives Linear Motion and Hydraulics Assembly Technologies Pneumatics Service Rexroth IndraMotion for Metal Forming Rollfeed Standard 04VRS R Edition 02 Functional Description

2 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Title Type of Documentation Document Typecode Internal File Reference Purpose of Documentation Record of Revision Rexroth IndraMotion for Metal Forming Rollfeed Standard 04VRS Functional Description DOK-IM*MLD-TF*RFS**V04-FK02-EN-P RS-4491a010526f55e20a6846a0004a372c-2-en-US-4 This documentation serves to describe the system solution "IndraMotion for Metal Forming - Rollfeed Standard 04VRS". Edition Release Date Notes B309-01/EN First edition for 04VRS B309-02/EN Modifications and supplements implemented Copyright Validity Published by Note 2007 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Bosch Rexroth AG Bgm.-Dr.-Nebel-Str Lohr a. Main, Germany Phone +49 (0)93 52 / 40-0 Fax +49 (0)93 52 / BRC/EAM4, SW (SyMu/MePe) This document has been printed on chlorine-free bleached paper.

3 Functional Description Rexroth IndraMotion Electric Drives Table of Contents Bosch Rexroth AG I/VI Table of Contents 1 System Introduction Brief Description Configurations Rollfeed Standard 1 (BASIC Control Unit) Rollfeed Standard 2 (ADVANCED Control Unit) Differences Between the Two System Solutions Further Documentation... 7 Firmware Documentation... 7 Hardware Documentation (Project Planning) Important Instructions on Use Intended Use Introduction Scope of Use and Application Improper Use Page 3 Safety Instructions for Electric Drives Safety Instructions - General Information Using the Safety Instructions and Passing them on to Others How to Employ the Safety Instructions Explanation of Warning Symbols and Degrees of Hazard Seriousness Hazards by Improper Use Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts and Housings Protection Against Electric Shock by Protective Extra-Low Voltage Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Protection Against Contact with Hot Parts Protection During Handling and Mounting Battery Safety Protection Against Pressurized Systems Functional Description Field of Application Operating Modes General Parameter Mode Manual Mode Automatic Mode General General Notes on Master Axis-Coupled Feed Instructions for the Configuration and Enabling of the Master Axis-Coupled Feed Motion Types of Application in the Automatic Mode... 30

4 II/VI Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Table of Contents Page Feed before Press in Continuous Operation Feed before Press in Single Stroke Press before Feed in Continuous Operation Press before Feed in Single Stroke Set-Up Mode Production Run Counting Sequence Diagnostic Product Data Utilization Mean Path Velocity Strokes per Minute Metering Wheel Override Micro-Adjust Roll Ventilation Product Data Administration Integrated Safety Technology Inputs / Outputs Overview of Input / Output Configuration General PLC Inputs General Meaning of PLC Inputs PLC Outputs General Meaning of PLC Outputs Input / Output Configuration on the Master Board Card General Meaning of the Other Signals on the X31 Plug Input / Output Configuration of the Control Communication Parallel Interface Profibus Library for Variable I/O Connections Background Description General Provision Interconnection of External and Internal Inputs and Outputs Output of User-Specific Diagnostic Messages Interface Variables of the Function "SetRollfeedUserDiagnosisText" Selection of the Desired Programming Language Notes on Programming Instructions on the Use of the Variable I/O Connection... 69

5 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG III/VI Table of Contents Page Example for the Use of the Variable I/O Connection HMI General VCP08 Key Description General Display Menu Keys Operating Keys Editing Keys Navigation Keys Special Keys Brief Description Overview General Main Menu Submenus Status Line Start Menu Main Menu Submenu "Part Data" (F1) General Submenu "Preset - Actual Production Run" (F1) Submenu "Load Default Part Data" (F2) Submenu "Feed Data" (F2) General Submenu "Preset - Overall Length / Overall Production Run" (F1) Submenu "Feed Parameters" (F3) Submenu "Feed Configuration" (F4) Submenu "Diagnostic" (F3) General Submenu "Inputs" (F1) Submenu "Outputs" (F2) Submenu "Versions" (F3) Submenu "Feed Diagnostic" (F4) Submenu "Set-Up" (F4) Submenu "Parameters" (F5) Submenu "System Parameters" (F1) Parameters Submenu "Load Basic Parameters" (F2) Submenu "Tools" (F3) Display Change password (F2) Forwarding Mode Functional Description General Command Format

6 IV/VI Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Table of Contents Page 8.3 Status Calls General Representation of Numbers in a Telegram List of System Status Calls General Status Call 00 Contouring Error Status Call 01 Current Rollfeed System Diagnostic Status Call 02 Rollfeed System Information Status Call 03 Travelled Feed Length Status Call 04 Metering Wheel - Data Status Call 05 Active Feed Length and Feed Velocity Status Call 09 Number of Strokes and Utilization of Feed Angle Status Call 10 Status of the Inputs (hex) Status Call 11 Status of the Outputs (hex) Status Call 12 Overall Production Run and Overall Travelled Length Status Call 14 Current Rollfeed System Diagnostic Status Call 19 Rollfeed Version Number Status Call 21 Status of Press' Operating Mode Status Call 22 Mean Path Velocity Status Call 25 Current Rollfeed System Diagnostic Status Call 28 Drive Status Status Call 29 Drive Firmware Version Input (Write) Calls General Input Call 00 Set Feed Length and Feed Velocity Input Call 03 Reset Overall Production Run Counter Input Call 04 Reset Travelled Overall Length Parameter Call General Parameter Call B101 Read Measuring Unit Parameter Call B107 Read Micro-Adjust Increment Parameter Input (Write) Command General Parameter Input B107 Set Micro-Adjust Increment Drive Parameter Read Call General Read Call S Parameters of the Drive Read Call P Parameters of the Drive Error Messages Checksum Formation Parameter System Parameters General P , Rollfeed Status Parameter General

7 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG V/VI Table of Contents Page Maximum Number of Press Strokes Active Traveling Profile Active Motion Profile P , Manual Velocity P , Set-up Velocity P , Bipolar Velocity Limit P , Rollfeed Configuration Parameter General Press / Punch Enabling Input Stopneg and Feed Interruptionneg Feed Monitoring Free Configuration of the I/O Signals Feed Angle via External Press Encoder Traveling Profile - Master Axis Coupling with RMA/VMA P , Cycle Time Monitoring P , Rollfeed Configuration Parameter General VCP 08 Bit 0 Control Panel VCP 08 Bit 1 Control Panel Evaluation Press Signal Top Dead Center (TDC) Press Signal Bottom Dead Center (BDC) Enabling of "Feed Interruption" via Parameter Internal Camshaft Gear P , Mean Path Velocity P , Part Number Selection P , Micro-Adjust Value P , Delay Time Closing Rolls P , Number of Press Strokes General Master Axis Coupling With External Press Encoder (Real Master Axis) Master Axis Coupling with Virtual Master Axis P , Rollfeed Diagnostic and Error Number P , Preset - Status Parameter P , Standstill Time of Press P , Internal Press Velocity P , Rollfeed System Diagnostic P , Part Data and Installation Parameters General Part Data Installation Parameters Parameter for the Traveling Profile and Cam Area Commissioning General Check List General

8 VI/VI Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Table of Contents Page Rollfeed Standard 1 (BASIC Control Unit) Rollfeed Standard 2 (ADVANCED Control Unit) Download of the VCP Application on the VCP 08.2 or VCP General General Notes Operating Instructions for the Download of the VCP-HMI Application Order Information Ethernet Cable Service Incident Replacement of Control Device with Stationarily Plugged MMC Diagnostic General Error Diagnostics General Product Data Error Command Parameter Error System Errors Diagnostic Messages Connection Diagrams General Input / Output Configuration on the Master Board Card Input / Output Configuration of the Parallel Interface Encoder Connection - Metering Wheel and External Press Encoder Encoder Connection ENS Encoder Port EN SSI Encoder Evaluation on MD Service and Support Helpdesk Service Hotline Internet Helpful Information Index

9 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 1/171 System Introduction 1 System Introduction 1.1 Brief Description Fig.1-1: Roll feed The system solution "IndraMotion for Metal Forming-Rollfeed Standard" is a single-axis feed for many different applications which can be custom-designed by means of specific hardware and software components. Rollfeed Standard was optimized for applications with a controlled feed of materials, such as e.g. metal, foil, or paper, and for the processing of these materials by means of sheers, punches, presses, or similar machines. The machine manufacturer or the operator enters system parameters via a user interface in order to specify the mechanical and operating properties. The system solution allows to administer up to 99 products or product data, respectively. The operation of the system solution is realized via existing input and output signal as well as via relevant installation parameters (see chapter 5 "Inputs / Outputs" on page 43 and chapter 9 "Parameter" on page 123). In addition to this, the operation can also be carried out via the operating terminal VCP 08 as well as via the existing input and output signals. With the VCP 08, the essential information and input fields required for the use of the system are available. The Rollfeed Standard system solution also supports an ASCII forwarding mode (cf. Chapter 8) that allows a serial communication connection between a PC (press control) and the system solution via a VCP 05 or a VCP08, respectively. This connection can be used by the PC to query process information from the Rollfeed system solution and to send process commands to the Rollfeed system solution.

10 2/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description System Introduction 1.2 Configurations Instead of the VCP 08, the user can also use the VCP 05. If the VCP 05 is used, however, the machine operating keys as well as the CLEAR, F6, and F7 keys are not available (see chapter 7 "HMI" on page 81). Principally, it is possible to prepare one's own interface for the most different operating terminals. The system information relevant for the display menus etc. are provided by the system parameters (cf. chapter 9 "Parameter" on page 123) Rollfeed Standard 1 (BASIC Control Unit) Hardware Components Fig.1-2: Rollfeed standard 1 (BASIC control unit) The following hardware components are required: drive control device "IndraDrive Basic Universal" featuring the following options: encoder interface on Option 1 (X8, ENS) for motor encoders control communication via Parallel Interface (X15, HCC01) or Profibus (X30, HCC03) MMC (X7, MultiMediaCard) The following hardware components are optional: encoder interface on Option 2 (X4, EN2) for metering wheel encoders on the drive control device "IndraDrive Basic Universal" start interlock L1 (X41) VCP 08 or VCP 05

11 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 3/171 System Introduction Software Components serial interface cable RS232 (RKB0004) between VCP 08 or VCP 05 (X3- SER1, 25-pin) and IndraDrive (X2, MiniDIN, 8-pin) serial cable RS232 (IKB0053) for forwarding mode between commissioning PC and VCP 08 or VCP 05 Ethernet crosslink cable or Ethernet standard cable (RKB0007 or RKB0008) between PC and VCP for the download of VCP application interface The following software components are required: drive firmware "MPB" with Synchronization function package and Indra Motion MLD-S on MultiMediaCard (FWA-INDRV*-MPB-04VRS-D5-1-NNN-TF) encapsulated technology function block on MultiMediaCard (FWS-MLDTFB-RFS-04VRS-D0) Engineering-Framework IndraWorks (SWA-IWORKS-D**-04VRS-D0-CD650) The following software components are optional: application interface on VCP 08 or VCP 05 (RFS_04VRS_VCP0x0x.cb) The ready-made interfaces for the operating terminals VCP 05 and VCP 08 are available on a CD or the Internet (Rexroth Portal). The access to the Rexroth Portal is only possible for registered users. IndraMotion for Metal Forming - CD (SWA-IM*MLD-MF*-04VRS-D0-CD650-COPY) IndraMotion for Metal Forming - Internet information_de/software_de/software_automationssysteme_de In the "\User" directory on the MMC supplied, the following files and documentations are available: release version of the system solution as a parameter file (Rollfeed_Standard_1_04Vxx.par) with related icon file (Boot.sdb) for the visualization on the VCP 05 or VCP 08 VCP-HMI applications (VCP 05 and VCP 08) description for the download of the VCP-HMI application IndraWorks project archive (Rollfeed_Standard_1_-04VRS_Template.zip) with integrated library for variable I/O connections ("Rollfeed_Standard_-04VRS.lib") functional description of Rollfeed Standard 04VRS release notes

12 4/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description System Introduction Rollfeed Standard 2 (ADVANCED Control Unit) Hardware Components Fig.1-3: Rollfeed standard 2 (ADVANCED control unit) The following hardware components are required: drive control device "IndraDrive Advanced" featuring the following options: encoder interface on Option 1 (X4) for motor encoders control communication via Parallel Interface (X15, HCC01) or Profibus (X30, HCC03) MMC (X7, MultiMediaCard) The following hardware components are optional: encoder interface on Option 2 (X8) for metering wheel encoders on the drive control device "IndraDrive Advanced" encoder interface on Option 3 (X10) for external press encoders on the drive control device "IndraDrive Advanced" safety technology S1 (X41) start interlock L1 (X41) VCP 08 or VCP 05 serial interface cable RS232 (RKB0004) between VCP 08 or VCP 05 (X3- SER1, 25-pin) and IndraDrive (X2, MiniDIN, 8-pin) serial cable RS232 (IKB0053) for forwarding mode between commissioning PC and VCP 08 or VCP 05 Ethernet crosslink cable or Ethernet standard cable (RKB0007 or RKB0008) between PC and VCP for the download of VCP application interface

13 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 5/171 System Introduction In case of feed motions that ought to be master axis-coupled in relation to an external press encoder (real master axis), the position resolution of the encoder type used must be high enough in order to ensure a satisfying control behavior of the feed axis. SSI encoder types are, typically, not suited for this. For this reason, it is recommended to use the following encoder types for the read-in of the press encoder position, if a master feed motion is to be coupled to the press encoder. GDM2.1 GDS2.1 Order information: Designation Material number GDM ,0V-H12,0 R GDS ,0V-H12,0 R Software Components The following software components are required: drive firmware "MPH" with Synchronization function package and Indra Motion MLD S on MultiMediaCard (FWA-INDRV*-MPH-04VRS-D5-1-NNN-ML) encapsulated technology function block on MultiMediaCard (FWS-MLDTFA-RFS-04VRS-D0) Engineering-Framework IndraWorks (SWA-IWORKS-D**-04VRS-D0-CD650) The following software components are optional: application interface on VCP 08 or VCP 05 (RFS_04VRS_VCP0x0x.cb) The ready-made interfaces for the operating terminals VCP 05 and VCP 08 are available on a CD or the Internet (Rexroth Portal). The access to the Rexroth Portal is only possible for registered users. IndraMotion for Metal Forming - CD (SWA-IM*MLD-MF*-02VRS-D0-CD650-COPY) IndraMotion for Metal Forming - Internet information_de/software_de/software_automationssysteme_de

14 6/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description System Introduction In the "\User" directory on the MMC supplied, the following files and documentations are available: release version of the system solution as parameter file (Rollfeed_Standard_2_04Vxx.par) with related icon file (Boot.sdb) for the visualization on the VCP 05 or VCP 08 VCP-HMI applications (VCP 05 and VCP 08) description for the download of the VCP-HMI application IndraWorks project archive (Rollfeed_Standard_2_-04VRS_Template.zip) with integrated library for variable I/O connections ("Rollfeed_Standard_-04VRS.lib") functional description of Rollfeed Standard 04VRS release notes Differences Between the Two System Solutions The two system solutions "Rollfeed Standard 1 (BASIC)" and "Rollfeed Standard 2 (ADVANCED)" have the following basic differences concerning the functions listed: Number of strokes If a number of strokes exceeding 600 strokes/min is required, the Rollfeed Standard 2 system solution must be used, since it features higher internal processing speeds. Analog override Only the Rollfeed Standard 2 system solution offers the possibility to set off the programmed traveling velocities against an analog override (cf. chapter 4.7 "Override" on page 38). Rollfeed Standard 1 does not offer this option. Integrated safety technology If different application-related safety functions, such as e.g. safe halt, safe start interlock, safely reduced velocity, or safe direction of travel are used, the Rollfeed Standard 2 system solution must be used, since the Safety Technology S1 (X41) option module is required for this. Encoder configuration In case of Rollfeed Standard 1, the standard encoder interface (ENS) must be used for the motor encoder. The optional encoder for the metering wheel can be freely chosen. In case of Rollfeed Standard 2, the encoder interfaces for the motor encoder or the optional metering wheel can be freely chosen. Synchronous feed motion via a master axis coupling A synchronous feed motion via an electronic motion profile (e.g. 5th order polynomial) in relation to a master axis (real master axis/external press encoder or virtual master axis) is only possible with the Rollfeed Standard 2 system solution. Analog output of the mean path velocity The analog output of the mean path velocity (P ) is only available for the drive control device "IndraDrive Advanced".

15 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 7/171 System Introduction Further Documentation Firmware Documentation Parameter description DOK-INDRV*-GEN-**VRS**-PA**-EN-P Notes on troubleshooting (diagnostic description) DOK-INDRV*-GEN-**VRS**-WA**-EN-P Functional Description DOK-INDRV*-MP*-**VRS**-FK**-EN-P Integrated safety technology DOK-INDRV*-SI*-**VRS**-FK**-EN-P Hardware Documentation (Project Planning) Power unit "IndraDrive C" DOK-INDRV*-HCSxx.1****-PR**-EN-P Power unit "IndraDrive M" DOK-INDRV*-HMS+HMD****-PR**-EN-P Control unit DOK-INDRV*-CSH********-PR**-EN-P Supply unit "IndraDrive M" DOK-INDRV*-HMV-*******-PR**-EN-P

16 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description

17 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 9/171 Important Instructions on Use 2 Important Instructions on Use 2.1 Intended Use Introduction Scope of Use and Application All Bosch Rexroth controls and drives are developed and tested in accordance with the state of the art technology. It is not possible to track the continuous further improvement of all materials our controls and drives may come into contact with (e.g. lubricants at machine tools). Reactions with the materials used in the Bosch systems cannot generally be excluded. Therefore, before using new lubricants, cleaning agents etc., must be checked for compatibility with the Bosch housing and device materials. The products may only be used for the intended purpose. When they are not used as intended, situations may arise resulting in damage to person or material. Bosch Rexroth, as the manufacturer of the products, shall not assume any warranty, liability or payment of damages in case of damage resulting from a non-intended use of the products. If the user fails to use the products as intended, the user shall assume sole responsibility for any resulting risks. Before using Bosch Rexroth products, the following prerequisites must be fulfilled to ensure their proper use: Anyone using our products must read and understand the corresponding safety notes and intended use of the product. If the products are hardware, they must be kept in their original state, i.e. no constructional modifications should be made. Software products may not be decompiled; their source codes may not be modified. Damaged or defective products must not be installed or put into operation. It must be ensured that the products are installed according to the regulations specified in the documentation. Bosch Rexroth drive controllers are intended to control electrical motors and monitor their operation. To control and monitor the motor, it may be necessary to connect additional sensors and actuators. The drive controllers must only be used with the accessories and mounting parts listed in this documentation. Do not install or connect components not expressly specified in this documentation. This also applies to cables and lines. The unit may be operated only with the explicitly specified component configurations and combinations and only with the software and firmware specified in the appropriate functional description. Before commissioning, every drive controller must be programmed to ensure that the motor executes the appropriate functions for the application.

18 10/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Important Instructions on Use 2.2 Improper Use The drive controllers have been developed for use in single and multi-axes drive and control tasks. To allow for application-specific requirements in the drive controllers, our product range comprises various device types with different drive powers and interfaces. The drive controller must only be operated under the mounting and installation conditions, the position, and the ambient conditions (temperature, type of protection, moisture, EMC, etc.) specified in this documentation. The use of the drive controllers in applications other than those specified or described in the documentation and the technical data is considered as "improper". Drive controllers must not be used if they are subjected to operating conditions not corresponding to the specified ambient conditions. They must not be operated under water, under extreme temperature fluctuations, or within extreme maximum temperatures. Furthermore, the drive controllers can only be used in applications approved by Bosch Rexroth. Please note the specifications outlined in the general safety instructions!

19 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 11/171 Safety Instructions for Electric Drives 3 Safety Instructions for Electric Drives 3.1 Safety Instructions - General Information Using the Safety Instructions and Passing them on to Others Do not attempt to install or commission this device without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation prior to working with the device. If you do not have the user documentation for the device, contact your responsible Bosch Rexroth sales representative. Ask for these documents to be sent immediately to the person or persons responsible for the safe operation of the device. If the device is resold, rented and/or passed on to others in any other form, these safety instructions must be delivered with the device in the official language of the user's country. WARNING Improper use of these devices, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death! Observe the safety instructions! How to Employ the Safety Instructions Read these instructions before initial commissioning of the equipment in order to eliminate the risk of bodily harm and/or material damage. Follow these safety instructions at all times. Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before commissioning the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation, as well as care in operation and maintenance, are prerequisites for optimal and safe operation of this device. Only assign trained and qualified persons to work with electrical installations: Only persons who are trained and qualified for the use and operation of the device may work on this device or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the product, as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and devices on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer.

20 12/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Safety Instructions for Electric Drives Follow all safety regulations and requirements for the specific application as practiced in the country of use. The devices have been designed for installation in industrial machinery. The ambient conditions given in the product documentation must be observed. Only use safety-relevant applications that are clearly and explicitly approved in the Project Planning Manual. If this is not the case, they are excluded. Safety-relevant are all such applications which can cause danger to persons and material damage. The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applications and suggestions. The machine and installation manufacturer must make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements. Commissioning of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application. Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective documentation (Project Planning Manuals of components and system). The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations. Technical data, connection and installation conditions are specified in the product documentation and must be followed at all times. National regulations which the user must take into account European countries: according to European EN standards United States of America (USA): National Electrical Code (NEC) National Electrical Manufacturers Association (NEMA), as well as local engineering regulations regulations of the National Fire Protection Association (NFPA) Canada: Canadian Standards Association (CSA) Other countries: International Organization for Standardization (ISO) International Electrotechnical Commission (IEC) Explanation of Warning Symbols and Degrees of Hazard Seriousness The safety instructions describe the following degrees of hazard seriousness. The degree of hazard seriousness informs about the consequences resulting from non-compliance with the safety instructions:

21 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 13/171 Safety Instructions for Electric Drives Warning symbol Signal word Danger Degree of hazard seriousness acc. to ANSI Z Death or severe bodily harm will occur. Warning Caution Death or severe bodily harm may occur. Minor or moderate bodily harm or material damage may occur. Fig.3-1: Hazard classification (according to ANSI Z 535) Hazards by Improper Use DANGER High electric voltage and high working current! Risk of death or severe bodily injury by electric shock! Observe the safety instructions! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! Observe the safety instructions! WARNING High electric voltage because of incorrect connection! Risk of death or bodily injury by electric shock! Observe the safety instructions! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Observe the safety instructions! Hot surfaces on device housing! Danger of injury! Danger of burns! Observe the safety instructions! CAUTION CAUTION Risk of injury by improper handling! Risk of bodily injury by bruising, shearing, cutting, hitting or improper handling of pressurized lines! Observe the safety instructions!

22 14/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling of batteries! Observe the safety instructions! 3.2 Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts and Housings This section concerns devices and drive components with voltages of more than 50 Volt. Contact with parts conducting voltages above 50 Volts can cause personal danger and electric shock. When operating electrical equipment, it is unavoidable that some parts of the devices conduct dangerous voltage. DANGER High electrical voltage! Danger to life, electric shock and severe bodily injury! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain and repair this equipment. Follow general construction and safety regulations when working on power installations. Before switching on the device, the equipment grounding conductor must have been non-detachably connected to all electrical equipment in accordance with the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the equipment grounding conductor is not permanently connected to the mounting points of the components provided for this purpose. Before working with electrical parts with voltage potentials higher than 50 V, the device must be disconnected from the mains voltage or power supply unit. Provide a safeguard to prevent reconnection. With electrical drive and filter components, observe the following: Wait 30 minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the electric voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Do not remove or plug in connectors when the component has been powered. Install the covers and guards provided with the equipment properly before switching the device on. Before switching the equipment on, cover and safeguard live parts safely to prevent contact with those parts. A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device according to the relevant standards. Secure built-in devices from direct touching of electrical parts by providing an external housing, for example a control cabinet.

23 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 15/171 Safety Instructions for Electric Drives For electrical drive and filter components with voltages of more than 50 volts, observe the following additional safety instructions. DANGER High housing voltage and high leakage current! Risk of death or bodily injury by electric shock! Before switching on, the housings of all electrical equipment and motors must be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests. The equipment grounding conductor of the electrical equipment and the devices must be non-detachably and permanently connected to the power supply unit at all times. The leakage current is greater than 3.5 ma. Over the total length, use copper wire of a cross section of a minimum of 10 mm 2 for this equipment grounding connection! Before commissioning, also in trial runs, always attach the equipment grounding conductor or connect to the ground wire. Otherwise, high voltages may occur at the housing causing electric shock Protection Against Electric Shock by Protective Extra-Low Voltage Protective extra-low voltage is used to allow connecting devices with basic insulation to extra-low voltage circuits. All connections and terminals with voltages between 5 and 50 volts at Rexroth products are PELV systems. 1) It is therefore allowed to connect devices equipped with basic insulation (such as programming devices, PCs, notebooks, display units) to these connections and terminals. WARNING High electric voltage by incorrect connection! Risk of death or bodily injury by electric shock! If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g. the mains connection) are connected to Rexroth products, the connected extra-low voltage circuits must comply with the requirements for PELV. 2) Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of connected motors. Some common examples are: improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. 1) "Protective Extra-Low Voltage" 2) "Protective Extra-Low Voltage"

24 16/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Safety Instructions for Electric Drives The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily harm and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.

25 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 17/171 Safety Instructions for Electric Drives DANGER Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. These measures have to be provided for by the user according to the specific conditions within the installation and a hazard and fault analysis. The safety regulations applicable for the installation have to be taken into consideration. Unintended machine motion or other malfunction is possible if safety devices are disabled, bypassed or not activated. To avoid accidents, bodily harm and/or material damage: Keep free and clear of the machine s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine s range of motion: use safety fences use safety guards use protective coverings install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the device if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a safety related starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Additionally secure vertical axes against falling or dropping after switching off the motor power by, for example: mechanically securing the vertical axes, adding an external braking/ arrester/ clamping mechanism or ensuring sufficient equilibration of the vertical axes. The standard equipment motor brake or an external brake controlled directly by the drive controller are not sufficient to guarantee personal safety! Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: maintenance and repair work cleaning of equipment long periods of discontinued equipment use Prevent the operation of high-frequency, remote control and radio equipment near electronics circuits and supply leads. If the use of such devices cannot be avoided, verify the system and the installation for possible malfunctions in all possible positions of normal use before initial startup. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation.

26 18/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Safety Instructions for Electric Drives Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious personal danger to those with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with heart pacemakers and metal implants are not permitted to enter following areas: Areas in which electrical equipment and parts are mounted, being operated or commissioned. Areas in which parts of motors with permanent magnets are being stored, repaired or mounted. If it is necessary for somebody with a pacemaker to enter such an area, a doctor must be consulted prior to doing so. The noise immunity of present or future implanted heart pacemakers differs greatly so that no general rules can be given. Those with metal implants or metal pieces, as well as with hearing aids, must consult a doctor before they enter the areas described above. Otherwise health hazards may occur Protection Against Contact with Hot Parts CAUTION Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of burns! Do not touch surfaces of device housings and chokes in the proximity of heat sources! Danger of burns! Do not touch housing surfaces of motors! Danger of burns! According to the operating conditions, temperatures can be higher than 60 C, 140 F during or after operation. Before accessing motors after having switched them off, let them cool down for a sufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated, the time required for cooling down is five times the thermal time constant specified in the Technical Data. After switching drive controllers or chokes off, wait 15 minutes to allow them to cool down before touching them. Wear safety gloves or do not work at hot surfaces. For certain applications, the manufacturer of the end product, machine or installation, according to the respective safety regulations, has to take measures to avoid injuries caused by burns in the end application. These measures can be, for example: warnings, guards (shielding or barrier), technical documentation Protection During Handling and Mounting In unfavorable conditions, handling and mounting certain parts and components in an improper way can cause injuries.

27 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 19/171 Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting! Observe the general construction and safety regulations on handling and mounting. Use suitable devices for mounting and transport. Avoid jamming and bruising by appropriate measures. Always use suitable tools. Use special tools if specified. Use lifting equipment and tools in the correct manner. If necessary, use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Do not stand under hanging loads. Immediately clean up any spilled liquids because of the danger of skidding Battery Safety Batteries consist of active chemicals enclosed in a solid housing. Therefore, improper handling can cause injury or material damage. CAUTION Risk of injury by improper handling! Do not attempt to reactivate low batteries by heating or other methods (risk of explosion and cauterization). Do not recharge the batteries as this may cause leakage or explosion. Do not throw batteries into open flames. Do not dismantle batteries. When replacing the battery/batteries do not damage electrical parts installed in the devices. Only use the battery types specified by the manufacturer. Environmental protection and disposal! The batteries contained in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations. Dispose of used batteries separate from other waste. Observe the local regulations in the country of assembly Protection Against Pressurized Systems According to the information given in the Project Planning Manuals, motors cooled with liquid and compressed air, as well as drive controllers, can be partially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids and cooling lubricating agents. Improper handling of the connected supply systems, supply lines or connections can cause injuries or material damage.

28 20/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling of pressurized lines! Do not attempt to disconnect, open or cut pressurized lines (risk of explosion). Observe the respective manufacturer's operating instructions. Before dismounting lines, relieve pressure and empty medium. Use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Immediately clean up any spilled liquids from the floor. Environmental protection and disposal! The agents used to operate the product might not be economically friendly. Dispose of ecologically harmful agents separately from other waste. Observe the local regulations in the country of assembly.

29 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 21/171 Functional Description 4 Functional Description 4.1 Field of Application The system solution "IndraMotion for Metal Forming Rollfeed Standard" was specifically developed for feed systems. It serves to control the feed of materials, such as e.g. metal, foil, or paper, and to process these materials by means of shears, punches, or presses. The press (shears) can be synchronized by means of 4 different types of application in the automatic operating mode. The positioning can be realized either via the motor or the metering wheel encoder. All feeds can be modified by way of a programmed Micro-Adjust (additive length). The synchronization between the roll feed and the press or shears, respectively, is controlled with the help of the input signal "Feed angle". In case of the system solution "Rollfeed Standard 2", the synchronization can also be carried out via an external press encoder (evaluation of the press position via the options card MD2). The feed motion can only be made, if the feed area was released. The system was designed so as to meet the highest requirements as regards functionality and safety. The signal exchange is realized via 24 V signals at defined inputs and outputs or via the Profibus field bus. A diagnostic system monitors the I/O and operating states and stops the system, if an error is reported. Comprehensive diagnostic messages are provided on the HMI in order to help the user with operating the device and in eliminating errors. Fig.4-1: Feed area By means of interruption and override, the loop control can be ensured. Fig.4-2: Roll feed

30 22/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description 4.2 Operating Modes General Parameter Mode 4 different operating modes are supported: Parameter mode Manual mode Automatic mode Set-up mode The parameter mode is activated, when the signal level "H" is detected on the "parameters" input (X31/5, P ). In the parameter mode, the drive switches over to phase 2. Now, the drive parameters can be modified. Usually, the parameter mode is only used for the initial switch-on of the drive control device for entering the machine's data. The parameters can either be input via the small operating terminal VCP 08 or with the help of Engineering-Framework IndraWorks. Almost all parameters can be modified by the user. The function of the individual parameters is given in the parameter description DOK INDRV* GEN **VRS**-PA02 EN P. Furthermore, the following listed parameters are used as system parameters (see chapter 9 "Parameter" on page 123). Parameter P P P P Function Rollfeed status parameter Manual velocity Set-up velocity Bipolar velocity limit P Rollfeed configuration parameter 1 P Cycle time monitoring P Rollfeed configuration parameter 2 P P P P P P P P P P P Mean path velocity Part number selection Micro-Adjust value Delay time closing rolls Number of press strokes Rollfeed diagnostic and error number Preset - status parameter Standstill time of press Internal press velocity Rollfeed system diagnostic Part data and installation parameters Fig.4-3: System parameters

31 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 23/171 Functional Description Manual Mode Automatic Mode General The comfortable user interface of the Engineering-Framework IndraWorks allows to store parameters on a PC. The parameter mode can be switched over to at any given point in time. For this reason, this should be secured by means of a key switch or other appropriate measures. In the manual mode, the inputs "Jog+" and "Jog-" can be used to display feeds with the velocity pre-defined in the Parameter P , Manual velocity. It is a percentage value related to the maximum installation velocity stipulated in the parameter P , Bipolar velocity limit. If the "feed angle" input is set to "0", no feed motion can be made. This can be reset with a push on the START key on the VCP 08 or through the enabling of the "Start" input. The following functions can be activated: roll ventilation Manual mode feed interruption override (only in case of IndraDrive Advanced) Jogging is not possible in case of: feed interruption stop no feed angle or no start In order to facilitate the commissioning, the "Stop neg " input (P ) and the "feed interruption neg " input (P ) do not have any function, if Bit 4 is set in the parameter P , Rollfeed configuration parameter 1. The automatic mode is enabled through the setting of the "Automatic" input. The "Automatic" output is set in order to indicate that the system is in the automatic mode. The automatic mode is launched through a positive edge on the "Start" input. The "Run" output reports when the automatic mode is enabled. In the automatic mode, the products are processed with the data entered for length, velocity etc. With a positive edge on the "Clear error" input and a disabled "Automatic" input, the automatic mode can be interrupted at any time. The feed motion for the "Rollfeed Standard 1" system solution is always made via the drive-internal operating mode "Drive-controlled positioning " (trapezoidal or triangular profile). The feed motion of the "Rollfeed Standard 2" system solution can be configured and allows the following traveling profiles: feed via the drive-internal operating mode "Drive-controlled positioning" (trapezoidal or triangular profile) feed via the drive-internal operating mode "Electronic motion profile" coupled to the internal virtual master axis (VMA)

32 24/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description feed via the drive-internal operating mode "Electronic motion profile" coupled to an external press encoder (real master axis, RMA) In case of the operating mode "Electronic motion profile with real/virtual master axis", the master axis position and feed axis are firmly linked to each other. The feed motion can be realized via an internally calculated "Dwell-to-dwell" motion profile or via a user-defined cam table (cam tables 2-8). Subject to the feed configuration (max. number of press strokes, feed length, maximum velocity, maximum acceleration etc.), an internally calculated "cam table 1" the standardized "5th order polynomial" profile is used for the internal "dwell-to-dwell" motion profile. With the automatic calculation of the "dwell-todwell" motion profile, an acceleration- and velocity-limited traveling profile is provided. In order for the motion limits of the feed axis (max. velocity, acceleration and jerk) to be complied with in case of master axis coupling, a maximum number of press strokes is calculated and provided as diagnostic parameter (cf. P , Element 10). If the press exceeds the maximum number of strokes, the feed axis exceeds the motion limits set, sets a velocity limitation ("E2059, Velocity setpoint limitation enabled") and generates, if parameterized, the error "F2039, Maximum acceleration exceeded" P , Bit 15). The desired traveling profile is set via the parameter P , Rollfeed configuration parameter 1 (Bit 11, 12). The desired type of profile (e.g. internal "dwell-to-dwell" profile) must be selected with the help of the parameter P , Part data and installation parameters (Element 406). By means of the elements 403 and 404 of parameter P , Part data and installation parameters, the feed area must be defined for a master axis coupling (switchon and switch-off angle for feed cams). Furthermore, the feed motion can be shortened by a parameterizable tolerance range in relation to the end of the feed area (switch-off angle) (cf. parameter P , Part data and installation parameters (Element 405)). If an external press encoder is used, the current position of the encoder is output in the parameter P , Rollfeed status parameter (Element 9). In order to avoid a reversely rotating feed axis in case of master axis coupling with external press encoder, a negative velocity limit must be parameterized for the external press encoder in the parameter P , Part data and installation parameters (Element 407). If the press moves backward and, in doing this, exceeds the velocity limit, the error "negative press velocity" is generated. If "0" is defined for the limit, the monitoring is disabled. In order to be able to read in and evaluate the position of the external press encoder (RMA), an encoder interface must be available on Option 3 in the Advanced drive control device. Overview of parameters relevant for master axis-coupled feed motions

33 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 25/171 Functional Description Parameter List element Scaling Function Default values or setpoints in case of master axis-coupled feed P ^0 degree Switch-on angle cam or start of the feed area Default value: 270 degree ^0 degree Switch-off angle cam or end (stop) of the feed area Default value: 90 degree ^0 degree Tolerance range for the end of the feed area (feed area is reduced by this value) Default value: 0 degree ^0 Default values for the motion profile: ^-4 rpm or 10^-6 rpm 1 = use of the internally generated "dwell-to-dwell" motion profile (cam table 1 via P or 5th order polynomial, internal automatic switch-over) = cam table 2-8 (P etc.). The cam tables 2-8 are freely available and must be generated by the user. Default value: 1 Note: Cam table 1 (P ) is used internally and not available for the user. Negative velocity limit for master axis coupling with RMA (to avoid a reversely rotating feed axis, if the press moves backwards) Default value: 0 rpm Note: With the default value "0" rpm, the monitoring is switched off, i.e. the feed axis moves backwards, if the press moves backwards and the automatic mode is enabled ^0 strokes/min Default of maximum number of press strokes (machine constant). If the internal "dwell-to-dwell" motion profile is used, the calculation for the feed profile and the maximally available number of press strokes is realized on the basis of this value. Default value: 500 strokes/min P ^0 Presetting of the traveling profile via Bit 11 and 12: Bit 11 = 0 trapezoidal Bit 11 = 1, Bit 12 = 0 master axis coupling RMA Bit 11 = 1, Bit 12 = 1 master axis coupling VMA P ^-2 strokes/min Number of press strokes for the VMA Note: In case of master axis coupling with VMA, this parameter has to be used to define the VMA velocity. The velocity for the VMA can be dynamically adjusted to the real press velocity. It is read in before every feed. Fig.4-4: Preset values or setpoints in case of master axis-coupled feed

34 26/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description Parameter List element Scaling Function P ^-4 mm or Diagnostic values or actual values in case of master axis-coupled feed 10^-6 inch Active parts or feed length 10 10^-2 strokes/min Maximum number of press strokes for master axis-coupled feed motions. Note: 11 10^0 Active traveling profile: During an active calculation or configuration of the motion profile, this value is set to "0". 0 = trapezoidal 1 = master axis-coupled with RMA 2 = master axis-coupled with VMA 12 10^0 degree Active switch-on angle cams or active start of the feed area (cf. P , Element 403) 13 10^0 degree Active switch-off angle cams or active end of the feed area (cf. P , Element 40) 14 10^0 degree Active tolerance range for the end of the feed area (cf. P , Element 405) 15 10^0 Active motion profile, cam table 1-8 (cf. P , Element 406) Fig.4-5: Parameter Bit Name Function 1 = internally generated "dwell-to-dwell" motion profile (cam table 1 or 5th order polynomial) = cam table 2-8 (P etc. Diagnostic values or actual values in case of master axis-coupled feed Overview of additional output signals relevant for master axis-coupled feed motions P Motion profile valid The output signalizes that the calculation of the maximum number of press strokes as well as the parameterization of the defined motion profile is completed and valid for the master axis coupling. Only if this output is set can the automatic mode be launched. Otherwise, an error message is generated (error number 109). Fig.4-6: Note: The output is always set for the "trapezoidal" traveling profile. Additional output singals relevant for master axis-coupled feed Overview of diagnostic messages relevant in case of master axis-coupled feed motions

35 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 27/171 Functional Description Parameter Error number Function P Negative press velocity, i.e. the press turned backwards in the automatic mode with master axis coupling RMA. 109 Master axis-coupled motion profile not valid, i.e. the internal calculations and configurations are not yet completed. The automatic mode was launched too early. 118 Configuration error - motion profile (internal error) 138 Number of strokes (P ) too high for VMA, i.e. the value is higher than the maximally possible number of press strokes (cf. P , Element 10) 139 Number of strokes (P ) too small for VMA, i.e. less than or equal to "0". Fig.4-7: Diagnostic messages relevant for master axis-coupled feed If master axis-coupled feed motions are used, the maximally possible number of press strokes (P , Element 10) is made available. The parameters given in the table below affect the calculated value of the maximum number of press strokes and on the start, in case the internal calculation and configuration of the motion profile is modified. During this period of time, the "motion profile valid" output (P-01411, Bit 15) as well as the diagnostic parameters for the maximum number of press strokes (P , Element 10) is set to "0". It is not possible to launch the automatic mode during this period of time (cf. error message "Master axis-coupled motion profile not valid", error number 109). Modifications to the relevant parameters of the traveling profile are recognized with the cycle time indicated in the table. The cycle times are defined through the internal call of the respective PLS task used. In the default setting, the cycle time for the motion task (MOTION_TASK) and for the parameter task (PARA_TASK) amounts to 2 ms and 1,000 ms, respectively. Parameters relevant for the calculation of the maximum number of press strokes Parameter List element Function Comment Cycle time P feed length Active parts or feed length via active part number (P ) MOTION_TASK S Jerk limit PARA_TASK S Acceleration limit PARA_TASK P Velocity limit PARA_TASK

36 28/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description Parameter List element Function Comment Cycle time P Start angle feed area or switch-on angle cam PARA_TASK 404 End angle feed area or switch-off angle cam PARA_TASK 405 Tolerance range for the end of the feed area 406 Presetting for the motion profile 408 Max. number of press strokes P Traveling profile (Bits 11 and 12) Internal D-D profile and free cam table 2-8 Setpoint (machine constant) trapezoidal master axis coupling with RMA master axis coupling with VMA PARA_TASK PARA_TASK PARA_TASK PARA_TASK Fig.4-8: Parameters relevant for the calculation of the maximum number of press strokes Procedure for the setting of the motion profile Setpoint parameter Actual value parameter Function In order to make sure that the desired feed configuration is parameterized and internally active, the existing values of the diagnostic parameters (actual values) must be read out and compared to the setpoints. Only if those values tally and the "motion profile valid " output is set may the automatic mode be launched. Comparison of setpoints and actual values in case of master axis-coupled feed P (Element 408) P (Element 10) Maximum number of press strokes P (Bits 11, 12) P (Element 11) Displacement profile (trapezoid, RMA, VMA) P (Element 403) P (Element 12) Start angle or switch-on angle cams P (Element 404) P (Element 13) Stop angle or switch-off angle cams P (Element 405) P (Element 14) Tolerance range P (Element 406) P (Element 15) Motion profile (internal RR, cam table 2-8) Fig.4-9: General Notes on Master Axis-Coupled Feed Comparison of setpoints and actual values in case of master axis-coupled feed In case of the switch-over from the traveling profile of master axis coupling with VMA/RMA to the trapezoidal profile, the automatic mode must not be launched, until the trapezoid profile is displayed in the diagnostic parameter (P , Element 11). ("Motion profile valid" output is always set for trapezoidal profile). Any modification made to the feed configuration (e.g. start/end angle) and the feed length in case of master axis coupling are only possible in the manual mode or with the cycle stop being enabled (cf. "Run" output). If, in case of master axis coupling via VMA, the velocity of the VMA (P ) is set to a higher value than the internal calculated maximum number of press strokes, the error message "Number of strokes (P ) too high for VMA" (error number 138) is generated.

37 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 29/171 Functional Description If the internal "dwell-to-dwell" motion profile is used, the maximum number of press strokes (machine constant, P , Element 408) must be defined. The calculation of the feed motion is realized on the basis of this value. If the setpoint for the maximum number of press strokes (P , Element 408) is higher than the maximally possible number of press strokes (P , Element 10), the internal "dwell-to-dwell" motion profile is calculated on the basis of the indicated maximally possible number of press strokes (P , Element 10). Instructions for the Configuration and Enabling of the Master Axis-Coupled Feed Motion 1. Parameterization of limits in the drive S , Positioning jerk (optional) S , Bipolar acceleration P , Bipolar velocity limit 2. Parameterization of the desired traveling (master axis coupling with VMA, RMA or via trapezoidal profile) P , Bits 11 and Parameterization of the desired motion profile (internal "dwell-to-dwell" motion profile or free cam table 2-8) P , Element Parameterization of maximum number of press strokes (machine constant) P , Element Parameterization of feed settings start angle feed area or switch-on angle cam (P , Element 403) end angle feed area or switch-off angle cams (P , Element 404) tolerance range for the end of the feed area (P , Element 405) 6. Parameterization of feed length P , Element 1-99 (element depends on the part selection P ) 7. Reloading of the current feed configuration via the parameter P for the verification of the predefined settings active traveling profile (P , Element 11) active motion profile (P , Element 15) current maximally possible number of press strokes (P , Element 10) active start angle or switch-on angle cam (P , Element 12) active end angle or switch-off angle cam (P , Element 13) active tolerance range for the end of the feed area (P , Element 14) active feed length (P , Element 1) 8. Waiting, until the "Motion profile valid" (P , Bit 15) is set. 9. Now, the automatic mode can be launched.

38 30/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description Modifications to the feed configuration are only accepted in the manual mode or with the cycle stop being enabled. Example: Types of Application in the Automatic Mode Master Axis Coupling with Real Master Axis The Automatic Mode is Enabled and the Feed Motion is Master Axis-Coupled via the Virtual Master Axis (VMA). The Feed Length is to be Modified. Set "Cycle stop" input (P , Bit 4) to "0" Wait until the cycle stop is enabled, i.e. the "Run" output (P , Bit 4) is set to "0" Write a new feed length (P , Element 1-99) Verification of the new feed length (P , Element 1) Wait until the "Motion profile valid" (P , Bit 15) is set Accept new maximally possible number of press strokes (P , Element 10) and take it into account for the velocity presetting (P ) for the virtual master axis (VMA) Launch (P , Bit 2) of the automatic mode In the automatic mode, one distinguishes between the types of application "Press before Feed" and "Feed before Press" as well as "Press - single stroke" or "Press - continuous operation". The different types of application are selected via the two respective inputs. In case of feed motions via a master axis coupled to the external press encoder (RMA), the operating mode "Press - continuous operation" is always set internally. For this traveling profile, one has to make sure that - in the "Feed before Press" type of application - the first feed motion is realized via the positioning of the virtual master axis. In this case, the positioning velocity is defined with the help of the parameter P , Number of press strokes. In the "Press before Feed" type of application, the last feed motion is realized via the positioning of the virtual master axis. In this case, the positioning velocity is determined on the basis of the current velocity of the external press encoder during the last press stroke. The switch-over from "Press before Feed" to "Feed before Press" and vice versa is only accepted internally, if the automatic mode is disabled (see "Run" output).

39 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 31/171 Functional Description Feed before Press in Continuous Operation Fig.4-10: Feed before Press in Single Stroke Feed before press in continuous operation The "Press" output is switched on, after the first feed is completed. In the continuous operation, the output stays switched on during the automatic operation. The output is switched off, if a failure or an error is recognized or if a "cycle stop" or "halt" is triggered. Fig.4-11: Feed before press in single stroke In case of a single stroke, the "Press" output is switched on after the feed cycle is completed.

40 32/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description Press before Feed in Continuous Operation If the edge on the "feed angle" input is rising or in case of "cycle stop" or "halt", the "Press" output is switched off. Fig.4-12: Press before feed in continuous operation The "Press" output is switched on after a "cycle start". In the continuous operation, the output stays switched on during the automatic operation. The output is switched off, if a failure or an error is recognized or if a "cycle stop" or "halt" is triggered.

41 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 33/171 Functional Description Press before Feed in Single Stroke Set-Up Mode Fig.4-13: Press before feed in single stroke In case of a single stroke, the "Press" output is switched on after a "cycle start". If the edge on the "Feed angle" input is rising, the "Press" output is switched off. After a feed cycle is completed, the "Press" output is switched on again and the cycle begins again. The set-up mode allows to traverse - in the automatic mode - a complete product with a separate velocity via the "Jog" inputs. This velocity is entered in the parameter P , Set-up velocity. The "Set-up" function has, basically, has the same function as the "Automatic" operating mode. However, the feed lengths are traversed via the inputs "Jog+" and "Jog-". As soon as the feed length is achieved, the outputs "Feed length achieved" and "Pressing allowed" are set. The press control is not launched automatically, but must be triggered externally. Production runs are counted. The set-up mode can only be quit, if a complete cycle is completed. If this operating mode is to be quit earlier, this can be made through setting the "Clear errors" input with the set-up mode being disabled. At the end of the cycle, the "Run" output is deleted. With a positive edge on the "Clear errors" input and a disabled "Setup" input, an active set-up mode can be interrupted at any time. Clear Remaining Portion of the Feed Length In the set-up mode, usually, the drive-internal operating mode "Drive-controlled positioning" (trapezoidal or triangular profile) is enabled (for exception, see "Automatic Tracing of the Feed Length" on page 34). In the set-up mode, the user has the possibility to clear the currently remaining portion of the feed length. The remaining length is deleted by a positive edge on the "Clear errors" input, if no jogging motion is active. In the "Feed before Press" operating mode, then, a complete feed length can be done again, with

42 34/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description Automatic Tracing of the Feed Length out a press stroke having to be executed. This process can be repeated as often as you like. In the "Press before Feed" operating mode, however, the current cycle is immediately completed after the remaining length is deleted, i.e. a further feed motion is only possible, after the press stroke was realized. After the feed length was jogged, the user has the possibility to enable the automatic tracing of the currently remaining portion of the feed length by defining a positive edge on the "Start" input. In this case, the "Jog+" input must not be activated any more in order to reach the final position. If no feed motion was yet made via the jogging inputs (start position valid), the activation of the automatic tracing of the feed length triggers the feed motion with the parameterized motion profile. In case of a master axis-coupled feed motion with virtual master axis or external press encoder, the virtual master axis is always internally positioned for this. 4.3 Production Run Counting Overall Production Run Actual Production Run 4.4 Sequence Diagnostic In the set-up mode, the press' operating mode Single stroke is activated internally. The finished products are counted in the "Automatic" operating mode and "Setup" function. The current overall production run is displayed in the parameterp , Rollfeed status parameter and can be modified according to the preference of the user (see chapter 8 "Forwarding Mode" on page 113). In case of the operation via the VCP 08, the overall production run can always be reset to any value in the menu "Preset - overall length/overall production run (F1)". The currently finished products are counted in the "Automatic" operating mode and "Set-up" function. The actual production run is displayed in the parameterp , Rollfeed status parameter and can be modified according to the preference of the user (see chapter 9 "Parameter" on page 123). If the production run setpoint is achieved, a system message is output (VCP 08 or P ) and the automatic program is stopped according to the clock. In case of the operation via the VCP 08, the actual production run can always be reset to any value in the menu "Preset - actual production run (F1)". The increase of the actual production run is always made at the end of a press cycle. In the "Feed before Press" operating mode, this is done after the feed was completed and after the subsequently falling (punch) or rising (press) edge of the feed angle. In the "Press before Feed" operating mode, the actual production run is increased after a complete feed triggered by a press stroke. When the production run setpoint is achieved, the actual production run is deleted upon the next restart of the automatic mode. If "0" is defined for the production run setpoint, a continuous running without limitation of the production run is enabled. The current status of the "Rollfeed Standard" system solution is principally displayed on the VCP 08. In addition to the display on the VCP 08, the current diagnostic text is available in the parameter P , System diagnostic. The display or output of the system diagnostic can be realized in the languages German, English, French, Spanish, or Italian. In case of the VCP 08, the language is selected in the menu "Display "Tools" (F3)". If no VCP 08 exists, the language can be selected via the drive parameter S , Language switching.

43 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 35/171 Functional Description The following table gives an overview of possible system-specific diagnostic texts: No. Diagnostic text Fig.4-14: 1 A Production run achieved 2 S Roll is open 3 S Stop is present 4 S Feed angle is missing 5 S E Pressing allowed 6 S Pressing allowed 7 S Interruption enabled 8 S Both jogging inputs enabled 9 S Jog+ 10 S Jog- not possible 11 S Jog- 12 S E Jogging allowed 13 S Feed is incomplete 14 S Jogging allowed 15 A Roll is open 16 A Stop is present 17 A Cycle stop enabled 18 A No cycle start 19 A Interruption enabled 20 A Feed motion 21 A Waiting for feed angle 22 A Waiting for press 23 M Roll is open 24 M Stop is present 25 M Interruption enabled 26 M Feed angle is missing 27 M Both jogging inputs enabled 28 M Jog+ 29 M Jog- 30 M Jogging disabled 31 No diagnostic Diagnostic texts The shorthand symbols used in the diagnostic text have the following meaning: A_: S_: S_E_: M_ automatic mode is enabled. set-up mode is enabled. set-up mode is preselected, but not yet enabled. Via the "Setup" input, the set-up mode can be disabled again. manual mode is enabled.

44 36/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description 4.5 Product Data Utilization The precise description of the individual diagnostics is given in chapter 11.2 "Error Diagnostics" on page 155. The utilization is the ratio between the time which a feed requires and the time which is available to the feed. A utilization smaller than 90 % (output X15/32, P ) signalizes to the machine operator that the maximum of the feed velocity is not yet achieved and that the press velocity can be increased. If the value of 100 % is exceeded, this leads to a feed angle loss immediately putting the installation to a standstill. The error is then indicated in the status line of the VCP 05 or VCP 08. If the feed angle area is not used to full capacity, the press velocity can be increased. The current utilization is displayed in the parameter P , Rollfeed status parameter. Fig.4-15: Utilization Fig.4-16: Mean Path Velocity Calculation of utilization The mean path velocity can be output via an analog output (X32/1 and X32/3) as an approximate value for the control of the coil drive (reel). This function activated in the parameter P , Rollfeed configuration parameter 1 takes into account the material velocity, the number of press strokes and the processing time. At maximum velocity (parameter P , Bipolar velocity limit), 5 Volts are output via the analog output 1 of the X32 plug. The currently mean path velocity is always available via the parameter P , Mean path velocity for diagnostic displays and evaluations. The analog output of the mean path velocity is only availabe for the drive control device "IndraDrive Advanced". In the parameter P , Control parameter of analog output, the direct output of voltage signals via P must be set (Bit 2 equals '0').

45 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 37/171 Functional Description Technical data of the analog output: Data Unit min. typ. max. Output voltage V 0 +5 Output load kohm 5 Output current ma 0 +1 Converter width of digital-to-analog converter incl. sign Bit 8 Resolution mv/inc 19,5 Precision at R = 5 kohm % 5 of MBE 1) Precision at R = 10 kohm % 2.5 of MBE 1) Conversion time (incl. build-up period) µs 10 Cyclic conversion µs depending on the firmware Short circuit protection included Overload protection included Strokes per Minute 4.6 Metering Wheel 1) MBE: full scale of measuring range Fig.4-17: Analog output With each rising edge of the "feed angle" signal, the period of time elapsed since the last positive edge is determined. This time was available to the last feed (stroke). It is determined and displayed as the current number of strokes (strokes per minute) of the installation. In order to compensate for any slip between the feed rolls and the material, the length measurement can be switched over from a motor encoder to an external metering wheel encoder. The metering wheel must only be actived, if the metering wheel and the material surface are in contact. If such a contact is not possible, the length measurement must be switched over back to the motor encoder. In the manual mode, the motor encoder is always used. The metering wheel can be activated via the "metering wheel" input, provided it was enabled in the parameter P , Rollfeed configuration parameter 1. In order to reduce a jerky slip behavior, the position difference added up can be dampened by means of a filter. The time constant can be adjusted in the parameter P , Actual position value - smoothing time constant for hybrid position control. Thanks to the metering wheel operation, any slip that might occur between the material and the drive motor is compensated via the position control. The currently actual slip value is indicated in P , Actual slip value in %. It refers to one metering wheel rotation. If the calculated slip exceeds the value given in parameter P , Monitoring range - slip in % (value not equal to 0), the slip monitoring generates the error message F2036, Excessive actual position value difference and the drive reacts with the configured error reaction. For the determination of the monitoring range, the maximum slip occurring, e.g. during a processing cycle, is stored in the parameter P , Maximum occurred actual slip value in %.

46 38/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description The slip monitoring is disabled with the value "0" in parameter P , Monitoring range - slip in %. The value in parameter S , Monitoring range - encoder 2 must be set to "0". Otherwise, the error "F2036, Excessive actual position value difference" is generated. For the parameterization of the function, the following parameters are used: P , Rollfeed configuration parameter 1 P , Actual position value - smoothing time constant for hybrid position control P , Actual slip value in % P , Maximum occurred actual slip value in % P , Monitoring range - slip in % For the parameterization of the metering wheel, the following parameters are used: S , Position encoder type 2 S , Encoder 2 resolution P , Feed constant 2 (optional encoder) P , Gear 2 - load side (optional encoder) P , Gear 2 - encoder side (optional encoder) P , Control word - encoder 2 (optional encoder) In order to be able guarantee a satisfying control behavior of the feed axis in the metering wheel operation, the position resolution of the metering wheel encoder used must be high enough. TTL encoder types are, typically, not suited for this. It is therefore recommended to use a sine encoder (1V ss ). The metering wheel encoder is an optional (external) encoder that is connected according to the connection plan (see chapter 12.3 "Input / Output Configuration of the Parallel Interface" on page 160). 4.7 Override All velocities programmed can be adjusted by means of an analog override. If this function is enabled in the parameter P , Rollfeed configuration parameter 1, the programmed velocity is used, provided an analog input voltage of +10 V is present at the inputs X32/4 and X32/5. If this analog input voltage is reduced, the traveling velocity is reduced proportionally. The traveling velocity Vo results from the multiplication of the programmed traveling velocity Vp and the override factor F (F = 0-1 corresponds to 0 V-10 V). Application: loop control change of velocity

47 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 39/171 Functional Description 4.8 Micro-Adjust 4.9 Roll Ventilation Fig.4-18: Velocity calculation with analog override The programmed traveling velocity (Vp) in the "manual mode" corresponds to parameter P , Manual velocity "set-up mode" corresponds to parameter P , Set-up velocity "automatic mode" corresponds to the velocity configured in the parameter P , Part data and installation parameters This function is only available for the drive control device "Indra Drive Advanced", provided the feed motion via the drive-internal operating mode "Drive-controlled positioning" (trapeoidal or triangular profile) was also selected. The Micro-Adjust functionality is used to correct the preselected feed length. The Micro-Adjust function can be defined with the help of the parameter P , Micro-Adjust value. In case of an operation via the VCP 08, the correction value can be changed by the Micro-Adjust increment. The correction value is valid for all feed lengths. In case of a change of product, the Micro-Adjust is automatically reset to zero. If this function is enabled in the parameter P , Rollfeed configuration parameter 1, the drive is switched to a torque-free state and the rolls are opened, when the tool enters the material, in order to avoid a mechanical redundancy. For the ventilation of the feed rolls, the "Roll ventilation" output (X32/8, P ) is set, which controls an external (hydraulic or similar) device opening the feed rolls. The signal for the roll ventilation, comes externally to the control, via the input X15/7 (P ) or X15/25 (P ). As long as the signal for the roll ventilation is present, all metering wheel motions are ignored and the output for the roll ventilation is switched on. Motions of the motor encoder do not generate errors and are not undone, when the function is switched off. A feed is delayed until the "Rolls closed" signal is present. The ventilation of the feed rolls can be done in different ways. 1. Roll ventilation in the manual mode If an "electrical / mechanical ventilation" is enabled in the parameter P , Rollfeed configuration parameter 1, the "Roll ventilation enabled" output is set for the ventilation of the rolls, to the extent that a voltage of 24 V is present at the "Roll ventilation - manual mode" input in the manual mode. As long as the input is present, the output, too, remains set. Upon the switch-over to the automatic mode, the output is automatically removed.

48 40/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description 2. Roll ventilation in the automatic mode If an "electrical / mechanical ventilation" is enabled in the parameter P , Rollfeed configuration parameter 1 and if a voltage of 24 V is present at the input "Roll ventilation allowed", the "Roll ventilation enabled" output is set by synchronism with the "Roll ventilation - automatic mode" input. The "Roll ventilation allowed" input can be used to block the "Roll ventilation" function in the automatic mode. With the help of the parameter P , Delay time closing rolls, the user can choose whether the rolls are to be closed automatically after a predefined period of time [in ms] or whether the rolls are only closed, if the "Rolls closed" input (X31/7, P ) is enabled. If, in the parameter, a time not equal to "0 ms" is entered, the "Rolls closed" input (X31/7, P ) is not effective. The rolls are expected to be closed after this waiting time. If "0 ms" are set, the closing of the rolls must be acknowledged via the "Rolls closed" input (X31/7, P ). Signal diagram for the roll ventilation with closing of rolls via the "Rolls closed" input (X31/7, P ): Fig.4-19: Roll ventilation in the automatic mode via the "Rolls closed" input Signal diagram for the roll ventilation with closing of rolls via "time delay":

49 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 41/171 Functional Description Fig.4-20: Roll ventilation in the automatic mode via time delay 4.10 Product Data Administration Trapezoidal or Triangular Profile Up to 99 parts with feed data can be stored on the MultiMediaCard (MMC). The feed data comprise the following parameters: feed length maximum feed velocity production run setpoint acceleration The feed data are defined and stored by means of the parameter P , Part data and installation parameters (see chapter 9 "Parameter" on page 123). The feed velocity and acceleration are valid for the traveling profile via the driveinternal operating mode "Drive-controlled positioning" (trapezoidal or triangular profile) in accordance with the predefined product data. In addition to his, a jerk can be parameterized for the feed motions by means of the parameter S , Bipolar jerk limit. This jerk, however, does not depend on any products and is equally valid for all feeds. Master Axis Coupling with Virtual Master Axis Master Axis Coupling with Real Master Axis For the feed via the drive-internal operating mode "Electronic motion profile", coupled to the internal virtual master axis (VMA), the acceleration during the feed motion is derived from the selected profile type (5th order polynomial or cam table). The internal positioning velocity of the virtual master axis must be preset via the parameter P , Number of press strokes. In order to comply with the motion limits of the feed axis (cf. parameter P , Bipolar velocity limitand S , Bipolar acceleration), this preset value must not exceed the admissible number of strokes. The maximum number of press strokes is made available in the parameter P , Rollfeed status parameter (Element 10). For the feed via the drive-internal operating mode "Electronic motion profile", coupled to a real master axis (RMA, external press encoder), the velocity and acceleration during the feed motion are derived from the selected profile type (5th order polynomial or cam table) and directly depend on the current number of press strokes. In order to comply with the motion limits of the feed axis (cf. parameter P , Bipolar velocity limitand S , Bipolar acceleration),

50 42/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Functional Description 4.11 Integrated Safety Technology the number of press strokes must not exceed the admissible maximum value. This value is made available in the parameter P , Rollfeed status parameter (Element 10). If, during a master axis-coupled feed motion, the feed is interrupted, e.g. due to the "Stop" input, the remaining portion of the feed length is traced via the trapezoidal or the triangular profile with the parameterized velocity and acceleration data. "Rollfeed Standard" can use the integrated safety technology of the IndraDrive drive systems. In relation to the integrated safety technology, the system solution supports the following functions: logical continuation of a feed motion after interruption to due a safetytechnological operating mode (start interlock, safe halt, safe operating halt) automatic limitation of the velocity setpoints after activation of such a motion (SBB1-4) If the installation runs in the automatic or set-up mode, an active feed motion is interrupted through the enabling of the safe operating modes "Start interlock" or the special modes "Standstill (Safe Halt / Safe Operating Halt)". After the safe operating mode was completed, any feed motions already started are logically continued. A partial portion of the feed length that was already made is thus always taken into account. If the system solution identifies the active safe operating state "Safe motion 1, 2, 3, or 4" (SBB1-4) in the manual or automatic mode, the preset velocity setpoint is automatically limited to the value defined in the parameter P , Part data and installation parameters (list element 401). The presetting has a proportional effect on the parameterized value of the respective velocity threshold (P , P , P , or P ). If the value in the P (list element 401) is set to "0", the system solution does not automatically limit the velocity setpoints. In this case, the superordinate control itself is responsable for the definition of reduced velocity setpoints in the manual or automatic mode (P , P , P ).

51 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 43/171 Inputs / Outputs 5 Inputs / Outputs 5.1 Overview of Input / Output Configuration General PLC Inputs General The two following tables give an overview of all available inputs and outputs with their internal interconnections to the PLC input and output words used as well as their respectively stored function. Parameter Bit no. I/O Function Comment P I Parameter Mode 1 I Feed angle 2 I Rolls closed 3 I Jog+ 4 I Jog- 5 I Roll ventilation - automatic mode This signal is OR-linked: to the corresponding operating key of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. to the corresponding input via P , Bit 14 This signal is OR-linked: to the corresponding operating key of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. to the corresponding input via P , Bit 15 This signal is only effective, after the parameter P , Rollfeed configuration parameter 2 was enabled. The corresponding signal via P , Bit 11 is then ineffective.

52 44/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Inputs / Outputs Parameter Bit no. I/O Function Comment P I Manual neg / Automatic 1 I Set-up 2 I Start This signal is OR-linked to the corresponding operating key of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. This signal is OR-linked to the corresponding operating key of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. This signal is OR-linked to the corresponding operating key of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. 3 I Stop neg the parameter P , Rollfeed configuration parameter This signal is only evaluated, if the input is enabled in 1. 4 I Cycle stop neg ating key "STOP" of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , This signal is AND-linked to the corresponding oper Rollfeed configuration parameter 2. 5 I Clear errors 6 I Press BDC 7 I Press - Single stroke neg / Continuous running Deletes errors and forces the automatic or set-up operation to stop. This signal is only evaluated, if the Press BDC function is enabled in the parameter P , Rollfeed configuration parameter 2. 8 I Feed interruption neg the parameter P , Rollfeed configuration parameter This signal is only evaluated, if the input is enabled in 1. 9 I Press before Feed 10 I Roll ventilation - manual mode 11 I Roll ventilation - automatic mode 12 I Roll ventilation allowed 13 I Metering wheel 14 I Jog+ 15 I Jog- This signal is only effective, after the parameter P , Rollfeed configuration parameter 2 was enabled. The corresponding signal via P , Bit 5 is then ineffective. This signal is only available, if the "Profibus" control communication is used. The signal is then OR-linked: to the corresponding operating key of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. to the corresponding input via P , Bit 3 This signal is only available, if the "Profibus" control communication is used. The signal is then OR-linked: to the corresponding operating key of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. to the corresponding input via P , Bit 4

53 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 45/171 Inputs / Outputs Parameter Bit no. I/O Function Comment P P I Feed interruption neg P , Rollfeed configuration parameter 2 was enabled. After the enabling, the signal is AND-linked This signal is only effective, after the parameter to the corresponding input via P , Bit 8. 0 I Preset - actual production run of active part 1 I Preset - overall production run 2 I Preset - overall length Meaning of PLC Inputs Parameter Mode Feed angle Rolls closed Jog+ Fig.5-1: PLC inputs This input is used to switch over the control to the operating mode "Parameter mode". Usually, the parameter mode is only required for the initial commissioning for entering the machine's data. In this operating mode, the power unit is switched off. The feed angle serves to synchronize the feed and the press. A feed motion is only possible, if the input is set. If an external press encoder exists, this signal can also be derived via a cam. For this, Bit 10 must be set in the parameter P , Rollfeed configuration parameter 1. The switch-on and switch-off angle must be stipulated in the parameter P , Part data and installation parameters (Elements 403 and 404). Via this input, the user can query if the rolls are closed. The feed is delayed until the input is "1". If no signal is present on the "Parameters" or on the "Automatic" input, the "Manual" operating mode is enabled. In this operating mode, the drive can now be moved forwards with a defined velocity. The drive is traversed, until the signal is present. In case of the automatic operating mode "Set-up", this input can be used to traverse all part length in the forward direction with a defined velocity. The jogging motion is launched upon a positive edge on the input. In the manual mode, the feed moves with the velocity stipulated in the parameter P , Manual velocity. The acceleration or delay corresponds to the values stipulated in the parameter S , Bipolar acceleration. In the set-up mode, the feed moves with the velocity stipulated in the parameter P , Set-up velocity. The acceleration or delay corresponds to the acceleration value given in the parameter P , Part data and installation parameters. If the parameterized or resulting feed length is negative, the direction of travel by means of "Jog+" is backwards, i.e. in the direction of the final position. Jog- In the "Manual" operating mode, the drive can be moved backwards with the help of this input. With the set-up mode being enabled, this input (Jog-) can be used to realize a backward motion to the initial point of the motion. The jogging motion is launched upon a positive edge on the input. The motion parameters correspond to the parameters of the "Jog+" input.

54 46/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Inputs / Outputs If the parameterized or resulting feed length is negative, the direction of travel by means of "Jog-" is forwards, i.e. in the direction of the initial position. Manualneg / Automatic This input enables the automatic mode. In the automatic mode, the programmed parts are processed with the part data entered. The switch-off of the input with the automatic mode being enabled ("Run" output is set) leads to the ending of the automatic mode in the cycle (see "Cycle stop neg " input). Set-Up Start With this input, the set-up operating mode is enabled. The feed is controlled via the inputs "Jog+" and "Jog-". The positive edge on the input "Start" launches the automatic program. After the production run was achieved or after a "Halt" or a "Cycle stop" was triggered, the automatic program must be relaunched via this input. In the set-up mode, this input is used to enable the automatic tracing of the currently remaining portion of the feed length. The automatic program can only be launched, if the automatic mode was preselected, i.e. the "Automatic" output (P , Bit 1) was set. Stopneg In order to allow for traveling motions, the "Stop neg " signal must always be present in all operating modes. If this signal disappears, the automatic mode as well as any current feed motion is interrupted and the "Press" output is deleted. After the "Stop neg " signal has switched again to ""High"" and a new ""Start"" edge was output, an interrupted automatic mode is restarted. Without the "Stop neg " signal, no jogging motions are possible in the manual mode. If the input is not to be used, it must be firmly wired to 24 V. If, in the automatic or set-up mode, a product cycle is interrupted by the Stop input, the product cycle is logically continued after the automatic or set-up mode was enabled again. A partial portion of the feed length that was already made is thus always taken into account. An active feed motion is decelerated up to standstill by means of the acceleration value allocated in the parameter P , Part data and installation parameters. In order to facilitate the commissioning, this input does not have any function, if Bit 4 is set in the parameter P , Rollfeed configuration parameter 1. Cycle Stop Neg If the signal disappears from this input, the automatic program is stopped once the cycle is completed. The "Start" input can be used to continue the automatic program. The cycle is deemed as completed, when the feed and the press stroke were realized. If the input is not to be used, it must be firmly wired to 24 V. A falling edge on the input within a cycle always triggers a cycle stop, even if the input is set again in this cycle. Clear Errors With a positive edge on the "Clear errors" input, all pending errors are deleted. In the set-up mode, this input is used to delete the currently remaining portion of the feed length.

55 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 47/171 Inputs / Outputs With a positive edge on the "Clear error" input and a disabled "Automatic" or "Set-up" input, an active automatic or set-up mode can be interrupted at any time. Any remaining portion of a feed motion is thus deleted: Press BDC Press - Single Strokeneg / Continuous Operation This input is used by the press to report when its "Bottom dead center" is reached. The Press BDC signal is only evaluated, if the evaluation of the signal is enabled in the parameter P , Rollfeed configuration parameter 2. The press can be operated either in the continuous operating mode or in the single stroke mode. With the help of this input, the user chooses if the press is stopped after each single stroke or if the press is only stopped, after the production run was achieved, in case of a halt or a failure. In case of feed motions via a master axis coupled to the external press encoder (RMA), the operating mode "Press - continuous operation" is always set internally. Feed Interruptionneg This input serves to interrupt a feed motion. If the signal at this input disappears, an ongoing feed motion is interrupted and the remaining distance is stored. After the signal comes in again, the automatic program is continued at the spot where the signal disappeared without a new start signal being required. Any remaining feed length still to be realized is launched. The material length is not lost through the disappearance of the signal. This input can e.g. be used in order to report to the feed that no material is left in the material pit. If the input is not to be used, it must be firmly wired to 24 V. An active feed motion is decelerated up to standstill by means of the acceleration value allocated in the parameter P , Part data and installation parameters. The feed interruption neg input is only active in the press' operating mode single stroke. Press Before Feed The cycle of a feed consists of a press stroke and the traversing of a feed length. This input is used to choose whether the cycle begins with a press stroke and ends with a feed or vice versa. A switch-over from "Press before Feed" to "Feed before Press" and vice versa is only accepted internally, if the automatic mode is disabled (see "Run" output). Roll Ventilation - Manual Mode Roll Ventilation - Automatic Mode Roll Ventilation Allowed The is used to enable the roll ventilation in the "Manual" operating mode. If this input is set, the output for the ventilation of the feed rolls is switched on. While the roll is opened, however, it can be traversed with the help of the inputs "Jog +" and "Jog-". The enabling of this function is effected in the parameter P , Rollfeed configuration parameter 1. If "Roll ventilation allowed" is released, the "Roll ventilation enabled" output is set by synchronism with the "Roll ventilation - automatic mode" input. The drive is switched to a torque-free state. The torque on the drive is only reactivated again with the "Rolls closed" signal or after a pre-programmed period of time elapsed. By means of this input and the parameter P , Rollfeed configuration parameter 1, the "Roll ventilation - automatic mode" is enabled. If the "Roll ventilation - automatic mode" is set, the "Roll ventilation enabled" output is switched on for the ventilation of the feed rolls and the drive is switched to a torque-free state. As long as the roll ventilation is enabled, metering wheel motions are ignored. Motions addressed by the cycle sequence are not realized.

56 48/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Inputs / Outputs PLC Outputs General Metering Wheel Preset - Actual Production Run of Active Part Preset - Overall Production Run Preset - Overall Length A monitoring is only effected by the feed angle with the function "Press - continuous operation". With this input, it is possible in the automatic mode and for the automatic "Setup" function to switch over the position control from the motor encoder to the metering wheel encoder in order to compensate for any slip between the material and the feed rolls. The enabling of this function is effected in the parameter P , Rollfeed configuration parameter 1. This input serves to preset a value for the output actual production run of the active part in the parameter P , Rollfeed status parameter (list element 3). The value of the actual production run is set to the value defined in the parameter P , Preset - status parameter. This input serves to preset a value for the output overall production run in the parameter P , Rollfeed status parameter (list element 6). The value of the overall production run is set to the value defined in the parameter P , Preset - status parameter. This input serves to preset a value for the output overall length in the parameter P , Rollfeed status parameter (list element 7). The value of the overall length run is set to the value defined in the parameter P , Preset - status parameter. Parameter Bit no. I/O Function Comment P O Roll ventilation enabled P O Manual P O Automatic P O Set-up P O Failure neg P O Run P O Pressing allowed P O Press P O Utilization < 90 % P O Drive ready P O Feed length achieved P O P O Warning Production run setpoint achieved P O Cycle time exceeded P O Reserved P O Motion profile valid Meaning of PLC Outputs Roll Ventilation Enabled Fig.5-2: PLC outputs This output reports it when the "Roll ventilation" is enabled. With the help of this signal, the roll can be opened according to its clock cycle.

57 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 49/171 Inputs / Outputs Manual Automatic Set-Up Failureneg Run Pressing Allowed Press The output output signalizes that the "Manual" operating mode is enabled. Only the jogging function can be used via the inputs "Jog+" and "Jog-" or via the corresponding keys on the VCP. The automatic output signalizes that the "Automatic" operating mode is enabled. The automatic program can be launched. The automatic operation is only quit, if the selection is annulled or if one of the following events occurs: production run achieved cycle stop failure This output reports it when the automatic operating mode "Setup" is enabled. Now, the feed length can be traversed via the inputs "Jog+" and "Jog-". The output is enabled, if no failure is pending. In case of a failure, the output is deleted. The "Run" output is enabled, if the automatic or set-up mode was preselected and the automatic program was launched or the set-up operation is enabled, respectively. If the production run was achieved or if a "halt" or a "cycle stop" were output, this output is deleted. The enabling of the automatic mode requires an edge on the "Start" input. This output is only relevant for the set-up mode. It indicates when the pressing process is allowed in the set-up mode. In case of the "Press - single stroke" mode, this output is cyclically set in the sequence. In case of the "Press - continuous operation" mode, the output remains pending, until the programmed production run is achieved or the automatic processing is interrupted due to an error or the stop input. The interface for the release of the press is a safety device which generates a signal allowing to couple in or couple out the press coupling. Level "H" leads to a couple-in process and the press is running (provided all other logical safety devices on the press work regularly). Level "L" leads to a couple-out process and the press stops. The machine's manufacturer should include this signal in the other "logical safety devices" of the press. Do not use this signal in order to start up the press without the other safety conditions, such as e.g. the "opened safety lock", "emergency stop machine" etc. Utilization < 90 % Drive Ready Feed Length Achieved Production Run Setpoint Achieved The time control of the "Press" signal depends on the setting of the interface in relation to the press and the operating mode. The specific time control of this signal is given in the sequence diagrams in chapter 4 "Functional Description" on page 21. If this output is not set, the feed area is utilized to a capacity of more than 90 %. If the number of press strokes is increased further or if the feed length is programmed to a larger value, this can lead to the fact that the feed cannot be ended in the feed range available. In this case, the "feed monitoring" message would be output. The output reports that the drive is in the operating mode and torque-loaded. The output is set, as soon as the programmed feed length is achieved. If the edge on the "feed angle" input is rising, the output is deleted. If the production run setpoint of the current product is achieved, this output is set and the message "Production run achieved" is generated. After a new "Start", the output is also deleted again.

58 50/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Inputs / Outputs Warning Cycle Time Exceeded Motion Profile Valid Subject to the operating mode and parameter settings, numerous monitoring tasks are carried out. If, during this, a status is detected which still allows the normal operation, but which leads to an error in the further course, the "Warning" output is set to "1". The output serves to monitor the installation. If the preset cycle time is exceeded, the installation is at a standstill without error (see parameter P , Cycle time monitoring). The output signalizes that the calculation of the maximum number of press strokes as well as the parameterization of the defined motion profile is completed and valid for the master axis coupling. Only if this output is set can the automatic mode be launched. Otherwise, an error message is generated (error number 109). The output is always set for the "trapezoidal" traveling profile. 5.2 Input / Output Configuration on the Master Board Card General The two following tables show the default configuration of the I/O signals to the X31 plug and the X32 plug on the master board card. The default configuration is set in the state of delivery and can be restored after any modification that might have been made (see chapter "P , Rollfeed Configuration Parameter 1" on page 127, Bit 9). The default assignment of the I/O signals - if parameterized - is set after a phase switching from the parametrization mode to the operating mode. After the executed command "Load basic parameters", a phase switching must be activated first. Pin I/O Function Parameter Bit no. 1 O Operational relay Rel(a) P O Operational relay Rel(b) P I Free S I E-Stop neg P I Parameter P I Feed angle P I Rolls closed P PWR U ext PWR GND ext Fig.5-3: X31 plug Pin I/O Function Parameter Bit no. 1 - Analog output 1 1) Analog output 2 1) Analog_GND 1) Analog input 1 U+ 1) S Analog input 1 U- 1) S

59 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 51/171 Inputs / Outputs Pin I/O Function Parameter Bit no. 6 I Jog+ 2) 3) P I Jog- 2) 3) P O Roll ventilation enabled P I Roll ventilation - automatic mode 1) 4) P ) These signals are only configured for the drive control device "Indra Drive Advanced". 2) This signal is OR-linked to the corresponding operating key of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. 3) This signal is OR-linked to the corresponding input via P-1391 Bit 14 or Bit 15, respectively. 4) This signal is only effective, after the parameter P , Rollfeed configuration parameter 2 was enabled. The corresponding signal via the input P , Bit 11 is then ineffective. Fig.5-4: X32 plug Meaning of the Other Signals on the X31 Plug Operational Relay E-Stopneg If, in the parameter P , Rollfeed configuration parameter 1, Bit 9 is set, the configuration of the plugs X31 and X32 can be changed according to the preference of the user. Modifications are also maintained after a switch-off or a phase switching. The operational contact acknowledges that the drive control device is operational in order to apply the mains voltage. The operational contact is open, when: the control voltage is not applied to the drive control device 24 V are not applied to the E-Stop input At this input, +24 V must be present in the operating state. If this input is removed, the operational contact is opened and the drive is stopped (see "Optimum standstill procedure"). 5.3 Input / Output Configuration of the Control Communication Parallel Interface The following table gives the default configuration of the I/O signals on the parallel interface (X15 plug). The default configuration for the I/O signals is set in the state of delivery and can be restored after any modification that might have been made (see chapter "P , Rollfeed Configuration Parameter 1" on page 127, Bit 9). The default assignment of the I/O signals - if parameterized - is set after a phase switching from the parametrization mode to the operating mode. After the executed command "Load basic parameters", a phase switching must be activated first. Pin I/O Function Par. Bit Pin I/O Function Par. Bit 1 I Manual neg /Automatic 1) P I Feed interruption neg 3) P I Set-up 1) P I Press before Feed P I Start 1) P I Roll ventilation - manual mode P

60 52/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Inputs / Outputs Pin I/O Function Par. Bit Pin I/O Function Par. Bit 21 I Stop neg 3) P I Roll ventilation - automatic mode P I Cycle stop neg 2) P I Roll ventilation allowed P I Clear errors P I Metering wheel P I Press BDC 4) P I Free 5) I Press - Single stroke neg / Continuous running P I Free 5) PWR GND ext PWR U ext O Manual P O Drive ready P O Automatic P O Free O Set-up P O Feed length achieved P O Failure neg P O Production run setpoint achieved P PWR U ext PWR U ext O Run P O Warning P O Pressing allowed P O Cycle time exceeded P O Press ON P O Free O Utilization < 90 % P O Free PWR U ext ) This signal is OR-linked to the corresponding operating key of the VCP 08, provided the control panel VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. 2) This signal is AND-linked to the "STOP" operating key of the VCP 08, provided the control panel of the VCP 08 is enabled in the parameter P , Rollfeed configuration parameter 2. 3) This signal is only evaluated, if the input is enabled in the parameter P , Rollfeed configuration parameter 1. 4) This signal is only evaluated, if the Press BDC function is enabled in the parameter P , Rollfeed configuration parameter 2. 5) These signals are freely available and can e.g. be used for the safety technology. Fig.5-5: X15 plug, HCC01 If, in the parameter P , Rollfeed configuration parameter 1, Bit 9 is set, the configuration of the Parallel Interface (X15 plug) can be changed according to the preference of the user. Modifications are also maintained after a switch-off or a phase switching Profibus If Profibus is used as control communication, the following default configuration is provided for the cyclic setpoint and actual value data channel in the drive. The default configuration for the cyclic data channels exists is set in the state of delivery and can be restored after any modification that might have been made (see chapter "P , Rollfeed Configuration Parameter 1" on page 127, Bit 9).

61 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 53/171 Inputs / Outputs The default configuration for the cyclic commanded value data channel and actual value data channel - if parameterized - is set after a phase switching from the parametrization mode to the operating mode. After the executed command "Load basic parameters", a phase switching must be activated first. Default Configuration of Setpoint Data Channel In the parameter P , Field bus: configuration list of cyclic setpoint data channel, in the 1st list element, the parameter P , Field bus control word 2nd list element, the parameter P , PLC input %IW1 are parameterized. Thus the 2nd word in the cyclic setpoint channel always corresponds to the parameter P As of the 3rd list element in parameter P , the configuration of the setpoint data channel can be extended according to the preference of the user and is thus freely available for further drive parameters. Setpoint data channel 1st word 2nd word 3rd word P P Acc. to the preference of the user Fig.5-6: Configuration in the setpoint data channel The writing of parameter P , Field bus control word does not have any effects on the "Rollfeed Standard" system solution. The field bus control word is ineffective. Default Configuration of Actual Value Data Channel In the parameter P , Field bus: configuration list of cyclic actual value data channel, in the 1st list element, the parameter P , Field bus status word 2nd list element, the parameter P , PLC output %QW1 are parameterized. Thus the 2nd word in the cyclic actual value channel always corresponds to the parameter P As of the 3rd list element in parameter P , the configuration of the actual value data channel can be extended according to the preference of the user and is thus freely available for further drive parameters. Actual value data channel 1st word 2nd word 3rd word P P Acc. to the preference of the user Fig.5-7: Configuration in the actual value data channel Example of a configuration in a cyclic data channel with IndraWorks:

62 54/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Inputs / Outputs Fig.5-8: Profibus "Process data output" Fig.5-9: Profibus "Process data input" If, in the parameter P , Rollfeed configuration parameter 1, Bit 9 is set, the configuration of the cyclic setpoint and actual value data channel can be changed according to the preference of the user. The only exception to this is parameter, P This is always configured as the 1st word in the setpoint channel. All other modifications are even maintained after a switch-off or a phase switching.

63 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 55/171 Library for Variable I/O Connections 6 Library for Variable I/O Connections 6.1 Background In certain applications, users wish to be able to invidually adjust the default configuration of the inputs and outputs of the Rollfeed Standard system solution. At the same time, it should be possible that users realize a variable connection of inputs and outputs. At the same time, it should be possible that users realize a variable connection of inputs and outputs with the output of user-specific diagnostic messages. 6.2 Description General The Rollfeed Standard system solution offers now the possibility to both individually adjust the default configuration of inputs and outputs as well as to implement one's own variable connections of inputs and outputs. Furthermore, user-specific diagnostic messages can be generated and displayed. The generation of the input and output image is swapped out to freely accessible programs. These programs can be extended and adjusted by the user by means of the Rexroth Indralogic programming system. The configuration and operation is carried out with the Engineering tool "IndraWorks MLD". The "IndraLogic " programming tool is embedded in "IndraWorks MLD". The documentation entitled DOK-INDRV*-MLD-**VRS**-AW02- EN-P describes the specific functionalities of Rexroth IndraMotion MLD and explains the embedding of the PLC into the drive as well the technical possibilities and functions Provision Library, Programs and Templates The provision is realized as IndraWorks project archive "Rollfeed_Standard_1_04VRS_Template.zip" or "Rollfeed_Standard_2-_04VRS_Template.zip" on the MMC, in the ".\User" directory. This archive includes an IndraLogic template program into which the required library "Rollfeed_Standard_04VRS.lib" is integrated. Said template program also contains, unter the ".\Rollfeed" folder, the two following programs (see fig. 6-2 "I/O programs in the state of delivery" on page 57): HandleRollfeedInputSignals (reading of inputs) HandleRollfeedOutputSignals (writing of outputs) The user-defined extensions have to be integrated in these programs. They implement the required interface for the I/O connection of the system solution. The default connections of the system solution are set in its state of delivery. The programs are written in the Function Block Diagram (FBD) programming language. The names of the programs called "HandleRollfeedInputSignals" and "HandleRollfeedOutputSignals" must not be modified.

64 56/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections In the "\Rollfeed" folder, an additional subfolder "\Original" exists. This subfolder contains the original programs for the variable I/O connection in the state of delivery. The ".\Original" folder is a back-up directory. The individual programs make available the default connections of the system solution in the following programming languages: HandleRollfeedInputSignalsFBD (FBD - Function Block Diagram) HandleRollfeedOutputSignalsFBD (FBD - Function Block Diagram) HandleRollfeedInputSignalsLD (LD - Ladder Diagram) HandleRollfeedOutputSignalsLD (LD - Ladder Diagram) HandleRollfeedInputSignalsST (ST Structured Text) HandleRollfeedOutputSignalsST (ST Structured Text) Fig.6-1: Library manager in the state of delivery

65 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 57/171 Library for Variable I/O Connections Task Configuration Fig.6-2: I/O programs in the state of delivery In addition to the template program, the task configuration of the system solution is alsow set in the state of delivery. The following three tasks are configured with their respective program calls: MOTION_TASK MOTION_PRG PARA_TASK PARA_PRG VISU_TASK VISU_PRG Fig.6-3: Configuration of the motion task for RFS 1 in the state of delivery

66 58/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections Fig.6-4: Configuration of the motion task for RFS 2 in the state of delivery Fig.6-5: Configuration of the parameter task in the state of delivery If the task configuration is modified by the user, the functionality of the system solution might not be guaranteed any more. For this reason, the task configuration must only be modified, after the Bosch Rexroth customer service was contacted.

67 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 59/171 Library for Variable I/O Connections Fig.6-6: Configuration of the visualization task in the state of delivery Interconnection of External and Internal Inputs and Outputs Proces Input and Output Image External Inputs and Outputs Before the program code is called in the task cycle, the switching states at the inputs are read and stored in the "Process input image" (PII). This information is then fed to the system solution where it is processed. The states of the "Process output image" (POI) are transferred to the physical outputs at the end of the task, after the program code was processed. The system solution (PLC) can use the process image image and the process output image in order to access the analog and digital inputs / outputs of the drive. The following parameters can be used as input and output image in relation to the I/O channel (process image): Addr. Ident. no. Format Parameter name 0 P bytes PLC input WORD0 AT %IB0 2 P bytes PLC input WORD1 AT %IB2 4 P bytes PLC input WORD2 AT %IB4 6 P bytes PLC input WORD3 AT %IB6 14 P bytes PLC input WORD7 AT %IB14 16 P bytes PLC input WORD8 AT %IB16 18 P bytes PLC input WORD9 AT %IB18 20 P bytes PLC input WORD10 AT %IB20 22 P bytes PLC input WORD11 AT %IB22 38 P bytes PLC input WORD19 AT %IB38

68 60/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections Addr. Ident. no. Format Parameter name 100 P bytes PLC input WORD25 AT %IB P bytes PLC input WORD26 AT %IB P bytes PLC input WORD32 AT %IB128 Fig.6-7: Process input image (PII) Addr. Ident. no. Format Parameter name 0 P bytes PLC output WORD0 AT %IB0 2 P bytes PLC output WORD1 AT %IB2 4 P bytes PLC output WORD2 AT %IB4 6 P bytes PLC output WORD3 AT %IB6 14 P bytes PLC output WORD7 AT %IB14 16 P bytes PLC output WORD8 AT %IB16 18 P bytes PLC output WORD9 AT %IB18 20 P bytes PLC output WORD10 AT %IB20 22 P bytes PLC output WORD11 AT %IB22 38 P bytes PLC output WORD19 AT %IB38 Fig.6-8: Process output image (POI) In the default configuration, the system solution uses the following input and output words: P : PLC input WORD0 AT %IB0 P : PLC input WORD0 AT %IB2 P : PLC input WORD0 AT %IB4 P : PLC input WORD0 AT %IB6 P : PLC output WORD0 AT %IB0 P : PLC output WORD0 AT %IB2 Internal Inputs and Outputs The access to the input and output words is made in the PLC program via the global variables contained in the library "Rollfeed_Standard_04VRS.lib": wp_0_1390_i wp_0_1391_i wp_0_1392_i wp_0_1393_i wp_0_1410_q wp_0_1411_q These variables are used to interconnect external inputs and outputs with internal inputs and outputs. The following global structure variables are available for internal inputs and outputs strfsinputs_gb strfsoutputs_gb.

69 Functional Description Rexroth IndraMotion Electric Drives With the help of the internal inputs and outputs of structure variables, the functionality of the system solution, such as e.g. the manual mode or the automatic mode, must be enabled or disabled. Only if all internal inputs and outputs are used is the full functional scope of the system solution applied. Composition of the structure variable "strfsinputs_gb": Bosch Rexroth AG 61/171 Library for Variable I/O Connections Fig.6-9: Structure of internal inputs Composition of the structure variable "strfsoutputs_gb":

70 62/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections Fig.6-10: Structure of internal outputs Fig.6-11: Example for the interconnection of external and internal inputs in the FBD programming language

71 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 63/171 Library for Variable I/O Connections Fig.6-12: Example for the interconnection of external and internal outputs in the FUP programming language For the free I/O programming, the inputs (Bits) of the following PLC inputs and outputs words (global PLC variables) can also be used without any limitations, since they are provided, but not used, by the system solution. The process image of these inputs and outputs (PII, POI) is made available automatically by the system solution via the corresponding PLC variables. Ident. no. PLC variable Free inputs (Bits) Comment P wp_0_1390_i 6 to 15 P wp_0_1391_i 14 and 15 Only for Parallel Interface control communication P wp_0_1392_i All except 11 P wp_0_1393_i 3 to 15 Fig.6-13: Free PLC inputs Ident. no. PLC variable Free inputs (Bits) Comment P wp_0_1410_q 1 to 15 P wp_0_1411_q 14 and 15 Fig.6-14: Free PLC outputs Output of User-Specific Diagnostic Messages If it is necessary to access further analog and digital inputs / outputs of the drive in the PLC program, inputs and outputs must be specifically created and configured for this (see documentation DOK- INDRV*-MLD-**VRS**-AW02-EN-P, Chapter 5.2 "Data channels of the IndraMotion MLD"). Presetting for User-Specific Diagnostic Messages User-specific diagnostic messages can be defined with the help of the Rexroth IndraLogic programming system through editing the "strollfeeduserdiag_gb" global variable's string declaration. This global variable "strollfeeduserdiag_gb" is part of the provided IndraLogic project and freely

72 64/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections accessible for the user. It is stored in the "global variables" folder, in the "Global_Variables_User" object (see Ressources tab). The "strollfeeduserdiag_gb" variable is a structure of the ROLLFEED_USER_DIAGNOSIS_DATA type. This structure is embedded in the protected library "Rollfeed_Standard_04VRS.lib" and cannot be modified by the user. This structure is used in order to define the user diagnostic. The maximum text length for individual user diagnostics amounts to 60 characters and cannot be changed. For every single language of the system solution that is supported, 16 different user diagnostics are created in the default state. The number of user diagnostics for every language is defined via the constant "usimax_nbr_of_rollfeed_user_diag_text". This constant is also in the freely accessible area (Ressources tab - "Global Variables" folder - "Globale-_Variablen_User" object), i.e. the user can define themselves the number of user-specific diagnostic messages. The language for the user diagnostics is set automatically on the basis the respective language of the Rollfeed system solution (via VCP or S ). The languages supported are identical with those of the system solution (DE, EN, FR, IT, SP). If the constant "usimax_nbr_of_rollfeed_user_- DIAG_TEXT" is increased, the string declaration of the variable "strollfeeduserdiag_gb" must be complemented accordingly by the other diagnostic texts. Output of User-Specific Diagnostic Messages Fig.6-15: Presetting for user diagnostics The display of the user diagnostics is enabled via the function "SetRollfeedUserDiagnosisText". It is provided bz the "Rollfeed_Standard_04VRS.lib" library. The function must be equipped with an index which allows to select the desired user diagnostic. Via said index, the reference is made to the user diagnostics in the global var

73 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 65/171 iable "strollfeeduserdiag_gb". If a valid index is transferred to the function, the desired user diagnostic is attached to the existing Rollfeed system diagnostic, separated by means of the " " symbol. If the index is invalid, only the Rollfeed system diagnostic is indicated. It is thus also possible to switch off the display of the user diagnostic via this index (index = 0). The feedback value of the function is TRUE for a valid index or FALSE for an invalid index. The valid index range is between "1" and the value of the constant "usimax_nbr_of_rollfeed_user_diag_text". Library for Variable I/O Connections Interface Variables of the Function "SetRollfeedUserDiagnosisText" Range Name Data type Description VAR_INPUT UserDiagIdx USINT Here, the index is transferred to the desired user diagnostic (cf. "strollfeeduserdiag_gb") FALSE VAR_OUTPUT SetRollfeed-UserDiagnosisText BOOL The index is out of the valid range, i.e. no user diagnostic is indicated. TRUE The index is within the valid range, i.e. the user diagnostic is indicated. Fig.6-16: Interface variable function: SetRollfeedUserDiagnosisText The resulting diagnostic is shown in the status line on the VCO and stored in acoordance with the parameter P-01387, Rollfeed system diagnostic. The active index of the user diagnostic is also made available in the parameter P , Rollfeed status parameter (Element 16). Example: Active System Diagnostic "No Cycle Start" Active User Diagnostic "DE: Default user diagnosis text 01" "No cycle start DE: Default user diagnosis text 01" The call of the "SetRollfeedUserDiagnosisText" function is, by way of example, included in the open programs of the I/O images (HandleRollfeedInputSignals, HandleRollfeedOutputSignals), but not enabled (comment in case of ST, jump in case of FDB, LD)

74 66/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections Fig.6-17: Integration of the call of the function "SetRollfeedUserDiagnosisText" into the program "HandleRollfeedInputSignals" (FBD) Selection of the Desired Programming Language Subject to the desired programming language, the respective programs in the ".\Original" subfolder can be used as template. If the programming of the I/O connections is to be made e.g. in the ladder diagram, the programs "ReadRollfeedInputSignals" and "WriteRollfeedOutputSignals" must be deleted first.

75 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 67/171 Library for Variable I/O Connections Fig.6-18: Deletion of I/O programs Afterwards, the "ReadRollfeedInputSignalsLD" or "WriteRollfeedOutput SignalsLD" program must be copied into the "ReadRollfeedInputSignals" or "WriteRollfeedOutputSignals" program.

76 68/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections Fig.6-19: Copying of I/O programs Notes on Programming Admissible Changes The names of the programs called "HandleRollfeedInputSignals" and "HandleRollfeedOutputSignals" must not be modified. In order to ensure the complete functionality of the Rollfeed Standard system solution, the following framework conditions have to be complied with for the implementation of the user-defined functionality. Among the changes that can be made by the user are: allocation of PLC inputs to internal inputs in the "ReadRollfeedInputSignals" program. interconnection of additional PLC inputs with internal inputs in the "Read RollfeedInputSignals" program. additional PLC logic for the processing of PLC inputs and control in the "ReadRollfeedInputSignals" program. allocation of internal outputs to PLC outputs in the "WriteRollfeedOutput Signals" program. ouput of internal outputs to additional PLC outputs in the "WriteRollfeedOutputSignals" program.

77 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 69/171 Library for Variable I/O Connections Inadmissible Changes additional PLC logic for the processing of internal outputs for the control of PLC outputs in the "WriteRollfeedOutputSignals" program. Among the inadmissible changes that can be made by the user are: modifications to the task configuration (task names with attached program calls and task properties concerning priority and type). implementation of program code for the motion control of feed axes (e.g. axis control via PLCopen Motion blocks). The names of the programs "HandleRollfeedInputSignals" and "HandleRollfeedOutputSignals" must not be changed. The name and type of the variable "strollfeeduserdiag_gb" must not be changed. If inadmissible changes are made by the user, the regular functionality of the Rollfeed Standard system solution is no longer guaranteed. In case of multiple calls of the "SetRollfeedUserDiagnosisText" function within the open programs "HandleRollfeedInputSignals" or "HandleRollfeedOutput Signals", the respectively last function called determines the active user diagnostic. Code modifications or amendments made by the user within the template program affect the runtime behavior of the system solution. It might be necessary to increase the cycle times (interval time) of the cyclic task (e.g. MOTION_TASK). Thus, the response time of the system solution is reduced accordingly Instructions on the Use of the Variable I/O Connection Below, the steps are described which have to be taked in order to be able to use the variable I/O connection with the Rollfeed Standard system solution. 1. Switch off the drive and take out the MMC card (MultiMediaCard). 2. Copy the file "Rollfeed_Standard_1_04VRS_Template.zip" or "Rollfeed_Standard_2_04VRS_Template.zip" from the folder ".\User" of the MMC (MultiMediaCard) by means of the CARD READER to the commissioning PC.

78 70/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections Fig.6-20: Copy the archive file on the PC 3. Launch the commissioning tool "IndraWorks Engineering". Fig.6-21: Launch IndraWorks engineering 4. Use the menu "Restore\Project... " in IndraWorks in order to restore the archive file "Rollfeed_Standard_1_04VRS_Template.zip" or "Rollfeed_Standard_2_04VRS_Template.zip".

79 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 71/171 Library for Variable I/O Connections Fig.6-22: Restoration of a project 5. In the "Selection of Restoration Type" dialog, select the option "restoration of file system". Fig.6-23: Selection of restoration type 6. In the "Selection of Archive to be Restored" dialog, select the archive "Rollfeed_Standard_04VRS_-Template.zip" copied from the MMC to the PC.

80 72/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections Fig.6-24: Selection of the archive 7. In the "Selection of Target Directory" menu, select the target directory on the PC, into which the project "Rollfeed_Standard_04VRS_-Template.zip" is to be unzipped. Fig.6-25: Selection of the target directory on the PC 8. Confirm the selection made in the "Verification of User Settings" menu by means of the "Finish" button.

81 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 73/171 Library for Variable I/O Connections Fig.6-26: Confirmation of the selection After the archive "Rollfeed_Standard_1_04VRS_Template.zip" or "Rollfeed_Standard_2_04VRS_Template.zip" was successfully restored, the following "Summary" dialog appears. 9. In this dialog, activate the option "Open project when wizard is quit". Fig.6-27: Summary 10. Then press the "Close" button.

82 74/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections The project for the system solution is now opened. After the "Logic" node is activated and the "Open" menu item is selected - by means of the right mouse button, "IndraLogic" is opened. Fig.6-28: Opening of IndraLogic 11. Now, "IndraLogic" can be used to make the required modifications and amendments in the programs "HandleRollfeedInputSignals" and "HandleRollfeedOutputSignals". If the required modifications are realized, the new project can be loaded into the drive.

83 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 75/171 Library for Variable I/O Connections Fig.6-29: Download of the IndraLogic project 12. After the successful download of the IndraLogic project, it has to be launched. Fig.6-30: Launch of the IndraLogic project

84 76/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections 13. If, then, the modified functions of the project were verified and tested successfully, a boot project must be created. Thus, the newly implemented functionality of the project is also maintained, if the drive is switched off and on again. Fig.6-31: Creation of the boot project Example for the Use of the Variable I/O Connection Framework Conditions Task Configuration of External and Internal Inputs The system solution is used with the Parallel Interface control communication. The implementation is made in the ST (Structured Text) programming language. The "Roll ventilation - manual mode" function is not required. The automatic mode must only be activated, if 1. material is available and 2. the straightener is operational. Those two conditions must be queried via two inputs and the "Manualneg/Automatic" input (P , Bit 0) of the system solution must be activated as group status message. If one of the conditions is not met, a corresponding diagnostic must be indicated. The "Material available" input is to be read in via the "Roll ventilation - manual mode" input (P , Bit 10), since the function "Roll ventilation - manual mode" is not required. The signal must be wired to Pin 6 of the X15 plug, HCC01. The "Straighter operational" input is to be read in via the free Pin 8 of the X15 plug, HCC01, and to be wired accordingly. This signal is internally imaged into the free Bit 14 of parameter "P , PLC input WORD1 AT % IB2". The configuration is made in IndraWorks in the Signal Control Word dialog. (IndraWorks <Right mouse> button on the axiscontrol communication Signal control word)

85 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 77/171 Library for Variable I/O Connections Fig.6-32: Configuration of the input setting in the signal control word The allocations of the external inputs wp_0_1391_i.0 to the internal input "strfsinputs_gb.bautomatic" wp_0_1391_i.10 to the internal input "strfsinputs_gb.bliftrolls-manual" wp_0_1391_i.14 to the internal input "strfsinputs_gb. bjogfor-ward_2" in the "HandleRollfeedInputSignals" program are deleted or commented out. Presetting for User Diagnostics Fig.6-33: Disabling of the default connection with internal inputs The two user-specific diagnostic messages "Material not available" "Straightener not operational" are stipulated through editing the "strollfeeduserdiag_gb" global variable's string declaration. (Ressources tab - "Global Variables" folder - "Global_Variables_User" object)

86 78/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Library for Variable I/O Connections Implementation of the Status and Diagnostic Logic Fig.6-34: Presetting for user diagnostics In the "HandleRollfeedInputSignals" program, the required status logic is implemented with the help of variables for the inputs and the desired user diagnostic is output via the call of the function "SetRollfeedUserDiagnosis Text". Furthermore, the external inputs "Material available" (P , Bit 10) and "Straightener operational" (P , Bit 14) are AND-linked to the "Automatic" input (P , Bit 0) and allocated to the internal input "strfsinputs_gb.bautomatic". Amended code extract from the "HandleRollfeedInput-Signal" program: (*$ Read input signals of material and straightener $*) bmaterialready: bstraightenerready: = wp_0_1391_i.10; = wp_0_1391_i.14; (*$ Set Automatic mode depending on - Material ready $*) (*$ - Straightener ready $*) strfsinputs_gb.bautomatic: = bmaterialready AND bstraightenerready AND wp_0_1391_i.0 (*$ Set the user diagnosis text by calling function "SetRollfeedUser-DiagnosisText". The shown user diagnostic text can be edited in the "strollfeeduserdiag_gb" variable for each supported language (see "Ressources - Global_Variables_User"). With "UserDiagIdx" = 0, the user diagnostic is switched off. Set index between 1 and "usimax_nbr_of_rollfeed_user_diag_text" TO show the required user diagnosis text. $*) IF NOT bmaterialready THEN usiuserdiagidx: = 1; (* Material not ready *) ELSIF NOT

87 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 79/171 Library for Variable I/O Connections bstraightenerready THEN usiuserdiagidx: = 2; (* Straightener not ready *) ELSE usiuserdiagidx: = 0; (* no user diagnosis *) END_IF (* set user diagnosis text *) bfuncret: = SetRollfeedUserDiagnosisText(usiUserDiagIdx); Fig.6-35: Implementation of the status and diagnostic logic

88 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description

89 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 81/171 HMI 7 HMI 7.1 General The small operating terminal VCP 08 is a machine-operating terminal which can be used as input and operating unit for the system solution "IndraMotion for Metal Forming Rollfeed Standard". Fig.7-1: Operating terminal VCP 08 Password protection The VCP08 is provided with a 3 level password administration. It is possible to protect certain VCP08 screens using a password. The password protection is not active when shipped. The user administration is created as follows: User password (When shipped: "1186") Service password (When shipped: " ") Master password (When shipped: "571186") The password ID (numerical) corresponds to the numerical keys. USER is for example entered as 1186.

90 82/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI 7.2 VCP08 Key Description General The protected screens are marked in the overview (see chapter 7.4 "Overview" on page 87 and the following). To activate or deactivate the password protection or to change the password, the parameter menu of the VCP has to be used. It can be accessed via the main menu or by pressing F5. Press "F3 Tools" and then "F2- Change PWD". To carry out any actions (activate, deactivate and change) regarding the password protection require the master password. With regard to the password protection, the following boundary conditions have to be considered: After downloading the VCP application files for the first time, the passwords are reset to their initial state (as delivered). When assigning the same passwords to different user levels, only the lowest user level is activated. If only the Enter key is pressed during the password assignment in the corresponding input field, the password is not changed. By means of the master password, the passwords can be reset any time to their initial state (delivery state) in the screen for the password assignment. The master password is provided by the Bosch Rexroth customer support. The keyboard includes all keys required to enter data and to control the system. The LEDs of the different keys signalize to the machine operator which status the system is currently in. The key elements are situated under an embossed polyester foil resisting environmental influences. The inscription of the 2 upper operating key rows below the display as well as the operating key row right to the display can be changed. This can be done by means of two slide-in strips that can be inserted in from the right or upper side, respectively. For this system, the following two slide-in strips are included in the delivery. Fig.7-2: Lateral slide-in strip

91 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 83/171 HMI Fig.7-3: Lower slide-in strip If the VCP 05 is used, the operating keys JOG-, SETUP, AUTO, START, STOPP, JOG+, CLEAR, F6, and F7 are not available Display Menu Keys until Control of the display screens F1... F7 are function keys that are used to select menus or different functions. If it is possible to use a function key in order to display a further screen or to enable a stored function, the related LED is constantly on. Back to the first display level The Cursor home key brings the user back to the previous display screen Operating Keys If an editing field exists in the current screen menu and if the editing mode is enabled (the LED "Data release" is On), the editing mode must first be switched off with a push on the "Data release" key, before it is possible to switch over to the previous display menu. If, in parameter P , Rollfeed configuration parameter 2, Bit 0 or Bit 1 is set, the operating keys on the VCP 08 are active. They allow to traverse the axis in the manual mode and to switch between operating modes. During this process, the keys are checked for cable break.

92 84/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI If the connection between the IndraDrive control unit and the VCP 08 is interrupted, e.g. due to the removal of the cable, this is recognized. If the monitoring time (about 1.5 seconds) is exceeded, a VCP communication error is generated and indicated. Any axis motion is immediately stopped, if a connection error was detected. The connection test, however, is only active, if the operating keys of the VCP 08 have been enabled in parameter P , Rollfeed configuration parameter 2 (see chapter "P , Rollfeed Configuration Parameter 2" on page 130, Bit 0 and Bit 1). Jogging in negative direction (in the direction of the conveyor entry) for the "Manual" operating mode. The motion starts with a push on the JOG- key and stops, if said key is released again. In the automatic mode, with the set-up function being enabled, the feed motion is only carried out with the help of the Jog keys within the programmed feed length. Jogging in positive direction (in the production direction) for the "Manual" operating mode. The motion is starts with a push on the JOG+ key and stops, if said key is released again. In the automatic mode, with the set-up function being enabled, the feed motion is only carried out with the help of the JOG keys within the programmed feed length. Enabling of the automatic mode. A push on the AUTO enables the automatic mode. The LED is ON. If the key is pushed again, the automatic mode is disabled again and the system switches back into the manual mode. The LED is OFF. A switch-over from the "Automatic" operating mode is only possible, if the product was finished correctly, or must be acknowledged specifically with the CLEAR key. If the LED is blinking, the automatic mode is still enabled internally, however, the input is no longer present. If the system runs in the "Automatic" operating mode, a push on the START key triggers the launch of the program. The LED stays ON, as long as the "Start" input is present. Triggers a cycle stop of the installation. If the key is set, the LED is ON. If the LED is blinking, the automatic mode is either disabled or the "Cycle stop" input is not set via the control communication.

93 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 85/171 HMI The STOP key is zero-active. Enabling of the set-up mode. This keys is used to switch over to the set-up function, provided the installation runs in the automatic mode. The blinking LED shows that the set-up mode was selected, but not yet enabled. The set-up mode becomes enabled, when the start command is given. The LED is constantly ON as long as the set-up mode is internally active. The CLEAR key deletes all pending error messages. With a positive edge on the CLEAR key and a disabled "Automatic" input, the automatic mode can be interrupted at any time. If VCP 05 is used, the CLEAR button is not available Editing Keys In order to enable or disable, respectively, the editing mode, the special key "Data release" must be pushed. Only if the status LED "Data release" is ON can data be entered with the help of the editing keys. until The alphanumerical keyboard (Keys 0...9) serves to enter product data. The Decimal point key is used to change data in the editor.

94 86/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI The Plus key is used to change data in the editor. If, during the parameter input in the "System parameter" menu, the cursor is on the parameter number, a push on the Plus key increases the consecutive parameter number by one. In the "Tools" menu, the contrast of the display can be set via this key. The Minus key is used to change data in the editor. If, during the parameter input in the "System parameter" menu, the cursor is on the parameter number, a push on the Minus key decreases the consecutive parameter number by one. In the "Tools" menu, the contrast of the display can be set via this key Navigation Keys In the editing mode, the Cursor-left key positions the cursor one step further to the left. In the editing mode, the Cursor-right key positions the cursor one step further to the right. In the editing mode, the Cursor-up key positions the cursor one editing field upwards. In the editing mode, the Cursor-down key positions the cursor one editing field downwards Special Keys As long as the Help key is pressed, different information is displayed. Not used.

95 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 87/171 HMI The Data acceptance key serves to complete the data input. Data inputs are only accepted through a push on this keys, which permanently stores them. A switch between menus does not trigger the saving of data. With a push on the Data release key, the user can access the editing mode. The status LED "Data release" is ON. If the key is activated again, the editing mode is quit again. The LED is OFF. The Delete key removes, in the editor, the sign below the cursor. With the help of the Scroll key, it is possible to switch between the screens of a display menu. 7.3 Brief Description The display has a resolution of 320 x 240 pixel. It informs the user about the current status of the system and displays diagnostic messages in clear text. The keyboard comprises all keys required for the data input (parameters, feed length, product counter etc.) and for the control (switch-over of operating states, start, stop etc.) of the system. The LEDs of the different keys signalize to the machine operator the current status and the selected operating mode of the Rollfeed Standard system. In the current release version, the system solution supports the German and the English language for the VCP. The French, Spanish and Italian versions are currently being developed and will be provided in a later release version. 7.4 Overview General The given boxes show the screen displays. The menu control is ensured by the function keys F1 to F5 and MAIN. The function key MAIN is realized as global key and thus allows to directly return to the main menu from any submenu.

96 88/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Main Menu Submenus Fig.7-4: Overview of main menu Fig.7-5: Part data submenu Fig.7-6: Feed data submenu Fig.7-7: Diagnostic submenu

97 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 89/171 HMI Status Line Fig.7-8: Parameter submenu The topmost line of the VCP always shows the status messages. The status line cyclically indicates the current system status as clear text. In addition to this, the current time and date are displayed. The system status can be indicated in two different formats. 1. A pure text message as to the current status, such as "A0050, Parameterization level 1 active". 2. X: STATUS MESSAGE, where X is the indicator of the current operating mode and where the STATUS MESSAGE gives information about the system. A: Explanation: AUTOMATIC MODE S: SET-UP MODE S E: The SET-UP MODE is preselected, but not yet enabled. Via the "Set-up" input, the set-up mode can be disabled again. M: MANUAL MODE Example: A Feed motion The system runs in the automatic mode. A feed motion is currently active. Fig.7-9: Status line 7.5 Start Menu The start image appears for about 5 seconds, after the operating device is switched on. The time is firmly set; the sequence is not to be changed. If, during the display of the start image, the Data acceptance key is pushed, the display changes to the set-up menu. In the set-up menu, the "+/-" keys can be used to

98 90/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI select the desired language setting. A new activation of the Data acceptance or Data release key relaunches the VCP. Fig.7-10: Start menu Fig.7-11: Set-up menu 7.6 Main Menu Fig.7-12: Main menu The information given in the main menu comprises: number of the active part

99 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 91/171 HMI length of the active part in mm or inch velocity of the active part in percent current number of strokes of the installation in strokes per minute current utilization of the feed angle in percent current installation velocity [in m/min or inch/min] It is not possible to edit data on this page. If the operator pushes the HELP key, the following display is shown: Fig.7-13: Help display in the main menu 7.7 Submenu "Part Data" (F1) General Fig.7-14: Display Part data" trapeze/triangle

100 92/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Fig.7-15: Display "Part data" master axis coupling Depending on the traveling profile selected, the corresponding part data dialog is displayed. In both the display menus, the operator chooses the active Part number and can enter the following part data for the parts to be processed. In case of the traveling profile/trapeze 7 triangle, there are the following part data: length mm or inch velocity in % acceleration in % production run setpoint The data of the currently active part are only activated for the next production cycle. In case for the master axis coupled traveling profile, there are the following part data: length mm or inch production run setpoint start angle, stop angle and tolerance window in [ ] The part length, the start angle, the stop angle and the tolerance window can only be edited if a cycle stop or the manual mode is activated. During the calculation of the internal motion profile, an exclamation mark is displayed behind the editing field to enter the length. As long as the exclamation mark appears, the automatic mode cannot be started or an error is generated after the automatic start. The exclamation mark is created depending on the output signal "Motion profile valid" (P , bit 15). If, for the production run setpoint, a value higher than "0" is entered, the cycle is repeated until the production run is greater than or equal to the specified quantity. Then, the cycle is stopped and the output "Production run setpoint achieved" (X15/16, P ) is set. The entry of the quantity "0" specifies a continuous operation status. In this case, the cycle is continued, the actual production run counter going on. The operator can change the production run setpoint at any time during the run. If the cursor is positioned on the production run, a push on the "+" key adds a part to a quantity and a push on the "-" key deducts a part from the quantity. If the F1 key is pushed, a confirmation menu for the deletion of the active part's actual production run counter is displayed. If the F2 key is pushed, a confirmation menu for the setting of default values for the part data is displayed. Via the Micro-Adjust, the feed length can be corrected. The value is added to any feed length and eminently written into a parameter during editing. It is ap

101 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 93/171 HMI plicable to all products. The keys F3 and F4 increase or decrease, respectively, the Micro-Adjust by the parameterized increment. Both the Micro-Adjust value as well as the increment can be modified in the display menu "Feed parameter 1" at any time. The keys F6 and F7 are used to scroll up or down, respectively, in the part data trapeze/triangle table. If the operator pushes the HELP key, the following display is shown: Fig.7-16: Help display in the submenu "Part data" All product data are stored on the MultiMediaCard (MMC) Submenu "Preset - Actual Production Run" (F1) Fig.7-17: Submenu "Preset - actual production run" The F2 key serves to preset the actual production run of the active part to the predefined preset value. The preset value itself can be stipulated according to the preference of the user. If the operator pushes the HELP key, the following display is shown:

102 94/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Fig.7-18: Submenu "Load Default Part Data" (F2) Help display in the submenu "Preset - actual production run" Fig.7-19: Submenu "Load default part data" In this display menu, the parameterized part data can be reset to their default values with a push on the F1 key. For the part numbers 1-99, the default values are set for the length, velocity, acceleration and the production run setpoint. In the status output, the current status as well as an acknowledgement message is indicated after the enabling. Due to the loading of default values for the part data, current settings made to the part data are lost. To switch over to a different display during an active loading process is not possible. During the loading process, a display menu appears featuring a status line and the progress display.

103 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 95/171 HMI Fig.7-20: Submenu "Load status of default part data" If the operator pushes the HELP key, the following display is shown: Fig.7-21: Help display in the submenu "Load default part data" 7.8 Submenu "Feed Data" (F2) General Fig.7-22: Submenu "Feed data" The "Feed data" submenu informs the user about the overall length fed and the overall production run (cycles). These data are even maintained in case of a switch-off and subsequent switch-on. At the end of a cycle, the counters are updated. Partial feeds are not counted. Furthermore, the current press' operating mode (Press before Feed or Feed before Press) as well as the selected operating mode are displayed.

104 96/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI The operating mode can either be a Continuous Operation or Single Stroke. It is possible to switch from the continuous operation mode to the single stroke mode with the help of the F2 key and vice versa. If the continuous operation mode is selected, the press is not switched off after a press stroke was realized. In this case, the press is only switched off, if a counter was achieved, an error occurred or a stop signal was output. In case of the "Single stroke" operating mode, the press is switched on and off at the end or shortly before the end of each feed cycle. In addition to this, this display also indicates the current positions of the motor encoder and the metering wheel encoder. If the overall length and the overall production run are to be deleted, the F1 key can be used in order to switch over to the submenu "Preset - overall length / overall production run". With the help of the keys F3 and F4, the user can access the menus for the display and configuration of the feed parameters or the feed configuration. If the operator pushes the HELP key, the following display is shown: Fig.7-23: Help display in the submenu "Feed data" Submenu "Preset - Overall Length / Overall Production Run" (F1) Fig.7-24: Display in the submenu "Preset - overall length / overall production run"

105 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 97/171 HMI The F2 or F3 key can be used to preset the overall length or the overall production run to the respectively defined preset value. The preset value itself can be stipulated according to the preference of the user. If the operator pushes the HELP key, the following display is shown: Fig.7-25: Submenu "Feed Parameters" (F3) Help display in the submenu "Preset - length / production run" In the displays "Feed parameter 1"... "Feed parameter 3", the current values of the system-specific parameters are shown. If the editing mode is enabled, the parameters can be edited. With the Data acceptance key, the parameters are directly stored. The meaning and effect of the individual parameters are described in chapter 9 "Parameter" on page 123. It is possible to switch between the displays "Feed parameter 1"... "Feed parameter 3" with the help of the Scroll keys. Fig.7-26: Display "Feed parameter 1"

106 98/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Fig.7-27: Display "Feed parameter 2" Fig.7-28: Display "Feed parameter 3" The following parameters are indicated in the menus: P , Manual velocity P , Set-up velocity P , Bipolar velocity limit P , Cycle time monitoring P , Micro-Adjust value Micro-Adjust increment P , Delay time closing rolls P , Number of press strokes P , Standstill time of press P (Element 403), Switch-on angle of the external press encoder or feed area start in case of master axis coupling with external press encoder P (Element 404), Switch-off angle of the external press encoder or feed area end in case of master axis coupling with external press encoder P (Element 407), Negative velocity limit for external press encoder P (Element 408), maximum press strokes (machine constant) If the operator pushes the HELP key, the following display is shown:

107 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 99/171 HMI Submenu "Feed Configuration" (F4) Fig.7-29: Help display in the submenu "Feed parameters 1-3" In the displays ""Feed configuration 1"... "Feed configuration 4", the current values of the system-specific configuration are shown. If the editing mode is enabled, the configuration can be edited with the help of the keys "+" and "-". With the Data acceptance key, the settings are directly stored. The meaning and effect of the individual configuration settings are described in chapter 9 "Parameter" on page 123 (cf. parameters P and P ). It is possible to switch between the displays "Feed configuration 1"... "Feed configuration 4" with the help of the Scroll keys. Fig.7-30: Display in the menu "Feed configuration 1"

108 100/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Fig.7-31: Display in the menu "Feed configuration 2" Fig.7-32: Display in the menu "Feed configuration 3" Fig.7-33: Display in the menu "Feed configuration 4" The following configurations are indicated in the menus: Selection of press / punch (P , Bit 0) Override (P , Bit 1) Metering wheel (P , Bit 2) Electrical / mechanical ventilation (P , Bit 3) Input stop neg / Feed interruption neg enabled (P , Bit 4) Unit for translatory scaling (P , Bit 5) Feed monitoring (P , Bit 6) Cycle time monitoring (P , Bit 7) Analog output of mean path velocity (P , Bit 8)

109 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 101/171 HMI Automatic control panel VCP08 (P , Bit 0) Automatic control panel X15/3 VCP08 (P , Bit 1) Roll ventilation - automatic mode X32 (P , Bit 4) Evaluation of press signal BDC (P , Bit 5) Automatic start only for presses in TDC (P , bit 8) Feed interruption PLC (P , bit 6) Forwarding mode (P , Bit 2) Feed angle via external press encoder (P , Bit 10) Traveling profile "Trapezoidal" or "Master axis coupling with RMA or VMA" (P , Bit 11 and Bit 12) Motion profile (P Element 406) Modifications to settings of the traveling profile/motion profile only become effective, if the automatic / set-up mode is disabled or a cycle stop is enabled, respectively. If the operator pushes the HELP key, the following display is shown: 7.9 Submenu "Diagnostic" (F3) General Fig.7-34: Help display in the submenu "Feed configuration 1-4" Fig.7-35: Display in the submenu "System diagnostic"

110 102/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI The "Diagnostic" submenu gives the system-specific status and the drive status in clear text. With the help of the F1 or F2 key, the user can access the menu for the display of inputs and outputs. The F3 key serves to call the display of the existing versions. If the operator pushes the HELP key, the following display is shown: Fig.7-36: Submenu "Inputs" (F1) Help display in the submenu "System diagnostic" In the displays "Inputs 1"... "Inputs 4", the current values of the system inputs are shown. The meaning and effect of the individual inputs are described in chapter 5 "Inputs / Outputs" on page 43. It is possible to switch between the displays "Inputs 1"... "Inputs 4" with the help of the Scroll keys. Fig.7-37: Display in the menu "Inputs 1"

111 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 103/171 HMI Fig.7-38: Display in the menu "Inputs 2" Fig.7-39: Display in the menu "Inputs 3" Fig.7-40: Display in the menu "Inputs 4" If the operator pushes the HELP key, the following display is shown:

112 104/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Submenu "Outputs" (F2) Fig.7-41: Help display in the submenu "Inputs 1-4" In the displays "Outputs 1" and "Outputs 2", the current values of the system outputs are shown. The meaning and effect of the individual outputs are described in chapter 5 "Inputs / Outputs" on page 43. It is possible to switch between the displays "Outputs 1" and "Outputs 2" with the help of the Scroll keys. Fig.7-42: Display in the menu "Outputs 1" Fig.7-43: Display in the menu "Outputs 2"

113 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 105/171 HMI Fig.7-44: Display in the menu "Outputs 3" If the operator pushes the HELP key, the following display is shown: Submenu "Versions" (F3) Fig.7-45: Help display in the submenu "Outputs 1-2" Fig.7-46: Display in the submenu "Versions" In the "Versions" submenu, the following firmware versions / hardware IDs are output. Rollfeed Standard: Version of the firmware option Version of the visualization interface Drive: Manufacturer version control unit type

114 106/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Motor: motor type VCP: Firmware version If the operator pushes the HELP key, the following display is shown: Fig.7-47: Submenu "Feed Diagnostic" (F4) Help display in the submenu "Versions" Fig.7-48: Display in the submenu "Feed diagnostic" In the "Feed diagnostic" submenu, the following information is output. Active traveling profile Active motion profile current position of the external press encoder Active part length Start angle, stop angle as well as the tolerance window are active calculated maximum number of press strokes, relevant for the feed via master axis coupling If the operator pushes the HELP key, the following display is shown:

115 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 107/171 HMI Fig.7-49: Help display in the submenu "Feed diagnostic" 7.10 Submenu "Set-Up" (F4) Fig.7-50: Display in the submenu "Set-up" The "Set-up" submenu indicates the current status and the set-up mode settings. In the status, a clear test message is generated which informs the operator about the fact whether the partial length was processed or not. The length setpoint indicates the path that is actually to be processed. The actual length shows the path already traversed. In addition to this, the currently parameterized set-up velocity and the actual position value of the drive are output. If the editing mode is enabled, the set-up velocity can be edited. Any modification to the set-up velocity is stored directly. If the operator pushes the HELP key, the following display is shown:

116 108/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Fig.7-51: Help display in the submenu "Set-up" 7.11 Submenu "Parameters" (F5) Submenu "System Parameters" (F1) Fig.7-52: Display in the submenu "System parameters" In the "System parameters" display menu, the operator can both display and edit system parameters. A system parameter can be selected by means of an input in the "No." field, provided the editing mode is enabled. If the read access was successful, the date of the system parameter can be edited. For this, navigate the cursor in the input field to the value. With a push on the Data release key, the currently edited value is written into the system parameter. In order to be able to enter alphanumerical characters, the F5 key must be pushed. The allocation of the number in the "No." input field is indicated in the parameter list of the system parameters in chapter 9.1 "System Parameters" on page 123. The current value of the system parameter is cyclically output as long as the cursor is not on the input field of the value. If the operator pushes the HELP key, the following display is shown:

117 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 109/171 HMI Parameters Fig.7-53: Help display in the submenu "System parameters" Fig.7-54: Display in the submenu "Parameters" In the "Parameters" display menu, the parameters of the IndraDrive control unit can be both displayed and edited. If the editing mode is enabled, the operator can read any drive parameter through the input of the respective number. If the read access was successful, the date of the parameter can be edited. For this, navigate the cursor in the input field to the value. With a push on the Data release key, the currently edited value is written into the parameter of the control unit. In order to be able to enter alphanumerical characters, the F5 key must be pushed. The current value of the parameter is cyclically output as long as the cursor is not on the input field of the value. If the operator pushes the HELP key, the following display is shown:

118 110/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Fig.7-55: Help display in the submenu "Parameters" Submenu "Load Basic Parameters" (F2) Fig.7-56: Display in the submenu "Load basic parameters" In the "Load basic parameters" display menu, the user can, according to the selected option - ""Load default controller circuit parameters"" or ""Load default drive parameters" -," restore the basic settings in the drive. If the editing mode is enabled, the option setting can be selected with the help of the "+" or "-" key. This commands triggers the overwriting of all parameterizations made in the drive. The communication settings for the serial interface as well as the system-specific parameters of the Rollfeed Standard system solution, however, are maintained. If the operator pushes the HELP key, the following display is shown:

119 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 111/171 HMI Fig.7-57: Submenu "Tools" (F3) Help display in the submenu "Load basic parameters" Fig.7-58: Display in the submenu "Tools" In this menu, the user can set the language, the time, the date and the contrast of the display. For the entry of the language, the date and the time, the editing mode must be enabled. In addition to their direct input, the date, the time and the contrast can also be modified by means of the "+" or " " key. The selection of the language must be made via the "+" or the " " key. After the newly selected language was confirmed with a push on the Data acceptance key, the display automatically returns to the main menu. If the operator pushes the HELP key, the following display is shown: Fig.7-59: Help display in the submenu "Tools"

120 112/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description HMI Display Change password (F2) Fig.7-60: Display in the "Change password!" menu In this menu, "F2 PWD on" or "F3 PWD on" enables and disables the password protection generally. To adapt the default passwords after shipping to "1186" for "User", " " for "Service" and "571186" for "Master" as requested by the customer, the current password is to be entered and the new password is to be confirmed by entering it twice. Example: Change the user password "1186 to the new password "4711 Current password: 1186 New password: 4711 Repetition: 4711 Confirm the entries by pressing ENTER. If the operator pushes the HELP key, the following display is shown: Fig.7-61: Help display in the "Change password!" menu

121 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 113/171 Forwarding Mode 8 Forwarding Mode 8.1 Functional Description Rollfeed Standard supports a forwarding mode which allows a serial communication connection between the press control (hereinafter referred to as PC) and a Rollfeed system solution via a VCP HMI device. This connection can be used by the PC to query process information from the Rollfeed system solution and to send process commands to the Rollfeed system solution. The forwarding mode allows the ASCII communication between a PC and a Rollfeed system solution via a VCP HMI device. Any ASCII communication between the PC and the Rollfeed system solution is recognized and simply forwarded by the VCP HMI device without the latter affecting the communication. The basic principle of the connection between a PC and the Rollfeed system solution is shown in the following figure. Fig.8-1: Forwarding mode The PC is connected to the VCP (VCP05 or VCP08) via a serial RS 232 cable (IKB0053). Serial data sent by the PC are evaluated by the Rollfeed HMI application. If the data are recognized as Forwarding Protocol, they are forwarded to the Rollfeed system solution. The Rollfeed system solution then sends a telegram with the required data back to the PC or executes the queried command.

122 114/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Forwarding Mode The forwarding mode must be enabled in the parameter P , Rollfeed configuration parameter 2. The transfer format of the serial interface (RS232C) is set to the following values: baud 8 data bit 1 stop bit No parity No hand shake 8.2 General Command Format 8.3 Status Calls General Command Format Three different types of commands are supported. Every type is marked by a corresponding start symbol or by a message identifier in the command telegram. Message identifier ASCII Code (hex) Meaning Fig.8-2:? 0x3F Call, read operation (status calls, parameters calls) # 0x23 Write operation (parameter write command)! 0x21 Execution command (system macro commands) Telegram - start symbol / message identifier All telegram messages are finished with a Carriage Return and a Line Feed symbol (<CR><LF>). Furthermore, write command include a two-digit checksum which is separated from the other characters by a '$'. Status calls are commands that query the current status of the Rollfeed system solution. Every status call begins with the message identifier "?", followed by a blank character, a status call identifier (capital X), followed by two blank characters, and a two-digit call number. The telegram is finished with <CR><LF> (Carriage Return and Line Feed). Any additional information between the call number and the <CR> is ignored. Program:?_X nn<cr><lf> ( _ = blank character: 0x20) _ Line Feed ASCII Characters (0x0A) _ Carriage Return Symbol (0x0D) _ Two Characters for the Call Number _ Status Call Identifier: Capital X Followed by Two Blank Characters (0x58)(0x20)(0x20) _ Message Identifier:? and Blank Character 0x3F)(0x20) Response Format The response to a status call being output by the Rollfeed system solution has the following format:

123 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 115/171 Forwarding Mode Program: X_nn ####$hh<cr><lf> _ Line Feed Symbol (0x0A) _ Carriage Return Symbol (0x0D) _ $ (0x24) and Checksum, 2 Characters _ the Feedback Value or Message, max. 40 Characters _ The Number or Original Calls and Two Blank Characters (0x20) _ Capital X and a Blank Character (0x58)(0x20) Representation of Numbers in a Telegram Every single decimal and hexadecimal number is represented by the corresponding ASCII code. Negative numbers begin with a "-" sign (ASCII: 0x2D). A "+" sign (ASCII: 0x2B) for positive numbers is optional. A number without sign is interpreted as positive number. The decimal character is the "." (ASCII: 0x2E). It is not allowed to use blank characters or other characters between the individual numbers, the sign and the decimal point of a number. Leading or trailing zeros are not required, however, they are executed accordingly. The maximum length of characters for a decimal number amounts to 13 characters. In the description of the telegram, the following terms are used in order to represent the different types of numbers: [Float1] = a decimal number with exactly one decimal digit [Float3] = a decimal number with exactly three decimal digits etc. [Int2] = a two-digit integer number List of System Status Calls General Decimal Numbers Integer Numbers Binary Values Character Strings Status Call 00 Contouring Error Call Action Feedback [Int4] = a four-digit integer number with leading zeros etc. [Hex8] = an eight-digit hexadecimal number (4 bytes) [Char40] = a character string with a maximum of 40 characters?_x 00_<cr><lf> Status Call 01 Current Rollfeed System Diagnostic Call Action Feedback In the following text, blank characters are represented by an underscore "_". Reads the current contouring error of the feed axis (cf. parameter S ). X_00 [Float3]$hh<cr><lf>?_X 01_<cr><lf> Reads the current system diagnostic of the Rollfeed system solution. X_01 [max 32 char]$hh<cr><lf> Example: X_01 Motor has overtemperature!$4b<cr><lf>

124 116/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Forwarding Mode Status Call 02 Rollfeed System Information Call Action Feedback?_X 02_<cr><lf> Delivers the current system status. X_02_mx$hh<cr><lf> where m = current operating mode: 0 = manual mode 1 = automatic mode 3 = set-up mode 2 = parameterization mode, not available x = additional information: Automatic mode: 0 = feed not finished 1 = system is in the cycle and cycle start is enabled Manual mode: 0 = jogging disabled 1 = jogging enabled Status Call 03 Travelled Feed Length Call Action Feedback?_X 03_<cr><lf> Delivers the currently travelled feed length in the current feed cycle. X_03_[float]$hh<cr><lf> Example: X $A0<cr><lf Status Call 04 Metering Wheel - Data Call Action Feedback?_X 04_<cr><lf> Reads the current position values of the metering wheel and the feed axis' motor encoder. Program: X_04_xys_[Float3]_[Float3]$hh<cr><lr> _ Motor encoder Position _ Metering wheel position x = drive address, always 1 (1 axis only) y = always 0 s = status: 0 = metering wheel disabled 1 = metering wheel enabled Example: X $68<cr><lf> Status Call 05 Active Feed Length and Feed Velocity Call Action Feedback?_X 05_<cr><lf> Reads the current feed length [mm or inch] and the current feed velocity in [%] in relation to the bipolar velocity limit (cf. parameter P ). X_05_[Float3]_[Float1]$hh<cr><lf> Example:

125 Functional Description Rexroth IndraMotion Electric Drives X $E0<cr><lf> Status Call 09 Number of Strokes and Utilization of Feed Angle Call Action Feedback?_X 09_<cr><lf> Reads the current number of strokes in [strokes/min] and the utilization of the feed angle in [%]. X_09_[Int4]_[Int2]$hh<cr><lf> Example: X $AE<cr><lf> Status Call 10 Status of the Inputs (hex) Call Action Feedback?_X 10_<cr><lf> Reads the current digital input signals of the Rollfeed system solution. X_10_[Hex8]$hh<cr><lf> Example: X B64$63<cr><lf> Status Call 11 Status of the Outputs (hex) Call Action Feedback?_X 11_<cr><lf> Reads the current digital output signals of the Rollfeed system solution. X_11_[Hex8]$hh<cr><lf> Example: X $74<cr><lf> Status Call 12 Overall Production Run and Overall Travelled Length Call Action Feedback?_X 12_<cr><lf> Reads the overall production run and the overall travelled length of the feed axis. Program: X_12_[Int8]_[Float2]hh<cr><lf> _ Overall length _ Production run counter Example: X $85<cr><lf> Status Call 14 Current Rollfeed System Diagnostic Call Action Feedback?_X 14_<cr><lf> Delivers the current Rollfeed system diagnostic. X_14_[Char40]$hh<cr><lf> Example: Status Call 19 Rollfeed Version Number Call Action Feedback X 14 Motor has overtemperature!$26<cr><lf>?_x 19_<cr><lf> Delivers the version number of the Rollfeed system solution. X_19 [Char40]$hh<cr><lf> Example: X 19 Rollfeed Extended 01V01$0C<cr><lf> Bosch Rexroth AG 117/171 Forwarding Mode

126 118/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Forwarding Mode Status Call 21 Status of Press' Operating Mode?_X 21_<cr><lf> Delivers the status of the press' operating mode for "Single stroke / Continuous operation". Program: Status Call 22 Mean Path Velocity X_21_ $hh<cr><lf> 0 = Single stroke 1 = Continuous operation?_x 22_<cr><lf> Reads the average velocity of the material fed per Minute through the feed axis. This information corresponds to the current material flow. X_22_[Int7]$hh<cr><lf> Example: X $A8<cr><lf> Status Call 25 Current Rollfeed System Diagnostic Status Call 28 Drive Status?_X 25_<cr><lf> Delivers the current diagnostic text. Identical with call #14. X_25_[Char40]$hh<cr><lf> Example: X 25 Motor has overtemperature!$24<cr><lf>?_x 28_<cr><lf> Delivers the current diagnostic message of the drive (cf. parameter S ). X_28_[Char40]$hh<cr><lf> Status Call 29 Drive Firmware Version 8.4 Input (Write) Calls General Call Action Feedback Call Action Feedback Call Action Feedback Call Action Feedback Call Action Feedback?_X 29_<cr><lf> Reads the firmware version of the drive (cf. parameter S ). X_28_[Char40]$hh<cr><lf> Input calls are used to load values into the control or to reset counters or the status output Input Call 00 Set Feed Length and Feed Velocity Call Program: #_X 00_[Float]_[Float]$hh<cr><lf> _Feed velocity _Feed length Example: # X $82<cr><lf>

127 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 119/171 Forwarding Mode Derivations: # X 00 M+$2C<cr><lf> # X 00 M-$2A<cr><lf> Sets or changes the active feed length [mm or inch] and feed velocity [%]. Derivations: - M+: adding Micro-Adjust value to the current feed length - M-: subtracting Micro-Adjust value from the current feed length Acknowledgement of receipt: Y_$87<cr><lf> Input Call 03 Reset Overall Production Run Counter #_X 03$hh<cr><lf> Current command: # X 03$C1<cr><lf> Reset overall production run counter. Acknowledgement of receipt: Y_$87<cr><lf> Input Call 04 Reset Travelled Overall Length 8.5 Parameter Call General Action Feedback Call Action Feedback Call Action Feedback #_X 04$hh<cr><lf> Current command: # X 04$C0<cr><lf> Deletion of the travelled overall length. Acknowledgement of receipt: Y_$87<cr><lf> A parameter call has the general format:?_k_[parameter number]<cr><lf> If a parameter number is recognized as invalid, the controls sends back an error message (E_K_nnnn_INVALID) Parameter Call B101 Read Measuring Unit Call Action Feedback?_K_B101<cr><lf> Reads the preselected measuring unit. This is used for all calculations made in the control. Program: K_B101_[Char12]$hh<cr><lf> _ Units: "mm" or "in." Example: K B101 mm$c5<cr><lf> Parameter Call B107 Read Micro-Adjust Increment Call?_K_B107<cr><lf>

128 120/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Forwarding Mode Action Feedback Reads the current setting of the Micro-Adjust increment for the feed lengths. K_B107_[Float3]$hh<cr><lf> Example: K B $A1<cr><lf> 8.6 Parameter Input (Write) Command General A parameter input / write command has the following format: #_K_[Param.]_[Value]_[additional optional characters] $hh<cr><lf> The numerical value in the command must correspond to the type of the respective parameter in order to be interpreted correctly Parameter Input B107 Set Micro-Adjust Increment #_K_B107_[Float]$hh<cr><lf> Example: # K B107_1.234$1F<cr><lf> Sets the value for the Micro-Adjust increment of the feed lengths. Acknowledgement of receipt: Y_$87<cr><lf> 8.7 Drive Parameter Read Call General Command Action Feedback Read Call S Parameters of the Drive Call Action Feedback In order to guarantee the adaptation to CLM controls with OptiFeed command, the forwarding mode also provides a direct read access to all drive parameters, with the exception of the list parameters.?_k_s[int4]<cr><lf> Example:? K S0051<cr><lf> or in short? K S51<cr><lf> Reads the S parameters of the drive that were called. The feedback depends on the data type of the called parameter: Binary parameter: K_S[Int4]_[Hex8]$hh<cr><lf> Dec. parameter: K_S[Int4]_[Float3]$hh<cr><lf> String parameter: Example: K_S[Int4]_[Char40]$hh<cr><lf> K S $FD<cr><lf>

129 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 121/171 Forwarding Mode Read Call P Parameters of the Drive Call Action Feedback?_K_P[Int4]<cr><lf> Example:? K P0052<cr><lf> or in short? K P52<cr><lf> Reads the P parameters of the drive that were called. The feedback depends on the data type of the called parameter: Binary parameter: K_P[Int4]_[Hex8]$hh<cr><lf> Dec. parameter: K_P[Int4]_[Float3]$hh<cr><lf> String parameter: Example: 8.8 Error Messages Format Error Invalid Identifier Checksum Error String Invalid Wrong Parameter Value Not Implemented General Internal Error K_P[Int4]_[Char40]$hh<cr><lf> K P $FC<cr><lf> Every call and every command is confirmed by the control. In case of an error, one of the following error messages is sent back: E_00_Format_Error $hh<cr><lf> This error message is sent, if the data format received is invalid. Furthermore, there is a general error message which is output, if data cannot be correctly received due to inadmissible acknowledgements or wrong carriage return and / or line feed symbols. E_01_Identifier_Error$hh<Cr><Lf> This error is generated, if an identifier symbol is invalid, e.g. if a different character is received in case of a K, S, or P parameter call. E_02_#_Out_Of_Bounds_$hh<Cr><Lf> This error is sent, if the number in the identifier is higher than the maximum admissible number. E_03_Checksum_Error $hh<cr><lf> This error message is generated, if the checksum calculated by the control does not tally with the received checksum or if this checksum is missing. In case of a general communication error, the invalid checksum triggers a new call of the last command. E_04_String_Invalid $hh<cr><lf> This message is sent, if the data received are invalid, e.g. if the feed length does not have a decimal value. E_06_K_xxx_Invalid_$hh<Cr><Lf > This message is sent, if a downloaded parameter exceeded its limits. E_11_Not_Implemented_$hh<Cr><Lf > This error is output, if the function or information called is not available. E_99_Internal Error $hh<cr><lf > This error is fed back, when an internal error occurred.

130 122/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Forwarding Mode 8.9 Checksum Formation In order to guarantee that correct data are sent and received, a checksum is formed and verified by the Rollfeed system solution. In order to form said checksum, all hexadecimal ASCII codes of the characters before the "$" are added up. Then, the "High Byte" is added to the "Low Byte". Any overrun resulting from this is not taken into account. The two's complement of the "Low Byte" of this sum then leads to the result. The result is a 2-digit checksum which is sent to the calling device. Example: #_B_A03$B6<cr><lf>

131 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 123/171 Parameter 9 Parameter 9.1 System Parameters General In this chapter, the different parameters are described. They serve to determine and to adjust the installation components as well as to enable firmly defined function sequences. For the parameterization of the installation, the Engineering-Framework IndraWorks as well as the small operating terminal VCP 08 are available. No. Designation ID No. 1 Control word of encoder 2 (optional encoder) P Assignment optional encoder ->optional slot P Feed constant S Load gear - input revolutions S Load gear - output revolutions S Safely reduced velocity P (Element 401) 7 Bipolar velocity limit P Manual velocity P Set-up velocity P Bipolar acceleration S Emergency halt deceleration S Bipolar jerk limit S Position setpoint - smoothing time constant P Positioning range S Standstill window S Monitoring range S Monitoring range - slip in % P Rollfeed configuration parameter 1 P Rollfeed configuration parameter 2 P Number of press strokes P Standstill time of press P Cycle time monitoring P Micro-Adjust value P Delay time closing rolls P Preset - diagnostic parameters P Position polarities S Encoder type 2 (optional encoder) P Position encoder type 2 S Encoder 2 resolution S

132 124/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Parameter No. Designation ID No. 30 Feed constant 2 (optional encoder) P Current regulator - proportional gain 1 S Current regulator - integral action time 1 S Velocity regulator - proportional gain S Velocity regulator - integral action time S Speed controller - smoothing time constant P Position controller - Kv factor S Acceleration feed forward gain S Acceleration feed forward - smoothing time constant P Velocity control circuit: acceleration feed forward P Actual position value - smoothing time constant for hybrid position control P Peak torque/force limit P Motor peak current S Motor current at standstill S Maximum velocity of the motor S Cooling type P Fig.9-1: Parameter list P , Rollfeed Status Parameter General Below, the function of the system parameters is described that is not given in the parameter description DOK-INDRV*-GEN-**VRS**-PA02-EN-P. Via this list parameter, the diagnostic values (list number 0-19) given in the following table are indicated cyclically. List no. Description Access Scaling / measuring unit 0 Active part number Write-protected 10^0 10^-4 mm 1 Active part length Write-protected or 10^-6 inch 10^-4 % 2 Active part velocity Write-protected or 10^-6 % 3 actual production run of active part Write-protected 10^0 4 Strokes per minute Write-protected 10^0 strokes/min 5 Utilization of feed angle Write-protected 10^0 % 6 overall actual production run Write-protected 10^0 10^-2.19 yd 7 Travelled overall length Write-protected or 10^-2 inch

133 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 125/171 Parameter List no. Description Access Scaling / measuring unit 8 9 Travelled length in the current feed cycle Position of the external press encoder Write-protected Write-protected 10^-4 mm or 10^-6 inch 10^-4 mm or 10^-6 inch 10 Maximum number of press strokes Write-protected 10^-2 strokes/min 11 Active traveling profile Write-protected 10^ Active cam switch-on angle or start of feed area in case of master axis coupling Active cam switch-off angle or end of feed area in case of master axis coupling Active tolerance range in case of master axis coupling Active analytic motion profile in case of master axis coupling Write-protected Write-protected Write-protected Write-protected Reserved Fig.9-2: Maximum Number of Press Strokes Master Axis Coupling with Virtual Master Axis Master Axis Coupling with External Press Encoder Active Traveling Profile Status parameters 10^0 10^0 10^0 10^0 In order to comply with the motion limits of the feed axis (cf. parameter P , Bipolar velocity limitand S , Bipolar acceleration), the press must not exceed this number of strokes. The number of press strokes for the virtual master axis (cf. parameter P ) is monitored as to whether this maximum is exceeded. In order to comply with the motion limits of the feed axis (cf. parameter P , Bipolar velocity limitand S , Bipolar acceleration), this number of press strokes must not exceed this maximum value. The value of this parameter element indicates the active traveling profile and has the following meaning: 0 = traveling motion via trapezoidal or triangular profile 1 = master coupling with external press encoder (RMA) 2 = master coupling with virtual master axis (VMA) Active Motion Profile The value of the parameter element indicates the active analytic motion profile and has the following meaning: 1 = internally generated "dwell-to-dwell" motion profile (cam table 1 (P ) or 5th order polynomial) = cam table 2-8 (P etc.) Parameter attributes:

134 126/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Parameter Data length: Display format: Scaling / measuring unit: Minimum input value: -- Maximum input value: -- Default value: 0 Access: P , Manual Velocity 4 bytes, variable length decimal number with sign see table see table In the "Manual" operating mode, the drive is traversed with the set manual velocity by means of the "Jog+" or "Jog-" commands. The manual velocity [in %] is entered in the parameter P , Bipolar velocity limit. Parameter attributes: Data length: Display format: 4 bytes Scaling / measuring unit: 10^-2 % Minimum input value: 0 % Maximum input value: 100 % Default value: 20 % Access: P , Set-up Velocity decimal number without sign No write protection For the "Set-up function " in the "Automatic" operating mode, the drive is traversed with the predefined set-up velocity by means of the "Jog+" or "Jog-" commands. The set-up velocity [in %] is entered in the parameter P , Bipolar velocity limit. Parameter attributes: Data length: Display format: 4 bytes Scaling / measuring unit: 10^-2 % Minimum input value: 0 % Maximum input value: 100 % Default value: 20 % Access: P , Bipolar Velocity Limit decimal number without sign No write protection The "Bipolar velocity limit" describes the symmetrical velocity active in both directions [mm/min] or [inch/min]. The system automatically enters a 20 % higher value in the parameter S , Bipolar velocity limit. User should not change the parameter S , since it is overwritten again by the system. Parameter attributes: Data length: Display format: 4 bytes decimal number without sign

135 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 127/171 Parameter Scaling / measuring unit: 10^-3 mm/min or 10^-5 inch/min Minimum input value: -- Maximum input value: -- Default value: 1,000 mm/min Access: No write protection P , Rollfeed Configuration Parameter 1 General If the absolute difference between the parameters S and P is smaller than 1 [m/min] or 10 [inch/min], parameter S is automatically set to a value which is 1 [m/min] or 10 [inch/min] higher than the one stipulated in parameter P The parameter P is introduced to avoid the drive error "F8079 Velocity limit value exceeded". Structure of the parameter: Bit Designation / Function Comment 0 Press / Punch 0: press enabled 1: punch enabled 1 Override 0: override disabled 1: override enabled 2 Metering wheel 0: metering wheel disabled 1: metering wheel enabled 3 Electrical / mechanical ventilation 0: electrical / mechanical ventilation disabled 1: electrical / mechanical ventilation enabled 4 Enabling Stop neg / feed interruption neg input 0: stop neg and feed interruption neg input enabled 1: stop neg and feed interruption neg disabled 5 Measuring unit for translatory scaling 0: millimeter [mm] 1: inch [in] 6 Feed monitoring 0: feed monitoring enabled 1: feed monitoring disabled 7 Cycle time monitoring 0: cycle time monitoring disabled 1: cycle time monitoring enabled See chapter 4 "Functional Description" on page 21 See chapter 4 "Functional Description" on page 21 See chapter 4 "Functional Description" on page 21 Serves for commissioning purposes A modification only becomes effective with a phase switch-over from the parameterization mode to the operating mode. See chapter "P , Cycle Time Monitoring" on page 129

136 128/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Parameter Bit Designation / Function Comment 8 Analog output of mean path velocity 0: analog output of mean path velocity via analog output 1 disabled 1: analog output of mean path velocity via analog output 1 enabled 9 Free configuration of the I/O signals 0: free configuration of the I/O signals disabled 1: free configuration of the I/O signals enabled 10 Feed angle via external press encoder 0: feed angle via binary input signal 1: feed angle via position of the external press encoder (cam) 11 Traveling profile - master axis coupling 0: no master axis coupling enabled, trapezoidal or triangular profile enabled 1: master axis coupling enabled, selection RMA/VMA via Bit Selection of the master axis Reserved Press / Punch 0: master axis coupling with real master axis (external press encoder) 1: master axis coupling with virtual master axis Enabling Input Stopneg and Feed Interruptionneg Feed Monitoring Free Configuration of the I/O Signals Fig.9-3: P , Rollfeed configuration parameter 1 See chapter 4 "Functional Description" on page 21 The option "Feed angle via position of the external press encoder (cam)" is only available with Rollfeed Standard 2 (AD VANCED). For this, the "Servo" (SRV) or "Synchronization" (SNC) function package must be released. In case of Rollfeed Standard 1 (BASIC), the feed angle is always read in via the binary input signal. If the "Punch" functionality is enabled, the "Press" output (X15/13, P ) is switched off with a falling edge of the "Feed angle" single. If the "Press" functionality is enabled, the "Press" output is only switched off with a rising edge of the "Feed angle" signal. In order to facilitate the commissioning, the "Stop neg " input (X15/21, P ) has no function and the "Feed interruption neg " function is switched off, if the Bit is set to "1". If the "Feed monitoring" is enabled, the feed motion is monitored. A feed motion is only possible, if a signal is present on the "Feed angle" input (X31/6, P ). If the signal decreases during a feed process, the "Feed monitoring" error is generated. If the "Feed monitoring" is disabled, a traveling motion in the manual mode is also possible, if the "Feed angle" input is not present. This serves to facilitate the commissioning. All I/O allocations concerning the X31/X32 plugs as well as the configuration of the cyclic channels of the control communication are set to the default values, if the configuration is not activated. Modifications made are reset to default val

137 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 129/171 Parameter Feed Angle via External Press Encoder Traveling Profile - Master Axis Coupling with RMA/VMA ues after a restart or a phase switching. The default configuration is described in chapter 5 "Inputs / Outputs" on page 43. In case of an activated free configuration, the I/O allocations of the X31/X32 plugs and the configuration of the cyclic channels of the control communication can be parameterized according to the preference of the user. Modifications made in the parameterization mode are accepted after a phase switching to the normal mode. The modifications are also maintained after a new switch-on. If the use of the external press encoder is enabled, the synchronization between the roll feed and the press or shears is not made via the "Feed angle" input signal, but via the absolute position of the external press encoder. In this case, the synchronization is made on the basis of the parameterized cam. The parameterization of the cam area can be effected with the help of the parameter P , Part data and installation parameters (Elements 403 and 404). In case of master axis coupling with external press encoder (RMA), the synchronization of roll feed and press is always realized on the basis of the parameterized cam. Modifications to the traveling profile settings are only possible in the manual mode or with the cycle stop being enabled. Parameter attributes: Data length: Display format: Scaling / measuring unit: -- Minimum input value: -- Maximum input value: -- Default value: 0 Access: P , Cycle Time Monitoring 4 bytes binary number No write protection With the help of the parameter P , Bit 7, the monitoring function for the cycle time can be activated. Parameter P indicates the time values for this function in milliseconds. The motion of the press is monitored on the basis of the falling edge of the feed angle (X31/6, P ). In the "Automatic" operating mode, the falling edge of the "Feed angle" signal is monitored. If this edge is not present within the period of time preselected in the parameter, an error is output. The function "Clear errors" deletes the error diagnostic and the outputs. Then, the time monitoring is relaunched. Parameter attributes: Data length: Display format: Scaling / measuring unit: Minimum input value: Maximum input value: 4 bytes decimal number without sign 1 ms 0 ms 100,000 ms

138 130/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Parameter Default value: Access: 100,000 ms No write protection P , Rollfeed Configuration Parameter 2 General Structure of the parameter: Bit Designation / Function Comment 0 Enabling of VCP 08 control panel 0: VCP 08 control panel disabled 1: VCP 08 control panel enabled, AUTO via VCP08 only 1 Enabling of VCP 08 control panel 0: VCP 08 control panel disabled 1: VCP 08 control panel enabled, AUTO via X15/1 (P ) only 2 ASCII forwarding mode 0: disabled 1: enabled 3 Reserved 4 Configuration of "Roll ventilation - automatic mode" input 0: "Roll ventilation - automatic mode" input via X15/25 (P ) 1: "Roll ventilation - automatic mode" input via X32/9 (P ) 5 Evaluation of press signal "Bottom dead center (BDC)" 0: press signal BDC is not evaluated 1: press signal BDC is evaluated 6 Enabling of "Feed interruption" via parameter "PLC input %IW 2" (P , Bit 11) 0: input is not evaluated 1: input is evaluated 7 Enabling of internal camshaft gear 0: internal camshaft gear disabled 1: internal camshaft gear enabled 8 Evaluation press signal top dead center (TDC) 9-15 Reserved 0: Press signal TDC is not evaluated 1: press signal TDC is evaluated See chapter 8 "Forwarding Mode" on page 113 The setting via X32 / Pin 9 in the default I/ O configuration is only possible for the "Rollfeed Standard 2" system solution. See chapter 5 "Inputs / Outputs" on page 43 Only for commissioning purposes, velocity via P VCP 08 Bit 0 Control Panel Fig.9-4: P , Rollfeed configuration parameter 2 All VCP 08 operating keys, with the exception of AUTO and STOP, are ORlinked to the signals on the X15 plug. The STOP key is AND-linked to the "Cycle stop" signal on the X15 plug. The automatic mode can only be enabled / disabled by means of the AUTO key of the VCP 08.

139 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 131/171 Parameter VCP 08 Bit 1 Control Panel All VCP 08 operating keys, with the exception of AUTO and STOP, are ORlinked to the signals on the X15 plug. The STOP key is AND-linked to the "Cycle stop neg " signal on the X15 plug. The automatic mode can only be enabled / disabled by means of the "Auto" input X15/1 (P ). Evaluation Press Signal Top Dead Center (TDC) Press Signal Bottom Dead Center (BDC) Enabling of "Feed Interruption" via Parameter Internal Camshaft Gear If both Bit 0 and Bit 1 are parameterized to the value "1", Bit 1 has a higher priority, i.e. the automatic mode can only be enabled / disabled via X15/1 (P ). When the evaluation of the press signal "TDC" is activated, the automatic mode can only be operated if the feed angle is given (press in TDC) If the press is not in the TDC, it must me driven to the TDC in external manual mode. If the evaluation of the "BDC" press signal is enabled, further feed motions are only made, if the "Press BDC" signal was present. If the evaluation of the "Feed interruption neg " input is enabled, it is also possible to trigger a feed interruption by means of the input P , PLC input % IW2 (Bit 0). This input can be used in addition to the respective input via the control communication, e.g. for the loop control. It is possible to enable an internal camshaft gear for test purposes. For this, a feed angle from 270 degrees to 90 degrees is set. The press velocity can be predefined with the help of the parameter P , Internal press velocity. Parameter attributes: Data length: Display format: In the single stroke operating mode is used for the press, the user has to remember that the number of strokes that can be achieved depends on the time the drives requires for the feed motion. After the commissioning, the internal camshaft gear must be switched off again. Scaling / measuring unit: -- Minimum input value: -- Maximum input value: -- Default value: 0 Access: P , Mean Path Velocity 4 bytes binary number No write protection This parameter can be used to read out the mean path velocity of the feed in [mm/min] or [inch/min]. Data length: Display format: 4 bytes decimal number with sign

140 132/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Parameter Scaling / measuring unit: Minimum input value: -- Maximum input value: -- Default value: -- Access: P , Part Number Selection 10^-3 mm/min or inch/min write-protected This parameter sets the active part number for the automatic mode. The part number must be between "1" and "99". Modifications to a part number are only accepted after a cycle stop in the automatic mode. Parameter attributes: Data length: Display format: If the part number is defined via the corresponding menu in VCP 08, the part number is automatically set to P Scaling / measuring unit: -- Minimum input value: 1 Maximum input value: 99 Default value: 1 Access: P , Micro-Adjust Value 4 bytes decimal number without sign No write protection This parameter can be used to define the desired Micro-Adjust value. If the Micro-Adjust value is changed during a feed motion, this is only accepted in the following feed cycle. Parameter attributes: Data length: Display format: If the Micro-Adjust value is defined via the corresponding menu in VCP 08, the Micro-Adjust value is automatically set to P Scaling / measuring unit: Minimum input value: -- Maximum input value: -- Default value: Access: P , Delay Time Closing Rolls 4 bytes decimal number with sign 10^-4 mm or 10^-6 inch mm No write protection This parameter serves to predefine a period of time in [ms], after which the opened rolls are expected to have closed again. If, here, a time not equal to "0 ms" is entered, the "Rolls closed" input (X31/7, P ) is not effective. If "0 ms" are set, the closing of the rolls must be acknowledged via the "Rolls closed" input (X31/7, P ).

141 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 133/171 Parameter Parameter attributes: Data length: Display format: Scaling / measuring unit: Minimum input value: -- Maximum input value: -- Default value: Access: P , Number of Press Strokes General 4 bytes decimal number without sign 1 ms 0 ms No write protection This parameter can be used to preset the number of press strokes for the cycle start. With the help of this value, the parameters P , Mean path velocity and P , Rollfeed status parameter (List element 2 - strokes per minute) are initialized during the first press cycle. As of the second press cycle, the parameters are calculated via the internally determined cycle values and set accordingly. Master Axis Coupling With External Press Encoder (Real Master Axis) Master Axis Coupling with Virtual Master Axis For this traveling profile, one has to make sure that - in the "Feed before Press" type of application - the first feed motion is realized via the positioning of the virtual master axis. In this case, the positioning velocity is predefined with the help of this parameter's value. For this traveling profile, this parameter has to be used to set the positioning velocity for the internal virtual master axis. This value must be smaller than the maximum admissible number of strokes (cf. P , Rollfeed status parameter (List element 10). Parameter attributes: Data length: Display format: Scaling / measuring unit: Minimum input value: -- Maximum input value: -- Default value: Access: 4 bytes decimal number without sign 10^-2 strokes/min strokes/min No write protection P , Rollfeed Diagnostic and Error Number In this parameter, the system solution enters the current diagnostic and error numbers. If the "Rollfeed Standard" system solution diagnoses an error, an allocated error number is set in the parameter. In the error-free state, the existing status diagnostic is always made available (see chapter 11 "Diagnostic" on page 155). If the value is smaller than "100", a status diagnostic is displayed. If the value is greater than or equal to "100", a drive error or warning is applicable. For a more precise diagnostic, the clear text diagnostic is stored in the parameter P , Rollfeed system diagnostic.

142 134/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Parameter If a system-independent drive error or warning is present, the value of the parameter P , Rollfeed diagnostic and error number is equal to"100". The following table gives the possible diagnostic and error numbers with their description. P S Meaning Description (P ) Reserved 1 A4002 Status diagnostic A Production run complete 2 C1300 Status diagnostic S Roll open 3 A4002 or E2047 Status diagnostic S Stop is present 4 A4002 Status diagnostic S Feed angle is missing 5 A4002 Status diagnostic S E Pressing allowed 6 A4002 Status diagnostic S Pressing allowed 7 E2047 Status diagnostic S Interruption 8 E2047 Status diagnostic S Both jogging inputs 9 A4002 Status diagnostic S Jog+ 10 A4002 Status diagnostic S Jog- not possible 11 A4002 Status diagnostic S Jog- 12 A0010 or A4002 Status diagnostic S E Jogging allowed 13 E2047 Status diagnostic S Feed incomplete 14 E2047 Status diagnostic S Jogging allowed 15 C1300 Status diagnostic A Roll open 16 A4002 Status diagnostic A Stop is present 17 A4002 Status diagnostic A Cycle stop 18 A0010 or A4002 Status diagnostic A Cycle start only with feed angle 19 A0010 or A4002 Status diagnostic A No cycle start 20 E2047 Status diagnostic A Interruption 21 A4002 Status diagnostic A Feed 22 A4002 Status diagnostic A Waiting for feed angle 23 A4002 Status diagnostic A Waiting for press 24 A0010 or A4002 Status diagnostic M Roll open 25 A0010 Status diagnostic M Stop is present 26 A0010 Status diagnostic M Interruption 27 A0010 or A4002 Status diagnostic M Feed angle is missing 28 A0010 Status diagnostic M Both jogging inputs 29 A4002 Status diagnostic M Jog+ 30 A4002 Status diagnostic M Jog- 31 A0010 Status diagnostic M Jogging disabled

143 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 135/171 Parameter P S Meaning Description (P ) 32 Acc. to the preference of the user Drive diagnostic No system-specific diagnostic available. The drive diagnostic is applicable Reserved 100 Acc. to the preference of the user Drive error System-specific drive error or warning available. The drive diagnostic is applicable. 101 F2012 System error Time-out PLC task 102 F2011 System error VCP communication error 103 F2011 System error Drive firmware not supported 104 F2011 System error Error - feed monitoring 105 F2011 System error Cycle time time-out 106 F2011 System error Motion error 107 F2011 System error Roll ventilation during feed 108 F2011 System error Negative press velocity 109 F2011 System error Master axis-coupled motion profile invalid 110 F2011 Parameter error Manual velocity (P ) value too small 111 F2011 Parameter error Manual velocity (P ) value too high 112 F2011 Parameter error Set-up velocity (P ) value too small 113 F2011 Parameter error Set-up velocity (P ) value too high 114 F2011 Parameter error Velocity limit (P ) value too small 115 F2011 Parameter error Velocity limit (P ) value too high 116 F2011 Parameter error Monitoring cycle time (P ) value too small 117 F2011 Parameter error Monitoring cycle time (P ) value too high 118 F2011 System error Configuration error - motion profile 119 F2011 Parameter error Motion profile (P , ) invalid 130 F2011 Product data error Part number (P ) value too small 131 F2011 Product data error Part number (P ) value too high 132 F2011 Product data error Length (P ) value too small 133 F2011 Product data error Length (P ) value too high 134 F2011 Product data error Velocity (P ) value too small 135 F2011 Product data error Velocity (P ) value too high 136 F2011 Product data error Acceleration (P ) value too small 137 F2011 Product data error Acceleration (P ) value too high 138 F2011 Product data error Number of strokes (P ) too small 139 F2011 Product data error Number of strokes (P ) too high Fig.9-5: Rollfeed diagnostic and error numbers Parameter attributes: Data length: 4 bytes Display format: decimal number without sign Scaling / measuring unit: --

144 136/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Parameter Minimum input value: -- Maximum input value: -- Default value: 0 Access: P , Preset - Status Parameter write-protected By means of the parameter P , it is possible to make a presetting for the following diagnostic values in the parameter P , Rollfeed status parameter: actual production run of active part (see P , List element 3) overall actual production run (see P , List element 6) travelled overall length (see P , List element 7) The preset value is accepted with the following inputs (see chapter 5 "Inputs / Outputs" on page 43) in the corresponding list element of the P , Rollfeed status parameter: Preset - overall production run (P , Bit 1) Preset - overall length (P , Bit 2) Parameter attributes: Data length: Display format: For the definition of the preset value for the overall length, the scaling of the travelled overall length (P , List element 7) is to be taken into account. Scaling / measuring unit: -- Minimum input value: -- Maximum input value: -- Default value: 0 Access: P , Standstill Time of Press 4 bytes decimal number without sign No write protection This parameter serves to enter a period of time for the detection of a press stop in the automatic mode. If the press is stopped for a longer period of time than the parameterized period of time, after a restart, the parameters P , Mean path velocity and P , Rollfeed status parameter (List element 4 - strokes per minute) are initialized during the first press cycle on the basis of the value in the parameter P , Number of press strokes. As of the second press cycle, the parameters are calculated via the internally determined cycle values and set accordingly. If the press is not stopped for a longer period of time than the parameterized period of time, the currently calculated values are entered in the parameters P , Mean path velocity and P , Rollfeed status parameter (List element 4 - strokes per minute). Parameter attributes:

145 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 137/171 Parameter Data length: Display format: Scaling / measuring unit: Minimum input value: -- Maximum input value: -- Default value: Access: P , Internal Press Velocity 4 bytes decimal number without sign 10^0 seconds 0 seconds No write protection With the help of this parameter, the velocity for the internal camshaft gear can be defined. Parameter attributes: Data length: Display format: Scaling / measuring unit: Minimum input value: -- Maximum input value: -- Default value: Access: P , Rollfeed System Diagnostic 4 bytes decimal number without sign 10^-3 rpm 20 rpm No write protection This parameter serves to make available the current system diagnostic as clear text (see also chapter 11 "Diagnostic" on page 155). Parameter attributes: Data length: Display format: Scaling / measuring unit: -- Minimum input value: -- Maximum input value: -- Default value: -- Access: 1 bytes, variable length ASCII text write-protected P , Part Data and Installation Parameters General Part Data This parameter is used to define and store the relevant part data as well as installation parameters. A maximum of 99 parts can be administered. For every part, the following feed data are available. feed length in [mm] or [inch] (List elements 1-99) velocity in [%] in relation to the maximum velocity (P )

146 138/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Parameter Installation Parameters (List elements ) production run setpoint (List elements ) acceleration in [%] in relation to the maximum acceleration (S ) (List elements ) With the automatic mode being enabled, modifications to part data are always accepted with a falling edge on the feed angle. The feed length must be greater than "0". The preset velocity and acceleration values must be greater than "0 %" and smaller than or equal to "100 %". If "0" is defined for the production run setpoint, a continuous operation without limitation of the production run is enabled. The following installation parameters are defined via this parameter: safely reduced velocity in [%] (List element 401) If the safe operating status "Safe motion 1, 2, 3, or, 4" is enabled in the manual or automatic mode, the internally defined velocity setpoint is automatically limited to the value preset by the system solution. The presetting has a proportional effect on the parameterized value of the respective velocity threshold (P , P , P , or P ). If the value is set to "0", however, the system solution does not automatically limit the velocity setpoints. In this case, the superordinate control itself is responsible for the definition of reduced velocity setpoints in the manual or automatic mode (P , P , P ). Factor for the calculation of the monitoring time of the internal PLC task cycle (List element 402) Parameter for the Traveling Profile and Cam Area If the error "Time-out PLC task" (F2012 PLC error no. 2) occurs, the internal monitoring time can be increased. The monitoring time is increased by the product of the parameterized factor and the minimally possible resolution time. A modification to the parameter is only detected, after the user switched from the parameterization mode over to the operating mode. The following settings concerning the traveling profile and the cam area are defined via this parameter: switch-on angle cam or start of feed area in case of master axis coupling with external press encoder in [ ] (List element 403) The value must be between 0 and 360 degrees. Default value: 270 degree switch-off angle cam or end of feed area in case of master axis coupling with external press encoder in [ ] The value must be between 0 and 360 degrees. (List element 404) Default value: 90 degree

147 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 139/171 Parameter Tolerance range in case of master axis coupling with external press encoder in [ ] (List element 405) In case of master axis coupling with external press encoder, the feed motion can be shortened by this value in relation to the end of the feed area (switch-off angle). The value must be between 0 and 360 degrees. Default value: 0 degree Configuration of the motion profile in case of master axis coupling (List element 406) The following meaning is applicable: 1 = use of the internally generated "dwell-to-dwell" motion profile (cam table 1 via P or 5th order polynomial, internal automatic switchover) = cam table 2-8 (P etc.). The cam tables 2-8 are freely available and must be generated by the user. Default value: 1 Note: Cam table 1 (P ) is used internally and not available for the user. negative velocity limit for the master axis coupling with external press encoder [rpm] (List element 407) In order to avoid a reversely rotating feed axis in case of master axis coupling with external press encoder, a negative velocity limit can be defined for the external press encoder in the parameter. If the press moves backward and, in doing this, exceeds the velocity limit, the error "negative press velocity" is generated. If "0" is defined for the limit, the monitoring is disabled. Parameterization of maximum number of press strokes (machine constant) (List element 408) If the internal "dwell-to-dwell" motion profile is used, the calculation for the feed profile and the maximally available number of press strokes is realized on the basis of this value. Default value: 500 strokes/min Modifications to the traveling profile are only possible in the manual mode or with the cycle stop being enabled. The configuration of the part data and installation parameters made in parameter P is described in the following table: List element Use Scaling / measuring unit 0 Reserved 1 Feed length part 1 10^-4 mm or 10^-6 inch 2 Feed length part 2 10^-4 mm or 10^-6 inch Feed length part 99 10^-4 mm or 10^-6 inch

148 140/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Parameter List element Use Scaling / measuring unit 100 Reserved 101 Velocity part 1 10^-4 % or 10^-6 % 102 Velocity part 2 10^-4 % or 10^-6 % Velocity part 99 10^-4 % or 10^-6 % 200 Reserved 201 Production run setpoint part 1 10^0 202 Production run setpoint part 2 10^ Production run setpoint part 99 10^0 300 Reserved 301 Acceleration part 1 10^-4 % or 10^-6 % 302 Acceleration part 2 10^-4 % or 10^-6 % Acceleration part 99 10^-4 % or 10^-6 % 400 Reserved 401 Safely reduced velocity 10^-4 % or 10^-6 % Factor for the calculation of the monitoring time of the internal task cycle. Switch-on angle cam or start of feed area in case of master axis coupling with external press encoder. Switch-off angle cam or end of feed area in case of master axis coupling with external press encoder. Tolerance range in case of master axis coupling with external press encoder Configuration of the motion profile in case of master axis coupling. Negative velocity limit for the master axis coupling with external press encoder [rpm]. 10^0 10^0 degree 10^0 degree 10^0 degree 10^0 10^-4 rpm or 10^-6 rpm 408 Maximum number of press strokes (machine constant) 10^0 strokes/min Reserved Fig.9-6: Part data and installation parameters Parameter attributes: Data length: Display format: If the part data and installation parameters are configured with the help of the corresponding menus on the VCP 08, these are automatically set in P Scaling / measuring unit: Minimum input value: -- 4 bytes, variable length decimal number with sign see table

149 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 141/171 Parameter Maximum input value: -- Default value: -- Access: No write protection

150 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description

151 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 143/171 Commissioning 10 Commissioning 10.1 General 10.2 Check List General After the initial commissioning, the defined application-specific parameter values - also including the production data - are to be stored. Thanks to the stored parameter values, the reproducibility of the drive behavior on the respective machine axis is possible. By way of reloading stored parameter values, the initial status - which existed after the initial commissioing - can be restored again! The parameter back-up can be realized with the help of the commissioning tool "IndraWorks D". In order to guarantee a smooth commissioning, it is necessary that the correct hardware and software components be used. Below, you find a list of all parts and tools required for the initial commissioning. In the state of delivery, the system solutions Rollfeed Standard 1 and 2 are already equipped with the drive firmware (FWA) and the firmware option (FWS) on the supplied MMC. Rollfeed Standard 1 (BASIC): FWA-INDRV*-MPB-04VRS-D5-1-NNN-TF FWS-MLDTFB-RFS-04VRS-D0 Rollfeed Standard 2 (ADVANCED): FWA-INDRV*-MPH-04VRS-D5-1-NNN-ML FWS-MLDTFA-RFS-04VRS-D Rollfeed Standard 1 (BASIC Control Unit) The following hardware components are required: Drive control device "IndraDrive Basic Universal" featuring the following options: encoder interface on Option 1 (X8) for motor encoders control communication via Parallel Interface (X15, HCC01) or Profibus (X30, HCC03) MMC (X7, MultiMediaCard) IBM-compatible PC serial interface cable RS232 (IKB0041) between PC (9-pin) and Indra Drive (X2, MiniDIN, 8-pin) The following hardware components are optional: encoder interface on Option 2 (X4, EN2) for metering wheel encoders on the drive control device "IndraDrive Basic Universal" start interlock L1 (X41) VCP 08 or VCP 05

152 144/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Commissioning serial interface cable RS232 (RKB0004) between VCP 08 or VCP 05 (X3- SER1, 25-pin) and IndraDrive (X2, MiniDIN, 8-pin) serial cable RS232 (IKB0053) for forwarding mode between commissioning PC and VCP 08 or VCP 05 Ethernet crosslink cable or Ethernet standard cable (RKB0007 or RKB0008) between PC and VCP for the download of VCP application interface The following software components are required: drive firmware "MPB"with Synchronization function package and Indra Motion MLD S (FWA-INDRV*-MPB-04VRS-D5-1-NNN-TF) encapsulated technology function block (FWS-MLDTFB-RFS-04VRS-D0) Engineering-Framework IndraWorks (SWA-IWORKS-D**-04VRS-D0-CD650) The following software components are optional: application interface on VCP 08 or VCP 05 (RFS_04VRS_VCP0x0x.cb) The ready-made interfaces for the operating terminals VCP 05 and VCP 08 are available on a CD or the Internet (Rexroth Portal). The access to the Rexroth Portal is only possible for registered users. IndraMotion for Metal Forming - CD (SWA-IM*MLD-MF*-04VRS-D0-CD650-COPY) IndraMotion for Metal Forming -Internet information_de/software_de/software_automationssysteme_de In the "\User" directory on the MMC supplied, the following files and documentations are available: release version of the system solution as parameter file (Rollfeed_Standard_1_04Vxx.par) with related symbol file (Boot.sdb) for the visualization on the VCP 05 or VCP 08 VCP-HMI applications (VCP 05 and VCP 08) description for the download of the VCP-HMI application IndraWorks project archive (Rollfeed_Standard_1_-04VRS_Template.zip) with integrated library for the variable I/O connections ("Rollfeed_Standard_-04VRS.lib") functional description of Rollfeed Standard 04VRS release notes Rollfeed Standard 2 (ADVANCED Control Unit) The following hardware components are required: drive control device "IndraDrive Advanced" featuring the following options: encoder interface on Option 1 (X4) for motor encoders control communication via

153 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 145/171 Commissioning Parallel Interface (X15, HCC01) or Profibus (X30, HCC03) MMC (X7, MultiMediaCard) IBM-compatible PC serial interface cable RS232 (IKB0041) between PC (9-pin) and Indra Drive (X2, MiniDIN, 8-pin) The following hardware components are optional: encoder interface on Option 2 (X8) for metering wheel encoders on the drive control device "IndraDrive Advanced" encoder interface on Option 3 (X10) for external press encoders on the drive control device "IndraDrive Advanced" safety technology S1 (X41) start interlock L1 (X41) VCP 08 or VCP 05 serial interface cable RS232 (RKB0004) between VCP 08 or VCP 05 (X3- SER1, 25-pin) and IndraDrive (X2, MiniDIN, 8-pin) serial cable RS232 (IKB0053) for forwarding mode between commissioning PC and VCP 08 or VCP 05 Ethernet crosslink cable or Ethernet standard cable (RKB0007 or RKB0008) between PC and VCP for the download of VCP application interface The following software components are required: drive firmware "MPH"with Synchronization function package and Indra Motion MLD S (FWA-INDRV*-MPH-04VRS-D5-1-NNN-ML) encapsulated technology function block (FWS-MLDTFA-RFS-04VRS-D0) Engineering-Framework IndraWorks (SWA-IWORKS-D**-04VRS-D0-CD650) The following software components are optional: application interface on VCP 08 or VCP 05 (RFS_04VRS_VCP0x0x.cb) The ready-made interfaces for the operating terminals VCP 05 and VCP 08 are available on a CD or the Internet (Rexroth Portal). The access to the Rexroth Portal is only possible for registered users. IndraMotion for Metal Forming - CD (SWA-IM*MLD-MF*-04VRS-D0-CD650-COPY) IndraMotion for Metal Forming -Internet information_de/software_de/software_automationssysteme_de

154 146/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Commissioning In the "\User" directory on the MMC supplied, the following files and documentations are available: release version of the system solution as parameter file (Rollfeed_Standard_2_04Vxx.par) with related symbol file (Boot.sdb) for the visualization on the VCP 05 or VCP 08 VCP-HMI applications (VCP 05 and VCP 08) description for the download of the VCP-HMI application IndraWorks project archive (Rollfeed_Standard_2_-04VRS_Template.zip) with integrated library for the variable I/O connections ("Rollfeed_Standard_-04VRS.lib") functional description of Rollfeed Standard 04VRS release notes 10.3 Download of the VCP Application on the VCP 08.2 or VCP General In order to ensure the operation of the Rollfeed Standard system solution with the help of the VCP 08 or VCP 05, the application interface provided must be downloaded to the operating terminal. The download of the application interface must be carried out in the framework of an FTP download via Ethernet. The connection for the Ethernet communication is made either with the help of an Ethernet crosslink cable or, if an Ethernet switch is available, with the help of an Ethernet standard cable. For the communication establishment via Ethernet cross-link cable or Ethernet standard cable, the ready/made Rexroth cables with the order designation RKB0007 or RKB0008 (see chapter "Order Information" on page 152) can be bought General Notes Fig.10-1: Appication download via FTP server For the administration and configuration of the VCP devices, the set-up main (launch) dialog is available. This dialog can be called after switching on the VCP. For about 2 seconds, the call dialog appears on the display of the VCP.

155 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 147/171 Commissioning Enter Key The set-up main dialog is accessed with a push on the "Enter" key. Through this, you reach the main menu of the launch. The following functions are available via the menu: setting of IP address, subnet mask and device name execution of firmware updates (boot loader, image) display of device information like current IP address, MAC address, serial number storing of settings made in the registry The "Enter" key on the VCP 08 is marked with the symbol displayed on the left. Navigation and Operation With the VCP device "VCP 08.2", the user can navigate within the set-up main menu by means of the "Cursor" keys. A push on the "Enter" key selects the desired menu item. The input of numbers and alphanumerical characters is made via the front keyboard. It is generally possible to connect an USB keyboard to the device for navigation and operation purposes. Navigation and Operation Fig.10-2: Main menu "Set-up main" With the VCP device "VCP 05.2" or "VCP 08.2", the user can navigate within the set-up main menu by means of the Cursor keys. A push on the Enter key selects the desired menu item. The input of numbers and alphanumerical characters is made via the front keyboard. It is generally possible to connect an USB keyboard to the device for navigation and operation purposes Operating Instructions for the Download of the VCP-HMI Application Determination of the IP Configuration of the Commissioing PC In the following operation instructions, the individual procedures are described that are required in order to transfer the VCP application to the VCP 05.2 or VCP 08.2, respectively. The steps required are enumerated in the following list and are to be carried in the order given. On the commissioning PC, click "Start" and then "Execute...". Then, enter "cmd "in the "Execute" window. A Dos window opens. Enter "ipconfig" in the Dos window's input line and confirm the entry with the "Enter" key. The Dos window then shows the current IP configuration, i.e. the IP address and the subnet mask.

156 148/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Commissioning Switching on the VCP Call of the Set-up Main Dialog Fig.10-3: IP configuration of the commissioning PC Switch-on or restart the VCP device. After the Launch dialog appears on the display of the VCP, press "Enter" to call the set-up main dialog. After switch-on, the Launch dialog appears for about 2 seconds only. During this period of time, the "Enter" key must have been activated. Fig.10-4: Launch dialog Call of the IP Settings Dialog Fig.10-5: Set-up Main dialog In the Set-up Main dialog, navigate to the "IP settings" menu point by means of the "Cursor" keys and validate with "Enter".

157 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 149/171 Commissioning Call of the Fix Settings Dialog Fig.10-6: IP Settings dialog In the IP Settings dialog, navigate to the "Fix settings" menu point by means of the "Cursor" keys and validate with "Enter". Call of the IP Address Dialog Fig.10-7: Fix Settings dialog In the Fix Settings dialog, navigate to the "IP Address" menu point by means of the "Cursor" keys and validate with "Enter". A password dialog appears. Fig.10-8: Password dialog Enter " " as password and confirm the dialog with the "Enter" key. The dialog for the input of the IP address and the subnet mask appears. Input of the IP Adress and the Subnet Mask Fig.10-9: Fixed IP dialog In the IP input field of the IP dialog, enter the IP address for the VCP. If an Ethernet crosslink cable is used, an IP address can be entered, which is increased by one in relation to the IP address of the commissioning PC (see "Determination of the IP configuration of the commissioning PC").

158 150/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Commissioning Return to Set-Up Main Dialog Example: IP address of the PC: IP address of the VCP: If a standard Ethernet cable (connection via switch) is used, a free IP address of the network must be entered for the VCP. In the "Mask" input field, the subnet mask must be entered which was determined via the menu point "Determination of the IP configuration of the commissioning PC". After having entered the IP address and the subnet mask, the user can navigate to the OK button by means of the Cursor keys and quit the dialog with "Enter". Navigate to the home button via the "Cursor" keys and confirm all further dialogs with the "Enter" key, until the Set-up Main dialog appears again. Quit Set-Up Main Dialog Fig.10-10: Set-up main dialog Navigate to the Exit button by means of the "Cursor" keys and quit the dialog with "Enter". A dialog used for saving the modifications made to the registration appears. Confirm this dialog with the "Enter" key. The VCP reboots. The IP configuration entered for the VCP is not yet active after the booting process. Switching on and off the VCP Copying Application Files to the VCP by Means of an FTP Connection Fig.10-11: Registry dialog The VCP device must be switched off and on again. Only now are the entered IP address and subnet mask active on the VCP. For downloading the application user interface, an FTP connection must be established to the VCP device. The Windows Explorer or an FTP client software can be used to establish an FTP connection to the device. If the Windows Explorer is used, the previously determined IP address (e.g. "ftp:// ") must be entered in the Address input field.

159 Functional Description Rexroth IndraMotion Electric Drives Bosch Rexroth AG 151/171 Commissioning In order to ensure that an FTP connection can be established via the Windows Explorer, the option "Activate folder view for FTP sites" must be selected in the Internet Options dialog on the Extended tab. The Internet Options dialog can be accessed via Start - Settings - Control Panel - Internet Options. Fig.10-12: Internet options If the connection was established successfully, the application data are displayed in the flash of the VCP in the explorer. The TSVisRT folder contains corresponding data that are to be transferred to the terminal with the application's download (project file, INI file, protocol driver, runtime file).

160 152/171 Bosch Rexroth AG Electric Drives Rexroth IndraMotion Functional Description Commissioning Order Information Ethernet Cable Fig.10-13: FTP connection via Windows Explorer The following four files must be copied or overwritten in the TSVisRT directory of the VCP device: 1. Project file RFE_02V0x_VCP0802.cb 2. INI file TSvisRT_CE.INI 3. Protocol driver spst30xx.xxx.dll 4. Runtime file TSvisRT_CE.exe This can be done by means of Copy and Paste. After the files were copied, the VCP must be restarted. After this, the imported application user interface is active. Article name Material number Description The TSvisLD.exe must never be deleted on the device. RKB0007/002,5..(*******-*******-*******) R Ethernet cable, 10-Base-T, CAT.6+, crosslink, UL, readymade on both sides with RJ45 plug, 2.73 yd RKB0007/005,0..(*******-*******-*******) R Ethernet cable, 10-Base-T, CAT.6+, crosslink, UL, readymade on both sides with RJ45 plug, 5.47 yd RKB0007/010,0..(*******-*******-*******) R Ethernet cable, 10-Base-T, CAT.6+, crosslink, UL, readymade on both sides with RJ45 plug, yd RKB0007/025,0..(*******-*******-*******) R Ethernet cable, 10-Base-T, CAT.6+, crosslink, UL, readymade on both sides with RJ45 plug, 25.0 m RKB0008/002,5..(*******-*******-*******) R Ethernet cable, 10-Base-T, CAT.6+, UL, ready-made on both sides with RJ45 plug, 2.73 yd RKB0008/005,0..(*******-*******-*******) R Ethernet cable, 10-Base-T, CAT.6+, UL, ready-made on both sides with RJ45 plug, 5.0 m