TransKit1 Single/Dual Axis Solution. Application Description DOK-CONTRL-WZM*TK1-AW02-EN-P

Transcription

1 TransKit1 Single/Dual Axis Solution Application Description

2 TransKit1 Table of Content 1-2 Title TransKit1 Single/Dual Axis Solution Type of Documentation Application description Document Type code Internal file reference Document number, /EN Purpose of Documentation This documentation describes pre-engineered single/dual axis motion solutions for Powertrain applications. Specifically, TRANS-01 connector compatible configuration is available. Record of Revisions Description Release Notes Date DOK-CONTRL-WZM*TK1-AW01-EN-P April, 04 First issue March, 06 Release Copyright Rexroth Indramat GmbH, 2003 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). Publisher Bosch Rexroth Corporation 5150 Prairie Stone Parkway Hoffman Estates, IL Telephone Fax Dep. BRC/SIM/USA Note All rights are reserved with respect to the content of this documentation and the availability of the product.

3 TransKit1 Table of Content 1-3 Table of Contents 1 Introduction Goals Content Important Usage Directions Appropriate Use Introduction Areas of Use and Application Inappropriate Use Safety Instructions for Electric Drives and Controls Introduction Explanations Hazards by Improper Use General Information Protection Against Contact with Electrical Parts Protection Against Electric Shock by Protective Low Voltage (PELV) 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 Trans-01 retrofitting check list Ambient conditions Control topology TRANS-01 control parameters I/O-configuration NC Program Quotation content Frequently Asked Questions 5-1 Analog command interface (±10V), is it supported? Trans-01, how compatible is the TransKit1? MAC (Indramat) motors, can they be reused? MAC motor power cable, can it be reused? MAC motor tachometer and feeback cable, can it be reused? Axes, how many with the ControlBoxD? Fieldbus interfaces, are they available?

4 TransKit1 Table of Content VAC IO, is it available? G-code programming, is it used? NC-programs, can it be done at the BTV06? Auxiliary functions, do they work different with the ControlBoxD? Reverse program, is it available? Axes / Stations, can I simultaneously run two independent axes / stations? Adapter plates, are they required when replacing a MAC motor with MHD or MKD? Display of BTV06 is dark, why? Fuses, are there some in the ControlBoxC and ControlBoxD of the TransKit1? Heat exchanger, is it required? Cable (TRANS-01-DSC NC-cable), can it be reused? Cable (Control cable), can it be reused? Cable / (Position feedback cable), can it be reused? Cable / (MAC Motor feedback cable), can it be reused? Cable (DSC01 power cable), can it be reused? Cable (DSC03 power cable), can it be reused? Cable (TRANS power cable), can it be reused? MAC motor, can the feedback (encoder) be upgraded for use with DURADRIVE? MAC motor brake control, does it change? MAC motor blower control, does it change? VDC external control voltage, is it required? Battery for memory backup, is it used with the TransKit1? ControlBoxD, can I order it from Bosch Rexroth? Drive / motor selection, who can help? Networking the ControlBoxD? Drives that can be controlled with ControlBoxD? Are the DURADRIVE addresses changeable? PC communication, how is it setup in the ControlBoxD (TRANS200 inside)? LHA and/or LZH, is it supported? TAM panel, does it connect to the ControlBox? TAM panel, is there a compatible programming tool? Trans-01M, what would I use for retrofit? Programmable limit switches (Waypoints)? Spindle function, is it available with the ControlBoxD of TransKit1? Adaptive Depth function, is it possible with the ControlBoxD of TransKit1? Adaptive Feed function, is it possible with the ControlBoxD of TransKit1? Tapping function, is it possible with the ControlBoxD of TransKit1? PIM function, is it possible with the ControlBoxD of TransKit1? TransKit1 Configurations Type Code and ordering Items to order Valid type codes/configurations ControlBoxD Type Code TransKit1 TK1 - Type Code Basic TransKit1 elements

5 TransKit1 Table of Content Ratings of TransKit1 elements Ratings DURADRIVE amplifier Ratings ControlBoxD (discrete IO) TransKit1 Components TransKit1 Mounting Frame DURADRIVE Amplifier (with TK1) ControlBoxD components ControlBoxD connections & cables Terminal Block X50 of ControlBoxD Heat Exchanger (Optional) Internal 24VDC power supply ControlBoxD spare parts references Interface Descriptions Connector ST.3 Control supply voltage Connector St.1 Interface Control Cable Power supply ( see drawings BE2000: sheets 01/12 and 09/12) Power control functions ( see drawings BE2000: sheets 03/12 to 09/12) NC control functions Auxiliary functions Axis #1 functions Axis #2 functions Spare wires of the connector St Connector RX and TX SERCOS fiber optic Connector X54 and X55 DURADRIVE interlock cable Overview Connector X54 Drive #1 Interlock Cable Connector X55 Drive #2 Interlock Cable PIM Function External Tool Correction Connector X10 Serial port for programming Technical data Choosing the RS232C or RS485 cable RS232C/RS485 at TRANS200 in ControlBoxD Connector X20 Ethernet port for programming Ethernet networking overview Setup of Ethernet Converter PC TRANS200 System Configurator setup NC setup TRANS TRANS200 - Training TRANS200 - Documentation TRANS200 - WinTrans software TRANS200 Parameter adaptation TRANS200 - NC-programming

6 TransKit1 Table of Content Operation ControlBoxD - BTV06 HMI button description BTV06 HMI - screen description Cables and Accessories Selection List of Connectors and Ready-Made Cables Accessories Index 1

7 TransKit1 Introduction Introduction 1.1 Goals A large installed base of transfer machines exists and is an important base for high volume production, especially in automotive Powertrain. Such transfer machines installed from early 1980 to 2000 have many single or dual axis slides performing cyclical movements around the clock. In many cases retrofitting the existing electro-mechanical feed or older analog servo and control systems with programmable digital servo systems provide higher productivity while keeping investment low. Also the first generation analog single axis NC systems such as the TRANS-01 NC and DSC servo drives have performed close to 20 years of service. Many components of these systems are no longer available in the market and spare parts become difficult to source. To make the retrofit of these systems faster and easier, Bosch Rexroth now provides a scalable and cost effective digital upgrade TransKit1. Note: Due to the variety of applications, the solutions described here will still require machine specific alterations that must be implemented by knowledgeable integration personnel. Target application areas are: - Electro-mechanical single and dual axes feed packs (non servo) - TRANS-01 DSC systems (fixture mount) using discrete 24VDC IO connection - Any other single and dual axes servo feed system

8 TransKit1 Introduction 1-2 Transfer control architectures Centralized PLC control In the past mainly centralized PLC control architectures have been applied with transfer machines as shown below. The Indramat TRANS-01 and DSC drive platform was mostly used in machines with centralized PLC control. Discrete 24VDC (and some 115VAC) wiring was used to communicate with the TRANS-01 controller and DSC fixture mount servo drive. Central PLC for total machine control Remote I/O Remote I/O Remote I/O Digital I/O s Digital I/O s Digital I/O s PIM TRANS-01 MAC Motor TRANS-01 MAC Motor TRANS-01 MAC Motor DSC drive DSC drive DSC drive Fig. 1-1: Centralized transfer control architecture Distributed PLC control More recent machines eventually are also controlled with distributed PLC systems. This architecture allows faster integration, startup and ease of use and reuse of engineering. The TRANS-01 was also applied here. Fig. 1-2: Distributed transfer PLC control architecture TRANS-01/DSC retrofit architecture

9 TransKit1 Introduction 1-3 The TransKit1 employs digital intelligent controllers that satisfy the same architectures. Existing discrete wiring is utilized to connect to the existing PLC IO system. The ControlBox contains NC functionality with simple NC-programming. Digital intelligent drives are connected via SERCOS fiber optic link providing precision and extended diagnostics. These drives can run a variety of servo motors (rotary, spindle, linear, torque) employing also absolute feedback measuring systems that reduce wiring. All programs and parameters are programmed via PC-based Windows WinTrans software. The data of up to 32 TransKit1 systems can be networked and managed from the central machine PC. Fig. 1-3: TRANS-01 / DSC retrofit architecture The TransKit1 utilizes the TRANS200 NC controller with the discrete I/O communication to the PLC. It also provides HMI choices that display status and offer Offset, tool data and variable modifications. Even though the TransKit1 described here is suitable for most applications, Bosch Rexroth recommends TRANS200 NC controllers with Fieldbus connection to the PLC if the PLC is retrofitted as well. The TRANS200 controller offers Interbus, Profibus, DeviceNet and ControlNet interface slave modules. The Fieldbus connection will reduce wiring costs, increases diagnostics to the machine HMI.

10 TransKit1 Introduction Content The information provided in this document does describe the functionality of the single/dual axis retrofit solution. This document does not replace the documentation of the specific Bosch Rexroth products (TRANS200, BTV06, RECO02 IO, PPC-R, DURADRIVE HDC) used for the retrofit TransKit1. It merely describes the pre-engineered solutions and how they can be applied. The TransKit1 permits the following axis combinations based on parameter settings and installed DURADRIVE amplifiers: Motion (possible interpolation) DURADRIVE Axis #01 (left) DURADRIVE Axis #02 (right) -- Linear axis Rotary axis -- Linear, circular Linear axis Linear axis Linear Linear axis Rotary axis Time Rotary axis Rotary axis Linear, feed/rev (tapping) Linear axis Spindle axis -- Rotary axis Spindle axis Note: It is the integrators responsibility to review relevant product documentation referenced in this document in order to achieve a comprehensive understanding of the products involved. This applies especially to the NC-programming and functioning of the interface signals since they differ from the TRANS-01. The following sections provide safety information for applying electrical equipment, TransKit1 component description, interface information and integration and programming software guidelines. Standard Bosch Rexroth warranty to components and standard terms apply. Warranty is voided if modifications to the wiring and/or I/O Configuration are performed.

11 TransKit1 Important Usage Directions Important Usage Directions 2.1 Appropriate Use Introduction Bosch Rexroth products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability. The products may only be used in the manner that is defined as appropriate. If they are used in an inappropriate manner, then situations can develop that may lead to property damage or injury to personnel. Note: Bosch Rexroth, as manufacturer, is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks. Before using Bosch Rexroth products, make sure that all the prerequisites for appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use. If the product takes the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the manner described in the relevant documentation. Areas of Use and Application Products made by Bosch Rexroth and used for TransKit1 are designed for the control of servo drives. Control and monitoring of the drive system may require additional sensors and actors. Note: The components may only be used with the accessories and parts specified in this document. If a component has not been specifically named, then it may not be either mounted or connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant function descriptions. The motion control and every drive controller has to be parameterized/ programmed before starting it up, making it possible for the motor to execute the specific functions of an application.

12 TransKit1 Important Usage Directions 2-2 The motion control and drive system may only be operated under the assembly, installation and ambient conditions as described in this and respective product documents (temperature, system of protection, humidity, EMC requirements, etc.) and in the position specified. 2.2 Inappropriate Use Using the products outside of the above referenced areas of application or under operating conditions other than those described in this document and in specified technical data is defined as inappropriate use". TransKit1 components may not be used: If they are subject to operating conditions that do not meet the specified ambient conditions in this document. This includes, for example, operation under water, in the case of extreme temperature fluctuations or extremely high maximum temperatures or if If Bosch Rexroth has not specifically released them for that intended purpose. Please note the specifications outlined in the general Safety Guidelines! If modifications are made to the inside of the TransKit1 and wiring between the TransKit1 and the DURADRIVE amplifier without the specific approval of Bosch Rexroth.

13 TransKit1 Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls 3.1 Introduction Read these instructions before the initial startup of the equipment and eliminate the risk of bodily harm or material damage. Follow these safety instructions at all times. Do not attempt to install or start up this equipment without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation of the equipment prior to working with the equipment at any time. If you do not have the user documentation for your equipment, contact your local Bosch Rexroth representative to send this documentation immediately to the person or persons responsible for the safe operation of this equipment. If the equipment is resold, rented, transferred, or passed on to others, then these safety instructions must be delivered with the equipment. WARNING Improper use of this equipment, 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! 3.2 Explanations The safety instructions describe the following degrees of hazard seriousness in compliance with ANSI Z535. The degree of hazard seriousness informs about the consequences resulting from noncompliance with the safety instructions. Warning symbol with signal word Degree of hazard seriousness according to ANSI Death or severe bodily harm will occur. DANGER Death or severe bodily harm may occur. WARNING Bodily harm or material damage may occur. CAUTION Fig. 3-1: Hazard classification (according to ANSI Z535)

14 TransKit1 Safety Instructions for Electric Drives and Controls Hazards by Improper Use DANGER High voltage and high discharge current! Danger to life or severe bodily harm by electric shock! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! WARNING High electrical voltage due to wrong connections! Danger to life or bodily harm by electric shock! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Surface of machine housing could be extremely hot! Danger of injury! Danger of burns! CAUTION CAUTION Risk of injury due to improper handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock or incorrect handling of pressurized systems! Risk of injury due to incorrect handling of batteries! CAUTION

15 TransKit1 Safety Instructions for Electric Drives and Controls General Information Bosch Rexroth GmbH is not liable for damages resulting from failure to observe the warnings given in this documentation. Read the operating, maintenance and safety instructions in your language before starting up the machine. If you find that you can not 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 equipment. Only persons who are trained and qualified for the use operation of the equipment may work on this equipment or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the equipment 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 equipment 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. Follow all safety regulations and requirements for the specific application as practiced in the country of use. The equipment is designed for installation in industrial machinery. The ambient conditions given in the product documentation must be observed. Use only safety features and applications that are clearly and explicitly approved in the Project Planning Manual. For example, the following areas of use are not permitted: construction cranes, elevators used for people or freight, devices and vehicles to transport people, medical applications, refinery plants, transport of hazardous goods, nuclear applications, applications sensitive to high frequency, mining, food processing, control of protection equipment (also in a machine). The information given in this documentation 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. Startup 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.

16 TransKit1 Safety Instructions for Electric Drives and Controls 3-4 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 documentation "EMC in Drive and Control Systems. The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations. Technical data, connections and operational conditions are specified in the product documentation and must be followed at all times.

17 TransKit1 Safety Instructions for Electric Drives and Controls Protection Against Contact with Electrical Parts Note: This section refers to equipment and drive components with voltages above 50 Volts. Touching live parts with voltages of 50 Volts and more with bare hands or conductive tools or touching ungrounded housings can be dangerous and cause electric shock. In order to operate electrical equipment, certain parts must unavoidably have dangerous voltages applied to them. DANGER High electrical voltage! Danger to life, severe bodily harm by electric shock! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain or repair this equipment. Follow general construction and safety regulations when working on high voltage installations. Before switching on power, the ground wire must be permanently connected to all electrical units according to the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the ground wire is not permanently connected to the points of the components provided for this purpose. Before working with electrical parts with voltage higher than 50 V, the equipment must be disconnected from the mains voltage or power supply. Make sure the equipment cannot be switched on again unintended. The following should be observed with electrical drive and filter components: Wait five (5) minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Install the covers and guards provided with the equipment properly before switching the equipment on. Prevent contact with live parts at any time. A residual-current-operated protective device (RCD) must not be used on electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device. Electrical Components with exposed live parts and uncovered high voltage terminals must be installed in a protective housing, for example in a control cabinet.

18 TransKit1 Safety Instructions for Electric Drives and Controls 3-6 To be observed with electrical drive and filter components: DANGER High electrical voltage on the housing! High leakage current! Danger to life, danger of injury by electric shock! Connect the electrical equipment, the housings of all-electrical units and motors permanently with safety to the safety conductor at the ground points before power is switched on. Look in the connection diagram. This is even necessary for brief tests. Connect the safety conductor of the electrical equipment always permanently and firmly to the supply mains. Leakage current exceeds 3.5 ma in normal operation. Use a copper conductor with at least 10-mm² cross section over its entire course for this safety conductor connection! Prior to startups, even for brief tests, always connect the protective conductor or connect with ground wire. Otherwise, high voltages can occur on the housing that lead to electric shock. 3.6 Protection Against Electric Shock by Protective Low Voltage (PELV) All connections and terminals with voltages between 0 and 50 Volts on Bosch Rexroth products are protective low voltages designed in accordance with international standards on electrical safety. WARNING High electrical voltage due to wrong connections! Danger to life, bodily harm by electric shock! Only connect equipment, electrical components and cables of the protective low voltage type (PELV = Protective Extra Low Voltage) to all terminals and clamps with voltages of 0 to 50 Volts. Only electrical circuits may be connected which are safely isolated against high voltage circuits. Safe isolation is achieved, for example, with an isolating transformer, an opto-electronic coupler or when battery-operated.

19 TransKit1 Safety Instructions for Electric Drives and Controls Protection Against Dangerous Movements Danger Dangerous movements can be caused by faulty control of the 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 device 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. 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 injury 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. Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Secure personal safety by means of qualified and tested higherlevel monitoring device or measures integrated in the installation. Unintended machine motion is possible if monitoring device are disabled, bypassed or not activated. Pay attention to unintended machine motion or other malfunction in any case of operation. 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 movement: - use safety fences - use safety guards - use protective coverings - install light curtains or light barriers Fences and coverings must strong enough to resist maximum possible momentum, especially if solved parts can fly into the environment. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the machine if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Safe standstill can be achieved by switching off the power supply contactor or by safe mechanical locking of moving parts. Secure vertical axes against falling or dropping after switching off the motor power by, for example: - mechanically securing the vertical axes

20 TransKit1 Safety Instructions for Electric Drives and Controls adding an external braking/ arrester/ clamping mechanism - ensuring sufficient equilibration of the vertical axes The standard motor brake or an external brake controlled directly by the drive controller is 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 equipment 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. 3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Magnetic and electromagnetic fields generated near current-carrying conductors and permanent magnets in motors represent a serious health hazard to persons 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, hearing aids and metal implants are not permitted to enter following areas: - Areas in which electrical equipment and parts are mounted, being operated or started up. - Areas, in which parts of motors with permanent magnets are being stored, operated, repaired or mounted. If it is necessary for a person with a heart pacemaker to enter such an area, then a doctor must be consulted prior to doing so. Heart pacemakers that are already implanted or will be implanted in the future, have a considerable variation in their electrical noise immunity. Therefore, there are no rules with general validity. Persons with hearing aids, metal implants or metal pieces must consult a doctor before they enter the areas described above. Otherwise, health hazards will occur.

21 TransKit1 Safety Instructions for Electric Drives and Controls Protection Against Contact with Hot Parts CAUTION Housing surfaces could be extremely hot! Danger of injury! Danger of burns! Do not touch housing surfaces near sources of heat! Danger of burns! After switching the equipment off, wait at least ten (10) minutes to allow it to cool down before touching it. Do not touch hot parts of the equipment, such as housings with integrated heat sinks and resistors. Danger of burns! 3.10 Protection During Handling and Mounting Under certain conditions, incorrect handling and mounting of parts and components may cause injuries. CAUTION Risk of injury by incorrect handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock! Observe general installation and safety instructions with regard to handling and mounting. Use appropriate mounting and transport equipment. Take precautions to avoid pinching and crushing. Use only appropriate tools. If specified by the product documentation, special tools must be used. Use lifting devices and tools correctly and safely. For safe protection wear appropriate protective clothing, e.g. safety glasses, safety shoes and safety gloves. Never stand under suspended loads. Clean up liquids from the floor immediately to prevent slipping.

22 TransKit1 Safety Instructions for Electric Drives and Controls Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or material damage. CAUTION Risk of injury by incorrect handling! Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and cauterization). Never charge non chargeable batteries (danger of leakage and explosion). Never throw batteries into a fire. Do not dismantle batteries. Do not damage electrical components installed in the equipment. Note: Environmental protection and disposal! The batteries contained in the product should be considered as hazardous material for land, air and sea transport in the sense of the legal requirements (danger of explosion). Dispose batteries separately from other waste. Observe the legal requirements in the country of installation Protection Against Pressurized Systems Certain motors and drive controllers, corresponding to the information in the respective Project Planning Manual, must be provided with pressurized media, such as compressed air, hydraulic oil, cooling fluid and cooling lubricant supplied by external systems. Incorrect handling of the supply and connections of pressurized systems can lead to injuries or accidents. In these cases, improper handling of external supply systems, supply lines or connections can cause injuries or material damage. CAUTION Danger of injury by incorrect handling of pressurized systems! Do not attempt to disassemble, to open or to cut a pressurized system (danger of explosion). Observe the operation instructions of the respective manufacturer. Before disassembling pressurized systems, release pressure and drain off the fluid or gas. Use suitable protective clothing (for example safety glasses, safety shoes and safety gloves) Remove any fluid that has leaked out onto the floor immediately.

23 TransKit1 Safety Instructions for Electric Drives and Controls 3-11 Note: Environmental protection and disposal! The media used in the operation of the pressurized system equipment may not be environmentally compatible. Media that are damaging the environment must be disposed separately from normal waste. Observe the legal requirements in the country of installation.

24 TransKit1 Trans-01 retrofitting check list Trans-01 retrofitting check list The following checklist should be used as a planning guide for better preparation of a retrofit. While it covers the major areas of the retrofit it may not consider peculiarities of every installation. It is strongly recommended that the retrofitter visit the installation and review not only information on paper but also verify information on-site. It is possible that the field modifications made to many installations were never recorded properly. 4.1 Ambient conditions Do the overall ControlBoxD dimensions, mounting dimensions and connector locations satisfy the ambient conditions at the machine? Yes No Next Plan for modifications at the machine to mount the ControlBoxD. Do the overall dimensions of the selected TransKit1 satisfy the machine conditions? Yes No Next Plan for modifications at the machine to mount the TransKit1 frame. Is protection class IP65 sufficient for this application? Yes No Next Plan for modifications at the machine to provide IP65 environment. Will the Control be exposed to fluids other than water and/or water/oil emulsion (max. 5% oil)? Yes No The ControlBox, cabling, Next Motors and DURADRIVE are rated IP65 and for normal coolant composition (water plus 5% oil). If in doubt contact Bosch Rexroth representative. 4.2 Control topology Which parts of the machine shall be replaced? Drive amplifier with motors Motion control (NC-control)

25 TransKit1 Trans-01 retrofitting check list 4-2 PLC-hardware Which control topology is available? Supervisory logic is working with PLC Supervisory logic is working with contactor / relay One overall PLC, one PLC for each TRANS-01 One overall PLC, one remote IO for each TRANS-01 Which kind of PC communication network is installed in the machine with TRANS-01? RS422-coupling via LCA RS485 network Ethernet network no network Which interface to the ControlBoxD of the TransKit1 should be applied? INTERBUS Profibus DeviceNet ControlNet Discrete 24 VDC I/O-interface Other: NOTE: The ControlBoxD of the TransKit1 is only supporting discrete 24VDC IO. Check with Bosch Rexroth for a TransKit with Fieldbus connection. Which supplementary TRANS-01 equipment is or should be integrated at the machine? PIM (Positions-Interface-Module) for external BCD tool length correction input Additional position encoder (adaptive depth) Adaptive feed Type code of the existing TRANS-01 control system: Hardware: TRANS01. / / Firmware: TR -. Type code of the drive amplifier and motor: Motor: MAC

26 TransKit1 Trans-01 retrofitting check list 4-3 Drive amplifier: If applicable: Type code / make of the PLC PLC logic scan time: Before retrofit: ms After retrofit: ms Are there custom-made special installations or functions to be conserved? Which? Do you plan to retrofit the single axis controller TRANS-01? Yes No Choose the ControlBoxD as Next described in this document. Do you plan to retrofit the DSC drive amplifier? Yes No Choose one or two DURADRIVE amplifiers as offered with the TransKit1. Next The TransKit1 does not support analog (10V) drive interface (DSC, TDM, etc.) Do you plan to retrofit the MAC servo motor? Yes No Choose a MHD or MKD motor with DURADRIVE based on required performance. Contact your local Bosch Rexroth representative for help in selecting the proper motordrive combination and cables. Contact you Bosch Rexroth Electric Drives and Controls representative for information on how to refurbish a MAC motor that it can be used with the DURADRIVE (and other digital intelligent drives). Do you want to order a pre-wired and mounted TransKit1 that comes ready for installation with frame of super-structure? Yes No Review the type code for Next TransKit1 and check the overall dimensions. Do you want to replace 2 TRANS-01 systems on a station with one TransKit1 (provides one motion process)? Yes No Solution 1: Next Order a TransKit1 for each TRANS-01. Solution 2: Order TransKit1 with 2 DURADRIVEs. Plan for using only one Control Cable with

27 TransKit1 Trans-01 retrofitting check list 4-4 St.1. Modify PLC logic accordingly. Create NCprogram controlling two axes. 4.3 TRANS-01 control parameters Is a TRANS-01 parameter list available? Please keep for reference! Yes No Keep for future reference. Obtain the parameters from the TRANS-01 to be retrofitted. Is the existing parameter list complete, and is it identical with the parameters in the TRANS-01 system? Yes No Keep for future reference. Obtain the parameters from the TRANS-01 to be retrofitted. Are oscilloscope records (taken during the machining cycle of a workpiece!) for precise determination respective drive/motor dimensioning and cycle time(s)? Yes No Keep for future reference. Make the oscilloscope recording. The following signals give information about the current dimensioning: motor current and speed. This is also very useful for the cost-effective sizing / selection of the new drives. Are the calculations of the presently existing machine documented? Yes No Keep for future reference. Try to obtain all mechanical information that permit proper amplifier/motor sizing, minimizing cost and uncertainty. 4.4 I/O-configuration Is there up to date information about the interface signals used with the TRANS-01 application? Overview of interface signals interface table of the PLC current diagram of the supervisory/station PLC logic further signals: Yes No

28 TransKit1 Trans-01 retrofitting check list 4-5 Compare with the interface layout of the connector St.1 Try to obtain all above information so upfront wiring changes and logic changes can be planned and prepared. Are any extra signals to be considered in this system? Yes No Document the signals and Next compare with connector St.1 Establish an overview of switching signals or M-functions for control of specific functions (BCD-signals, M-functions) available with the Trans-01 and required after the retrofit. Yes No M-functions work different Next with the ControlBoxD of the TransKit1. Compare the functioning of auxiliary functions on connector St.1. NOTE: The TransKit1 does not support BCD signals. Which key functions are influencing the existing NC-program(s)? Yes No Record and compare them with Next the NC-program control signals of connector St NC Program Is any programming sheet available for the TRANS-01 NC program to be translated to the TRANS200 based NC-program? Yes No Review the sheet and compare with the TRANS200 NCcommands (see NC-Instruction documentation). Obtain the NC-program of the TRANS-01. Is the NC program available in ASCII format? Yes No Review the sheet and compare with the TRANS200 NCcommands (see NC-Instruction documentation). Obtain the NC-program of the TRANS-01. Is tool length correction used with TRANS-01? Yes No Note (save) the tool offset Next value of the tools to be used. Use a respective D-correction

29 TransKit1 Trans-01 retrofitting check list 4-6 for tool length (and radius) correction in the TRANS200. Is a process diagram available clearly explaining the flow of the NC program? Yes No Assure it informs which configured signals are necessary and how they become effective in the presently applied system logic for TRANS-01! Eventually a signal flow diagram or graphic is useful as well. Review the machining flow of the station/machine and confirm the desired flow after the retrofit. 4.6 Quotation content What is included in the retrofit quote/offer? A TransKit1 solution (ControlBoxD and DURADRIVE(s) mounted on frame and pre-wired) Selected individual components of TransKit1 Selected individual motors and cables Creating and updating wiring and cabinet diagrams Re-creating the NC program(s) Designing new I/O-configuration to the PLC I/O Creating a different parameter list Designing custom HMI for the BTV06/BTC06 HMI Other:

30 TransKit1 Frequently Asked Questions Frequently Asked Questions Analog command interface (±10V), is it supported? The ControlBoxD of the TransKit1 does not provide a 10V analog command interface. The ControlBoxD uses the digital fiber optic SERCOS interface and intelligent drives. Trans-01, how compatible is the TransKit1? The ControlBoxD provides discrete IO at connector St.1 and 115VAC control voltage power connector. Since the ControlBoxD is capable of controlling up to 2 axes, the signals on connector St.1 are not 100% compatible to the Trans01 (in function and pin location). SERCOS fiber optic cable is used to connect digital intelligent drives such as DURADRIVE (or Ecodrive DKC02.3). MAC (Indramat) motors, can they be reused? It is recommended to replace the MAC motor with the equivalent MHD and MKD servo motors. MAC motor power cable, can it be reused? The DURADRIVE and DKC drives can operate at 3x220VAC supply voltage resulting in the same motor voltage as with the Indramat DSC drives. However, the MHD and MKD motors are rated for higher voltage and therefore have different connectors. Adaptor cables must be used. MAC motor tachometer and feeback cable, can it be reused? Not directly, in some cases a cable adapter can be employed allowing the use of the existing tachometer and feedback cable. Axes, how many with the ControlBoxD? The TRANS200 motion controller included in the ControlBoxD can simultaneously control 4 servo and 3 spindle axes. But as configured and wired in the ControlBoxD and TransKit1, up to 2 digital intelligent drives can be operated. Fieldbus interfaces, are they available? The ControlBoxD is configured for discrete IO connection. You may also ask your Bosch Rexroth sales contact if another ControlBoxF and TransKit2 version is available. If not, the user can design another solution since the integrated TRANS200 controller permits the use of Interbus, Profibus, ControlNet or DeviceNet interfaces.

31 TransKit1 Frequently Asked Questions VAC IO, is it available? No, the ControlBoxD of the TransKit1 is configured for discrete 24VDC IO. If old Trans-01 systems were connected to 115VAC signals a converter was used. You can either re-apply these converters or design such a solution using respective 115VAC compatible IO and wiring. G-code programming, is it used? Yes, the ControlBoxD of the TransKit1 uses RS274-D based G-code programming with functional extensions. The command set is more powerful than the set of the TRANS-01 and therefore has differences that must be observed. NC-programs, can it be done at the BTV06? G-code NC-programs and cycles must be programmed via the Windows software WinTrans (Version 23VRS) running on a PC (with Windows NT4.0, Windows2000 or Windows XP). NC-variables, Offsets and tool data can be entered at the local HMI BTV06 or the portable HMI BTC06. Auxiliary functions, do they work different with the ControlBoxD? Yes, the auxiliary functions in the ControlBoxD work different than in the TRANS-01. ControBoxD offers also more functionality and 2 axes connection. This require careful review of available M-functions and how they work. The integrator must observe the differences outlined in the interface section of this documentation. Reverse program, is it available? In comparison to the one reverse program block of the TRANS-01, the TRANS200 allows the programming of many reverse vectors. Refer to the TRANS200 NC Programming Instructions DOK-TRA200-NC**PRO*V22-AW01-EN-P Axes / Stations, can I simultaneously run two independent axes / stations? The TRANS200 contained in the ControlBoxD can operate multiple axes in one NC channel/process but these axes interpolate when programmed in the same NC-block. Multi-process control is possible with the MTC200 CNC. Adapter plates, are they required when replacing a MAC motor with MHD or MKD? Yes, in some cases it may be necessary since the motor performance and size may differ. Check the overall space and compare frame sizes,

32 TransKit1 Frequently Asked Questions 5-3 motor shaft diameter and pilot-hole diameters. Additionally, motor power cable and motor feedback cable must be replaced. The tachometer cable of the MAC motor is no longer required. Display of BTV06 is dark, why? The BTV06 is equipped with a screen backlight saver to maximum backlight life. Press any button and the backlight will come on. Refer to Options menu of the BTV06 for setup of the backlight timer. Note: It is also possible that the 24VDC external or 115VAC (24V internal) are missing or the internal circuit breakers are tripped. Fuses, are there some in the ControlBoxC and ControlBoxD of the TransKit1? The ControlBoxD contains two circuit breakers mounted on the terminal strip. See chapter 5 for more information. Heat exchanger, is it required? The ControlBoxD is designed to work without heat exchanger up to an ambient temperature of 42 C. Mechanically the ControlBoxD is prepared for installation of a McLean heat exchanger (refer to section 4 for installation information). Cable (TRANS-01-DSC NC-cable), can it be reused? No, this cable is obsolete. The TransKit1 provides a new cable to connect the DURADRIVE to the ControlBox. Cable (Control cable), can it be reused? Yes, the cable can be reused. However, observe the St.1 connector signal functions and wiring as described in this documentation. Cable / (Position feedback cable), can it be reused? No, this cable cannot be used as is since it does not provide the conductors and shielding required for sinusoidal motor feedback systems. With the TransKit1, digital intelligent DURADRIVE amplifiers are used requiring a direct connection of the motor / slide position feedback cable to connector X4 / X8. Cable / (MAC Motor feedback cable), can it be reused? This cable is no longer required. New digital intelligent drives such as the DURADRIVE no longer use Tachometer and BLC commutation signals. These drives use intelligent motors, meaning the commutation angle is stored in the motor feedback.

33 TransKit1 Frequently Asked Questions 5-4 Cable (DSC01 power cable), can it be reused? Yes, but - the connector at the DSC side must be replaced with the respective connector that matches the DURADRIVE X13 socket - the control voltage (pin E, F,G) are no longer used and must not be connected - the cable can only be used with 3x220VAC, also for the DURADRIVE - the DURADRIVE/Motor selection must be based on 3x220VAC supply voltage Cable (DSC03 power cable), can it be reused? Yes, but - the connector at the DSC side must be replaced with the respective connector that matches the DURADRIVE X13 socket - the control voltage (pin E, F,G) are no longer used and must not be connected - the cable can only be used with 3x220VAC, also for the DURADRIVE - the DURADRIVE/Motor selection must be based on 3x220VAC supply voltage Cable (TRANS power cable), can it be reused? Yes, but - the cable provides the 115V AC to the ControlBoxD. The 220V AC supply is no longer supported. - the cable is only necessary if the ControlBoxD is equipped with internal power supply and/or the heat exchanger. - If the TransKit1 is applied as a new application (not a TRANS01 retrofit) and the 115V supply is necessary, the IKL0221 cable should be ordered. (Mat. No ) MAC motor, can the feedback (encoder) be upgraded for use with DURADRIVE? Not in the field. Check with Bosch Rexroth engineering providing your motor type code asking for motor upgrading. MAC motor brake control, does it change? Yes brake control changes. As with DSC drives, digital intelligent drives such as the DuraDrive directly control and monitor the brake current. The brake wires for the integrated motor brake (24VDC) are contained in the

34 TransKit1 Frequently Asked Questions 5-5 Bosch Rexroth supplied motor power cable (connector X5 of the DuraDrive). MAC motor blower control, does it change? Yes, the blower of a MAC motor is supplied directly to the blower. If installing new motors, e.g., MHD and MKD with blower, then observe blower voltage and connection. 24VDC external control voltage, is it required? Yes, the ControlBoxD of the TransKit1 ships without an internal 24VDC supply unless specified in the type code. Normally the 24VDC is supplied via the control cable on connector St.1 as it did for the Trans-01. Note: In case the external 24VDC supply does not meet the specification 24VDC +/-10% or has too much noise (spikes, dips) causing errors, an optional 24VDC supply can be installed in ControlBoxD. (The internal wiring is already prepared.) It will require the external 115V AC supply through the connector ST3. Observe the wiring directions explained in chapter 6.6. Battery for memory backup, is it used with the TransKit1? No, the TRANS200 motion controller and DURADRIVE use FlashCard technology without battery backup. The TRANS200 firmware and control data are stored on a removable PCMCIA card and the drive firmware and parameter data is stored on a removable programming module. Note: Do not remove these cards while control voltage is on. ControlBoxD, can I order it from Bosch Rexroth? Yes, contact your sales representative requesting ControlBoxD. You may also order the required cables separately. Drive / motor selection, who can help? Contact your local sales representative or contact inside sales support at your regional Bosch Rexroth office. Networking the ControlBoxD? Yes, the ControlBoxD provides at the bottom a 15pin Sub-D communications connector X10 that is IP65 rated. This connector permits RS232 (single point) and RS485 (multiple points) networking. As an option, the ControlBoxD can be equipped with Ethernet communication hardware and IP65 rated connection X20. Refer to chapter 7.7 for more details.

35 TransKit1 Frequently Asked Questions 5-6 Drives that can be controlled with ControlBoxD? The ControlBoxD connectors X1 and X2 and internal interlocking are preconfigured for cables that directly connect to the DURADRIVE (HDC amplifiers), permitting the simple installation of a TransKit1. However, using the same connectors at the ControlBoxD, the customer (OEM, integrator) can create his own design for proper interlocks and cables (no ready solution from BRC). The following drives using SERCOS can be operated: - DIAX02 servo drives (latest firmware) - DIAX03 servo drives (latest firmware) - DIAX04 (HDD, HDS) servo/spindle drives (latest firmware) - DKR spindle vector drives (latest firmware) - DKC servo drives (latest firmware) Are the DURADRIVE addresses changeable? NO! As shipped from Bosch Rexroth, the default drive addresses are - 01 for the left drive amplifier - 02 for the right amplifier selected with the switches S2 and S3 at the DURADRIVE programming modules. The TRANS200 I/O configuration requires that the addresses remain unchanged. Note: Addresses changes take effect at control voltage power on. PC communication, how is it setup in the ControlBoxD (TRANS200 inside)? When shipped from Bosch Rexroth the PC communication settings for the internal TRANS200 controller are setup as described in section 7.6. LHA and/or LZH, is it supported? No, these old networking solutions were exclusively used with Trans-01 and are not compatible with the ConrolBoxD / TransKit1. TAM panel, does it connect to the ControlBox? No, the TAM was exclusively used with Trans-01. TAM panel, is there a compatible programming tool? No, the TRANS200 motion controller in the ControlBoxD is programmed with PC-based software. NC-variables, Offsets and Tool Data can be modified via the local HMI BTV06 Also the diagnostics can be viewed there. Additionally, all ControlBoxD units (up to 32) can be networked to a single PC, e.g., at the head station.

36 TransKit1 Frequently Asked Questions 5-7 Trans-01M, what would I use for retrofit? The TRANS-01M is a modular unit typically installed in the machine control enclosure. A TRANS200 can be used in its place using a similar interconnection to the PLC as is used with the ControlBoxD of the TransKit1. Also, other digital intelligent drives with SERCOS such as Ecodrive (DKC02.3) for panel installation could be used in place of the DURADRIVE. Programmable limit switches (Waypoints)? The ControlBoxD of the TransKit1 provides 2 waypoint signals for Axis #1 via the connector St.1. No waypoints are available over St.1 for Axis #2. Spindle function, is it available with the ControlBoxD of TransKit1? Yes, but only Axis #02 can be used to operate a spindle motor. Note: The DURADRIVE can only control spindle motors with compatible feedback system and power. Since the TransKit1 uses IP65 rated DURADRIVE amplifiers, it does not permit spindle motor operation without feedback. Adaptive Depth function, is it possible with the ControlBoxD of TransKit1? Yes, adaptive depth is possible by connecting the encoder directly to the drive of Axis #1. For detailed information refer to the manuals: - NC Programming Instructions (DOK-TRA200-NC**PRO*V22-AW01-EN-P) - Description of Parameters (DOC-CONTRL-PAR*DES*V22-AW01-EN-P) Adaptive Feed function, is it possible with the ControlBoxD of TransKit1? Yes, adaptive feed is possible. For detailed information refer to the manuals: - NC Programming Instructions (DOK-TRA200-NC**PRO*V22-AW01-EN-P) - Description of Parameters (DOC-CONTRL-PAR*DES*V22-AW01-EN-P) Tapping function, is it possible with the ControlBoxD of TransKit1? Yes, tapping is possible as long as Axis #01 is a linear axis (slide) onto which a digitally controlled spindle motor (Axis #02) is mounted. Note: The specific mechanical requirements for floating (compression and/or tension) and rigid tapping (only with direct drive motor-spindle systems) must be observed. For detailed information refer to the manuals: - NC Programming Instructions (DOK-TRA200-NC**PRO*V22-AW01-EN-P) - Description of Parameters (DOC-CONTRL-PAR*DES*V22-AW01-EN-P)

37 TransKit1 Frequently Asked Questions 5-8 PIM function, is it possible with the ControlBoxD of TransKit1? No. The PIM option was not implemented in the ControlBoxD of TransKit1.

38 TransKit1 TransKit1 Configurations TransKit1 Configurations 6.1 Type Code and ordering Items to order A complete retrofit of Trans-01 and DSC requires: CBD-x-xx-xx-T2-IO ;Configuration of the ControlBoxD for discrete IO interface similar to Trans-01 (St.1) TK1-CBD-xxxx-xxxx ;Complete assembly of ControlBoxD with frame, interconnect cables and DURADRIVE amplifier(s) MHD, MKD, etc. ;Motors (servo and/or spindle) as needed IKG,IKS, IKL.. ;Cables: Motor power, motor feedback, DURADRIVE supply cable etc. Valid type codes/configurations ControlBoxD CBD-*-NN-NN-T2-*-IO CBD-*-HE-NN-T2-*-IO CBD-*-NN-05-T2-*-IO CBD-*-HE-05-T2-*-IO CBD-*-HE-10-T2-*-IO TK1 configuration TK1-CBD-****-**** TK1-CBD-****-**** TK1-CBD-****-NNNN TK1-CBD-****-NNNN TK1-CBD-****-****

39 TransKit1 TransKit1 Configurations 6-2 ControlBoxD Type Code The specifics of the ControlBoxD must be is specified with the following type code. Note: If only the ControlBoxD is ordered, the interconnecting cables must be ordered separately like the drives, motors and their cables. Type Code: CBD-V-NN-NN-T2-S-IO ControlBox Version BTV06 HMI... V 24VDC Supply 2) No internal 24VDC supply... NN Int. 24VDC/5A supply (1 axis) Int. 24VDC/10A supply (2 axes).. 10 Model 2) IP65, 42 C ambient temp.... NN IP65, 45 C ambient temp.... HE (includes a heat exchanger and user must consider DURADRIVE de-rating) Motion Control 1) NC motion (TRANS200)... T2 PC Communication Serial RS232C & RS485 networking port... S Ethernet networking port... E PLC Communication Discrete IO (24VDC)... IO 1) Motion programming software: T2 WinTrans software is used for programming and drive setup. Each PC running the software requires a license of: - 1 x SWA-TRA200-T11-23VRS-MS-CD650 (CD and installation docu) Further licenses can be purchased as - SWL-TRA200-T11-23VRS-MS-COPY (single seat license without CD) This software permits the user to network up to 32 ControlBox systems to a single PC running the WinTrans software. 2) 10A internal 24VDC power supply: -10- The heat exchanger option HE- must be installed. The heat exchanger must also be installed if the ControlBoxD is equipped in the field with a 10A power supply.

40 TransKit1 TransKit1 Configurations 6-3 TransKit1 TK1 - Type Code Use this type code to order the pre-configured TransKit1 that provides up to 2 axes and the ControlBoxD with digital IO for communication to the machine (e.g., supervisory PLC) similar to the old Indramat Trans-01 controller, all mounted an pre-wired on the frame.. The ControlBoxD (CBD- ) must be ordered as a separate item. Type Code: TK1-CBD-HDC1-NNNN c ControlBox Order via separate code... CBD- DURADRIVE axis 1 No drive...nnnn 040A...HDC4 100A...HDC1 200A...HDC2 DURADRIVE axis 2 No drive...nnnn 040A...HDC4 100A...HDC1 200A...HDC2 Note: The firmware SMT 02VRS is included with the defined DURADRIVEs.

41 TransKit1 TransKit1 Configurations Basic TransKit1 elements The following sections provide an overview about the components and configurations of the TransKit1 available from Bosch Rexroth USA. Note: The information in this document applies only to the configurations sold as a complete Bosch Rexroth solution with a valid Bosch Rexroth serial number attached to the upper left corner of the front panel. Front View Left View Fig. 6-1: TransKit1: ControlBoxD + Frame + 40A DURADRIVE A configuration typically consists of a ControlBoxD (SCE-20EL 1612LPSP; RAL 5010) and one or two IP65 rated DURADRIVE

42 TransKit1 TransKit1 Configurations 6-5 amplifiers mounted on a frame for quick and easy installation, e.g. at the transfer station. Discrete 24VDC IO is used to connect to the supervisory PLC controller using TRANS-01 compatible connectors. Note: The solutions described here do NOT provide a 100% compatible replacement of TRANS-01-DSC drive and MAC motor system. The integrator must perform modifications to the existing machine wiring hardware and software. For detailed information refer to section7. ControlBoxD can be equipped with optional BTV06 HMI for the diagnostics and data entry. A single axis system consists of the following major components that are delivered completely assembled and tested ready for installation: ControlBox with interface to discrete IO BTV06.Optional display for diagnostics, and data entry DURADrive amplifier Fig 6-1: TransKit1 example

43 TransKit1 TransKit1 Configurations 6-6 DURADRIVE amplifier 6.3 Ratings of TransKit1 elements Ratings DURADRIVE amplifier The TransKit1 is rated for a maximum of 42 C ambient temperature unless the optional heat exchanger is installed which brings the maximum ambient temperature to 47 C. However, at above 45 C the power of the DURADRIVE is de-rated as described in the product documentation Project Planning Manual DURADRIVE (DOK-DURADR-HDC01.1****-PR02-EN-P; ). Note: The DURADRIVE amplifier electronics are IP65 protected but to assure long-term trouble free operation any direct coolant exposure and wash down is not permitted. A bleeder resistor is integrated into the heat sink as well, requiring cleaning depending on the environmental conditions.

44 TransKit1 TransKit1 Configurations 6-7 Ratings ControlBoxD (discrete IO) ControlBoxD Designation Permissible ambient temperature operation Permissible ambient temperature storage Symb ol Unit ControlBox C +42 C/110 F w/o heat exchanger +47 C/116 F w. heat exchanger C C Protection rating IP65 IP65 only if all enclosure openings are properly closed! Air pressure kPa (operation) kPa (storage) Vibration Like DURADRIVE Installation altitude Like DURADRIVE TransKit1 Supply Voltage Rating The 24VDC control supply voltage for the ControlBoxD and DURADRIVE amplifier(s) can be supplied via connector St.1 unless an internal supply is ordered/installed. The following provides an overview about the power requirements: TransKit1 Supply Voltage Supply voltage regulated 24VDC ± 10% TransKit1 Supply Current ControlBox Axis 1 Axis 2 Total Electronics (excl. Drive electronics Motor brake Drive electronics Motor brake outputs) 0.8A 2A A A MIN 0.8A 2A 2A 2A 2A 8.8A MIN Note: If the externally supplied control voltage of 24VDC cannot meet the above requirements (e.g., excessive spikes, noise), an optional 24VDC supply kit is available for installation into the ControlBox. If such an installation occurs the 24Vinternal (St.1:D16, #64) and 24V external (St.1:C16, #2) wires provided via connector St.1 must be separated at the control cable end in the machine electrical enclosure. TransKit1 External Inputs The TransKit1 contains 24VDC external inputs that represent the interface to the supervisory PLC. Below you find the principle connection diagram of the external inputs (refer to section 7 for detailed interface signal description). Note: Each input represents a maximum (sinking) load of 10mA. The integrator must check that the connected discrete PLC output will operate with loads less than 10mA.

45 TransKit1 TransKit1 Configurations 6-8 TransKit1 External Outputs The solid state 24VDC outputs (sourcing) of the ControlBoxD are supplied by the 24V external (St.1:C16, #2) wire. Each TransKit1 output is short circuit proof with a short circuit current of 0.5A Note: With the old Trans-01 each output was limited to 150mA per output max. of 2.4A. +UL - 24VDC external ± 10% Note: The user must install surge suppression devices parallel to inductive loads. 6.4 TransKit1 Components The following sections describe the major components of the TransKit1.

46 TransKit1 TransKit1 Configurations 6-9 TransKit1 Mounting Frame Fig : Mounting frame (front and side view) The ControlBoxD and DURADRIVE(s) used with the TransKit1 are mounted on a frame made with extruded aluminum if ordered according to the type code. This frame has two sections, the top with the ControlBoxD and the bottom with one or two DURADRIVE amplifier(s).

47 TransKit1 TransKit1 Configurations 6-10 The sections are joined in the middle to allow compact shipment and quick installation at the machine. This also permits the mounting individually or as stacked arrangement. Cables between ControlBox and DURADRIVE are 1.5m long and accommodate several mounting locations. Individual Stacked Frame connection for flexible mounting and shipping Fig : Mounting arrangements (horizontal or vertical) Due to the specific machine conditions, the OEM or integrator will have to provide brackets to securely mount the frame to the machine. These brackets can be attached with mounting bolts using the aluminum slots. Note: The final mounting location and method must assure that the temperature; vibration and protection rating of the enclosure and DURADRIVE are not exceeded. A minimum of 8 mounting brackets for Individual (horizontal) arrangement or six for the stacked vertical arrangement must be used. Brackets should be distributed equally on each side so the aluminum frame and weight are supported properly. Accessories Optional accessories available from Bosch Rexroth Linear Systems (Refer to 40/50 Aluminum Structural Framing Catalog for furtherdetails). Mounting gusset Mounting gussets for 45x45 frame (PN ) are available if they fit the installation of the frame to the machine structure (indicated yellow in Fig ). A minimum of 6 gussets per frame should be used if the frame is mounted as one piece. Four (4) gussets must be used per frame section if mounted as two sections.

48 TransKit1 TransKit1 Configurations 6-11 DURADRIVE mounting For secure mounting of the DURADRIVE, 10mm T-blocks (galvanized steel) and spring (spring steel) elements are inserted into the slot of the mounting rails. Only this type of mounting will assure that the T-block (nut) remains in the preset position. Fig T-blocks for DURADRIVE mounting Universal configuration: One or Two drives -- any size Mounting Rail 1 Mounting Rail 2 Mounting Rail 3 M6: Mounting screw / 10mm T-block with spring (for 40A drives) 480 mm 480 mm 480 mm 3 pcs/per drive M6 T- Block (Part no ) 3 pcs/per drive Spring (Part no ) M8: Mounting screw / 10mm T-block with spring (100/200A drives) 3 pcs/per drive M8 T- Block (Part no ) 3 pcs/per drive Spring (Part no ) End caps for 45*45 profile 10pcs Fig T-block and spring part numbers Note: The T-block requires different screw sizes depending on the installed DURADRIVE. M6 for HDC01.1-A040N-SE01-01-FW (40 A drive) M8 for HDC01.1-A100N-SE01-01-FW (100A drive) and HDC01.1-A200N-SE01-01-FW (200A drive) The used steel screw must have a lock washer and be in the range of 10mm 15mm maximum.

49 TransKit1 TransKit1 Configurations DURADRIVE Amplifier (with TK1) Drive / Motor Sizing For drive and motor sizing and selection information and requirements refer to the Selection Data (DOK-DRIVE*-SERVO*WZM**-AU02-MS) or contact your Bosch Rexroth representative. Note: Especially when supplying the DURADRIVE with 3-phase 220VAC voltage speed and power sizing must be reviewed with the respective motor. The Project Planning Manual DURADRIVE (DOK-DURADR- HDC01.1****-PR02-EN-P; ) provides information for mains connection, startup and maintenance. Drive Interface The DURADRIVE uses the SERCOS digital fiber optic interface to connect to the ControlBox. The DURADRIVE must have SE01 defined in the type code and use the SMT-02VRS firmware as defined below: - HDC01.1-AxxxN-SE01-01-FW (where xxx = 040, 100 or 200) - FWA-ECODR3-SMT-02VRS-MS If the drive is replaced for any reason the programming module (containing the firmware and parameters) must be retained and the device-typical interface card of the new DURADRIVE must match. Drive parameter setup WinTrans software contains the DriveTop tool to configure, tune and troubleshoot the DURADRIVE using the SERCOS fiber optic link. This convenient method eliminates the need of laptop PC connection to X2 (cable IKB0006) of the DURADRIVE. Drive parameter description The details of drive parameters and their function are described in the functional description of the drive firmware or the help systems for that firmware (if installed on the PC that contains DriveTop). Typically the firmware version SMT 02VRS is used: Functional Description SMT 02 (285849; DOC-ECODR3-SMT-02VRS**-FK01-EN-P) Parameter Description SMT 02 (285850; DOC-ECODR3-SMT-02VRS**-PA01-EN-P) Troubleshooting SMT 02 (285852; DOC-ECODR3-SMT-02VRS**-WA01-EN-P) Firmware Version Notes (285851; DOC-ECODR3-SMT-02VRS**-FV01-EN-P) The DURADRIVE design requires that a blower unit LECH-xxxN is installed. In the case of the 100 A and 200 A drive controllers, the blower must always be connected. The drive cannot be enabled and powered up if the LECH-xxxN is disconnected (X14) and the drive H1 diagnostic LED shows the error F217 Blower not connected For ease of use and maintenance, the blower can be removed and replaced during drive operation if the drive is powered up already. During this time the drive shows the warning E217 Blower running too slow. Unless the drive shat off with the respective error because the unit or bleeder overheated since the blower was not running, the warning goes away once the blower is re-connected. Note: Although it is not recommended, the 40 A DURADRIVE can be run without the blower.

50 TransKit1 TransKit1 Configurations 6-13 X14: Blower connection Fig : DURADRIVE connection locations DURADRIVE control cable installation The control cables and motor feedback cable are routed into the Control signals. The 24VDC supply, the SERCOS fiber optic cable and the position feedback cables are installed via the cable bushing assembly of the DURADRIVE. Observe the installation instructions below when removing cables, e.g., during drive replacement.

51 TransKit1 TransKit1 Configurations 6-14 Control Voltage Feedback/Encoder connection The DURADRIVE electronics and blower are conveniently supplied from the ControlBoxD with 24VDC via the control cable. Note: The 0V DC line of the ControlBoxD and DURADRIVE are connected to the housing ground. This means that the 0V DC potential of external supply systems must be connected with the 0V DC line of the ControlBoxD! This must also be considered when connecting switches and wiring directly to the DURADRIVE! The motor feedback cables are directly connected to the DURADRIVE. Connector X4 (encoder 1 at motor) and X8 (encoder 2) are located behind the plastic cover. Follow the cable installation instructions below: Both connectors employ different feedback interfaces based on the cable used. Note: Feedback cable of MAC motors cannot directly be used with the DURADRIVE. Consult Bosch Rexroth sales and engineering for further information. DURADRIVE bottom connections The motor power and DURADRIVE main supply connectors are located at the bottom of the DURADRIVE.

52 TransKit1 TransKit1 Configurations 6-15 Fig : Power and motor power connectors HDC01.1-A040N Fig : Power and motor power connectors HDC01.1-A100/200N

53 TransKit1 TransKit1 Configurations 6-16 Drive Mains Voltage connection The DURADRIVE supply voltage (3 x x 480 VAC) is directly connected via connector X13 of the DURADRIVE located at the drive bottom. The cable and connector for this connection is not provided with the TransKit1 and must be ordered separately. Fig : DURADRIVE main supply connector X13 Note: The used cable must be rated according to the chosen supply voltage. Also the temperature sensor and brake wires must be shielded according to Bosch Rexroth specifications. It is recommended to use only original Bosch Rexroth cables suitable for the DURADRIVE. Motor Power connection The motor power cable gets connected to connector X5 from the bottom at the DURADRIVE. The cable and connector for this connection is not provided with the TransKit1 and must be ordered separately.

54 TransKit1 TransKit1 Configurations ControlBoxD components ControlBoxD connections & cables All connections to the ControlBoxD are performed with connectors assuring fast and reliable installation. Connectors labeled with St.x permit the use of existing TRANS-01 cables. Other connectors starting Xx provide new /different connectivity. UDS Serial<-> Ethernet IND5007 PPC-R / Trans200 24V DC BTV06 HMI = IKB0015 Ethernet CAT5 IKO0982 RS232 or RS485 X50 TX RX X53 X20 X54 X55 St.1 St.3 RKO0101 RKO0101 IND5008 / IND5009 Ethernet CAT5 IKL0221 IKS0580 IND3048 IND3048 Fig : ControlBoxD connection layout The above figure shows the location and connection of the different cables. Cables are available and described in section 10. St.3 Supply voltage for int. 24VDC and heat exchanger (115VAC) St.1 Machine 64 pin connector (discrete 24VDC) X20 Ethernet connector (CAT5) X53 Serial interface port (RS232 / RS485) X54 Drive 1 interlocking (discrete 24 VDC) X55 Drive 2 interlocking (discrete 24 VDC) TX SERCOS drive interface output (transmitter) fiber optic RX SERCOS drive interface input (receiver) fiber optic See chapter 7 for detailed description of the connections and signals.

55 TransKit1 TransKit1 Configurations 6-18 St.1 X55 TX St.3 X20 X10 X54 RX + Fig : ControlBoxD connectors (bottom view) F1 (115VAC 2/4A) Terminal Block X50 of ControlBoxD Inside the ControlBoxD, the terminal block marked X50 is used for discrete wiring. Each terminal uses cage-clamp technology and provides multiple connection points that are identified as follows: F2 (24VDC 6/10A) Remove jumper if internal 24VDC supply installed. Fig : ControlBoxD connectors (bottom view) The terminal block X50 uses multi-point terminal with cage clamp technology providing reliable connections and measuring points for troubleshooting.

56 TransKit1 TransKit1 Configurations 6-19 Additionally some terminals contain relais (K1, K2, K3, K4, K5, K6) and circuit breakers (F1 and F2) as indicated in the figure above and described in further detail in the sections below. Heat Exchanger (Optional) The ControlBoxD is prepared for installation of a heat exchanger on the left side. This heat exchanger is required if an internal 24VDC power supply greater than 5A is used to permit the maximum specified ambient temperature. ControlBoxD with heat exchanger ControlBoxD w/o heat exchanger The cutout is prepared for the McLean heat exchanger XR This permits the installation in the field if necessary. Note: The specified heat exchanger has separated air circulation between the inside and outside, preventing inside contamination. Special care must be applied to install the seal when installing the heat exchanger or plate. It is not permitted to blow or suck outside air into the ControlBoxD or install another heat exchanger model. Such modification will void warranty. The heat exchanger requires 115VAC supply voltage provided via St.3 of the ControlBoxD. Installation instructions Step 1: Switch control voltage power off by turning off the circuit breaker CB1 and disconnecting St.3 Step 2: Clean off the left side of the ControlBox using soapy water. Step 3: Remove the cover plate. Step 4: Clean sheet metal area where the seal is applied. Step 5: Position the heat exchanger and the flat seal properly.

57 TransKit1 TransKit1 Configurations 6-20 Step 6: Fasten the heat exchanger with the screws provided or screws of the cover plate. Make sure the seal is properly located on clean surface and the bolts are tightened as per manufacturer installation description. Step 6: Strip the wires and connect the 115VAC fan supply wires to the terminals X50:2BH/X50:3BH (115VAC) and X50:4BH (GND). Fig : Heat exchanger connections Step 7: Connect the 115VAC supply cable to connector St.3 of the ControlBox. Step 8: Turn on the circuit breaker CB1. Step 9: Confirm airflow of both fans inside and outside circuit. Step 10: Close the ControlBox. Internal 24VDC power supply Normally, the user supplies 24VDC via the St.1 connector by connecting the wires - Internal 24VDC and External 24VDC - Internal 0VDC and External 0VDC to the same 24VDC power supply in the machine control panel. In situations where no such 24VDC power supply is available or if the 24VDC supplied to the ControlBoxD do not meet the required quality, an optional 24VDC power supply can be installed into ControlBoxD. If installed, this optional power supply will only supply the internal controls (TRANS200, BTV06) as well as the DURADRIVE electronics and blower. The optically isolated inputs and outputs connected to connector St.1 remain supplied by the external 24VDC and external 0VDC.

58 TransKit1 TransKit1 Configurations 6-21 Depending on the machines grounding situation, the 0VDC internal and 0VDC external can be connected, e.g., if the 0VDC of the machine panel power supply is connected to GND. The ControlBox is prepared for connection of the Phoenix 24VDC power supply using pre-wired green connectors. Fig : Internal 24VDC power supply connections Installation instructions Step 1: Switch off circuit breaker CB1 and disconnect control voltage power off by disconnecting ST.3 Step 2: Assure that in the machine control panel the 24V Internal control wire of St.1 (D16) is disconnected from the 24V External wire of St.1 (C16). Connection of the wires can result in overloading of the internal or external 24VDC power supplies! Note: The internal 24VDC power supply of 5A (10A) is only rated to supply the internal ControlBox devices and the electronics and blower of up to two (2) DURADRIVE. Do not draw any power externally from the wire 24V Internal if the optional power supply is installed. Step 3: Snap the optional internal power supply on the DIN-rail to the right of the PPC-R controller rack. Step 4: Connect the pre-wired green connectors. Step 5: Confirm that Step 2 was performed on the machine panel side. Step 6: Connect the 115VAC supply cable to connector St.3 of the ControlBox and turn on circuit breaker CB1. Step 7: Make sure circuit breaker CB2 is on. Step 8: Confirm that 24VDC is supplied to the TRANS200 (H1 indicator must display changing characters ending at b ), the BTV06 and DURADRIVEs (H1 indicator must come on and end at Bb and Fan must operate). This may take about a minute. Step 10: Close the ControlBox.

59 TransKit1 TransKit1 Configurations 6-22 ControlBoxD spare parts references The following list provides basic spare component information at the time of document creation. Suppliers and models may change without notice and components may differ in the actual ControlBox purchased. BRC = Bosch Rexroth Electric Drives and Controls BRL = Bosch Rexroth Linear Motion and Assembly Technologies TK1 7/30/2003 Components Type Qty Supplier Supplier Part No Enclosure BSC2-20EL1612LP-M Enclosure 1 Saginaw Control Engineering BSC2-20EL1612LP-M SCE-20P16 Sub Panel 1 Saginaw Control Engineering SCE-20P16 Connector socket 115 VAC MSE LOHR # Plug, terminated HD 64 Terminated Plug # Lapp USA # Pin, HD MC #20-16 AWG, Dia 1.6mm Pin 64 Lapp USA # Base, HBE 24 With Double Levers Base, HBE 24 1 Lapp USA # Connector interconnect Duradrive 1 CONN INS0222/L01 1 LOHR # Connector interconnect Duradrive 2 CONN INS0222/L01 1 LOHR # Dust Cover Cap 1 LOHR # Chain, for dust cover cap 1 LOHR Screw, for dust cover cap 4 screws per cap 4 LOHR Complete terminal strip w fuses Din Rail Assy 1 Phoenix Proposal # E /220 VAC - 24VDC 5A supply 1 Phoenix # /220 VAC - 24VDC 10A supply (For double axes units) 0 Phoenix Panel Mount Base VS-15-SD 1 Steiner Electric Contact Plug, protective cover Q-PROT9/11 1 Steiner Electric CP-HCC4 1 Steiner Electric ZBN18 1 Steiner Electric Heat Exchanger {Optional} 0 McClean XR Screw, for BTV06 6 Screw, for connectors (power, 64 pin) M4 Torx - self tapping 6 Screw, for connectors (network) M3 Torx - self tapping 4 Screw, for connectors (drives) M2.5 Torx - self tapping 8 Mounting Frame Profile Profile 45 X 45 H -/-, L=680 2 BRL /680 Profile Profile 45 X 45 H -/-, L=950 2 BRL /950 Profile Profile 45 x 45 H -/-, L=480 3 BRL /480 Profile Profile 45 X 45 H -/-, L=310 2 BRL /310 Gusset Gusset 45 x 45 W/Fastnr 10-10MM 16 BRL End Cap End Cap ESD 45 x 45 & 45 X 45 BLK 10 BRL Connection Link Connection Link 10MM L=180MM 4 BRL Spring Clip, T-Block,Swivel BRL Spring Clip, T-Block,Swivel BRL Screw, for mounting Drive (100A, 200A) 6 Flat washer 6 Spring washer 6 Screw, for mounting Drive (40A) 6 Flat washer 6 Spring washer 6 Control system NC-card PPC-R01.2N-N-S1-FW 1 BRC Firmware FWA-PPCR0*-T01-23VRS-NN-XXXXXX 1 BRC Small HMI BTV06.1HN-RS-FW 1 BRC Firmware FWA-BTV06*-DOL-01VRS-EN 1 BRC Software SWA-BTV06*-T21-23VRS-MS-C1,44 1 BRC Control rack RMB BRC Input card RME DC024 1 BRC Output card RMA DC BRC mm fiber optic cable CABLE ASSEMBLY IKO0982/ BRC Serial communication cable CABLE ASSEMBLY IKB BRC Connector socket CONN INS0222/L01 2 BRC Fiber optic bulk-head connector CONN FIB-OPT BLKHD 01 UNS IP65 2 BRC

60 TransKit1 Interface Descriptions Interface Descriptions 7.1 Connector ST.3 Control supply voltage This connector supplies 115VAC (only) to the control box for the optional heat exchanger and internal 24VDC (optional) power supply, supplying the internal electronics of control box and DuraDrives. St.3 ControlBox GND 115VAC ±10% 60Hz TransKit power cable Fig : Connector ST.3 N L1 115VAC 60Hz Note: If using the existing TRANS-01 supply voltage connector, make sure you check that the supplied voltage is 115VAC. Higher voltage will result in damage of the heat exchanger. 7.2 Connector St.1 Interface Control Cable The IO configuration between the connector St.1 and the TRANS200 is provided by Rexroth Indramat as described here.

61 TransKit1 Interface Descriptions 7-2 Fig : ControlBoxD Default TRANS200 IO configuration Note: If the IO configuration of the TRANS200 does not match the configuration shown in the above figure then the description for St.1 in this documentation may no longer apply resulting in support difficulty! Contact the integrator for the specific functionality and help. This section describes the most important TRANS200 signal. More datils can be obtained from the documentation Application Manual TRANS200 - Interface Description (DOK-TRA200-SPS*COM*V22-AW01-EN-P). This section describes the signals for the connector St.1. St.1 is used to connect the discrete IO functionality to the ControlBox. The connector is compatible to the TRANS-01 St.1 connector, however, there are signal and functional differences that must be considered. Note: The user must review each of the signals contained in the connector St.1 since they differ in functionality when compared with the original Trans-01 controller. Note: The description of signals in this manual refers to the status of the signals at the time of the factory set-up and start-up. We guarantee the described functionality of the control assuming the proper in the field application. Any change in signal configuration as well as change of status of the static interface signals made afterwards, can cause the control malfunction and can disable the functionality of the BTV06 HMI. Therefore the configuration changes in the TK1 made afterwards will automatically void the system warranty..

62 TransKit1 Interface Descriptions 7-3 Power supply ( see drawings BE2000: sheets 01/12 and 09/12) Connector Signal Function description TRANS-01 note St.1:A16 0V internal 0V of supply voltage reference for internal components (TRANS200, BTV06 or BTA10 & BTC06, DURADRIVE electronics with Blower, circulation blower). If no internal power supply is installed then 0V internal and 0V external must be connected in the machine control panel. Identical to the TRANS-01 wiring. Connector Signal Function description TRANS-01 note St.1:B16 0V external 0V of supply voltage reference for external components (RME inputs and RMA outputs). If no internal power supply is installed then 0V internal and 0V external must be connected in the machine control panel. Identical to the TRANS-01 wiring. Connector Signal Function description TRANS-01 note St.1:C16 24V DC external 24V DC supply voltage for external components (RMA outputs). If no internal power supply is installed then 24V internal and 24V external must be connected in the machine control panel. Then the external supply voltage also supplies the internal components. The external 24VDC must be fused externally. Identical to the TRANS-01 wiring. Connector St.1:D16 24V DC internal Signal 24V DC supply voltage for internal components (TRANS200, BTV06, DURADRIVE electronics with Blower, circulation blower). Function If no internal power supply is installed then 24V internal and 24V external description must be connected in the machine control panel. Then the external supply voltage also supplies the internal components. The circuit breaker Q2 6A or 10A (depending on the power supply size and number of connected drives) must be installed if the internal power supply is used. TRANS-01 note Identical to the TRANS-01 wiring. Wiring See diagram below.

63 TransKit1 Interface Descriptions 7-4 Power control functions ( see drawings BE2000: sheets 03/12 to 09/12) Connector Signal Function description TRANS-01 note Wiring St.1:A14 Power enable PCPOWEN = 0: Power enablement blocked by the PLC PCPOWEN = 1: Power enablement released by the PLC The PLC uses this signal to indicate to the NC that the power may be switched on. This signal is provided in the event that the PLC itself assumes the evaluation of conditions for the power logic, including diagnosis ("Power logic Version 2"). The PLC then just passes on to the NC the information "Drives are ready for input power" in order to guarantee that the NC carries out the minimum diagnosis. If the PLC does not assume the evaluation of the conditions for inputting power, or if this diagnostic option is to be omitted, the PLC program must assign a logical '1' to the control signal. It was original signal Safety Limit. This signal is no longer used via cable since if need be, all travel limit switches are wired directly to the drive amplifiers (DURADRIVE). In general it is recommended to use motors with multi-turn absolute feedback and software travel limits. Slot 1 %I1.0.0 X4 1 #7 St.1 A14 PCPOWEN Control Cable #7 0V X50:33 B16 #1 Connector Signal Function description St.1:C1 Ready for power on PSPOWEN = 0: No power enabling signal from the NC PSPOWEN = 1: Power enabling signal from the NC The signal is valid in all modes. The NC employs this signal to tell the PLC that all conditions for power activation have been fulfilled for this station. The 'power enabled' signal is only issued if the following conditions are fulfilled: There is no NC error pending for the process to prevent power from being switched on (PSERROR=0) The 24 V supply for the process is OK (PCEXT24=1) (TransKit sets this signal statically HI) The station EMERGENCY STOP button has not been pressed (PCESTAT=1) There is no EMERGENCY STOP condition for the system (PCEMACH=1) (TransKit sets this signal statically HI). None of the three possible guards is open (PCESTP1=1, PCESTP2=1, PCESTP3=1) (TransKit sets these signals statically HI). No limit switch for this process has been actuated (all AxCOTRVL=1, x= axis number) (TransKit sets these signals statically HI).

64 TransKit1 Interface Descriptions 7-5 TRANS-01 note Wiring Slot 2 The power supply unit is ready for operation (PCBBSUP=1) (TransKit sets this signal statically HI). There is no excessively high temperature at the power supply unit (PCTPSUP=1) (TransKit sets this signal statically HI). The 'power enabled' signal is not output if one of the above-mentioned conditions are not satisfied. The NC station diagnosis will then display the first missing condition It was original TRANS-01 signal Main Contactor Control. %Q2.0.0 X4 1 St.1 #9 C1 Control Cable PSPOWEN #9 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Function description TRANS-01 note St.1:B10 Power ON PCPOWON = 0: No power request PCPOWON = 1: Power request via PLC The PLC employs this control signal for requesting the NC to activate the power for the station. The power request will be ignored as long as the NC does not issue the 'power enabled' (PSPOWEN) status signal. Otherwise, the NC issues the 'power on' (PSPOWON) signal to acknowledge the 'power request'. The power ON request signal can be activated by pressing the relevant button at the machine or station. In automatic mode, the power request signal may be supplied by central power activation at the plant's main control panel. If power activation should depend on additional external conditions, those conditions must logically be linked with the power request. It was the original signal Enable. The signal function is different now. It is powering up the drives connected to the ControlBox. Wiring Slot 1 %I1.0.1 X4 2 X50 10 \ K2 & K3 St.1 #17 B10 PCPOWON Control Cable #17 0V X50:33 B16 #1

65 TransKit1 Interface Descriptions 7-6 Connector Signal Function description St.1:D12 Drive DC-Bus voltage ready PCUDRDY = 0: Drive DC-Bus voltage not available PCUDRDY = 1: Drive DC-Bus voltage available Active in all modes tells the motion controller whether or not the DC bus voltage has been built up. This signal is reported by the 'UD contact' of the drive power supply unit. The controls internal power interlocking checks for this signal to have status 1 in order to allow motion. The user must read the 'UD contact' of both drives into the PLC and AND them before outputting them as the PCUDRDY signal. Note: If only one drive installed, then the drive s 'UD contact' can directly be wired to the PCUDRDY signal. TRANS-01 note This wire was not used with TRANS-01. Wiring Control Cable X3 St Machine Enclosure Slot 1 %I With PLC #24 D12 PCUDRDY #24 X V B16 #1 PLC Logic UD1 UD2 QUD X X X A4 B4 #54 #55 UD1 ;PLC input UD2 ;PLC input Red/ Blk Wht DURADRIVE #1 DURADRIVE #2 Red/ Wht Blk Interlock cable IND3048 Interlock cable IND3048

66 TransKit1 Interface Descriptions 7-7 Connector Signal Function description TRANS-01 note Wiring Slot 2 St.1:D3 Power is on PSPOWER = 0: Power has not yet been switched on PSPOWER = 1: Power is on The NC employs this signal to report that all signals are present that must be reported after power activation. If, in addition, all the general enabling signals exist, the NC will be able to execute programs for the station in question or the axes may be moved manually. The 'Power is ON' signal is only issued if the following conditions exist: The NC reports 'power ON' to the PLC (PSPOWON=1) The main contactor is closed (PCPWRDY=1) The DC bus voltage is available (PCUDRDY=1) The main spindle is operational (PCBBMSP=1) and Power enabled is OK (PSPOWEN=1) The 'Power is ON' signal is not issued if one of the above conditions is not satisfied. In this case, the NC station diagnosis shows the first missing condition in the list. It was the orginal signal Power Interrupt. Note: The signal meaning is different it is no fault. The tag at the indicator or meaning in the PLC program needs modification. %Q2.0.1 X4 2 St.1 #21 D3 Control Cable PSPOWER #21 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Function description TRANS-01 note Wiring Internal signal: Emergency Stop at Station PCESTAT = 0 Emergency Stop chain opened at the station (PB) PCESTAT = 10 Emergency Stop chain closed at the station (PB) This signals informs NC if the Emergency Chain has been broken on the station by activation of the Emergency Stop button. At delivery The terminals X50.13 and A50.14 are jumpered, since no Emergrncy Stop pushbutton is mounted on the ControlBox. This would supply the PCESTAT and EM.STOP input of both drives with 24V through the NO contact of the Emergency Stop relay K1. If local Emergency Stop button is necessary on the ControlBox it can be added during the machine integration. The pushbutton has to be properly mounted to maintain the IP65 status of the ControlBox. This signal is not transferred to the PLC.

67 TransKit1 Interface Descriptions 7-8 NC control functions Note: The signals listed here influence the operation of the motion and provide status feedback. Connector Signal Function description TRANS-01 note Wiring Slot 2 St.1:A3 Ready to start PSREADY = 0: Not ready to start PSREADY = 1: Ready to start The signal is effective in all modes. Note: Depending on the settings of the two parameters 'reverse program execution required' and 'reference required', executing a reverse program and/or the axis reference is not necessary for starting the advance program. The 'ready to start' signal indicates that a process is ready to be started. Depending on the setting of the 'reverse program execution required' parameter, a process is first ready to be started after a reverse program has been executed. In this reverse program, reference dimension must be established for all axes that belong to the process. The 'ready to start' signal is set when the reverse program is terminated with the 'jump with stop' (BST) or 'program end with reset' (RET) command. The 'ready-to-start' condition is also established when a forward program has been correctly executed. In this case, the forward program must be terminated by a 'jump with stop' (BST) or 'program end with reset' (RET) command. The 'ready to start' signal is cleared when an advance or reverse program is active (PSACTIV). Any type of jogging movement (single axis homing, jogging) cancels the 'ready to start' signal. Successful completion of the reverse program permits the 'ready to start' signal to be re-established. Single-axis homing of all axes does not permit the 'ready to start' signal to be established. It was the original signal Ready. The wiring can remain the same if the described functionality above is acceptable. %Q2.0.5 X4 6 St.1 #18 A3 Control Cable PSREADY #18 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Function description St.1:B3 NC-program active PSACTIV = 0: No NC program being executed PSACTIV = 1: NC program being executed The signal is effective in all modes. The 'NC program active' signal shows that an NC program is being executed. Distinction between advance and reverse program is not made here. The 'NC program active' signal is retained when an NC program is stopped by a stop command. The 'NC program active' signal is cleared when a 'jump with stop' (BST) or 'program end with reset' (RET) block is executed in the program. Unlike the 'NC block active' signal, the 'NC program active' signal is retained after each NC block in single block mode. Any type of jogging movement (single axis homing, jogging) cancels the 'NC

68 TransKit1 Interface Descriptions 7-9 program active' signal. Setting the 'clear error' signal in the PLC program without a pending process error clears the 'NC program active' signal (Control Reset). TRANS-01 note Wiring Slot 2 It was the original signal Run. The wiring can remain the same if the described functionality above is acceptable. %Q2.0.6 X4 7 St.1 #19 B3 PSACTIV Control Cable #19 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:D13 Program Stop PCSTOP = 0: No program stop PCSTOP = 1: Program stop Program stop has an effect in all modes. The 'program stop' signal interrupts program execution for this process. Axis movements are decelerated along a ramp, and program preparation is interrupted. The stopped process can be continued by starting an advance or a reverse program. The 'program stop' signal has to be cleared first however. Jog movements are not influenced by setting the 'program stop' signal. It was the original signal Tool Change. This signal is no longer used and if need be, a conditional jump can be programmed in the PLC to move the axes to a tool change position. Slot 1 %I1.0.7 X4 8 #26 St.1 D13 PCSTOP Control Cable #26 0V X50:33 B16 #1 Connector Signal Function description St.1:A2 Error active PSERROR = 0: No error PSERROR = 1: Error The signal has an effect in all modes. The NC uses the 'error' signal to notify the PLC of a process error. The clear error text is displayed in the diagnosis overview of the user interface. The error number can be read from the PLC by means of the multiplex channel (cf. Field bus documentation). A pending error must be cleared by setting the 'clear error' signal in the PLC program. The 'PSERROR' error signal is set again if the error condition is still active even after the error has been cleared. An NC program cannot be executed as long as an error status is pending.

69 TransKit1 Interface Descriptions 7-10 TRANS-01 note Wiring Slot 2 It was the original signal Fault. Can remain as wired. %Q2.0.3 X4 4 %I1.0.3 St.1 #22 A2 Control Cable PSERROR #22 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Connector Signal Function description St.1:A10 Clear error / Control Reset PCCLEAR = '0' - No action PCCLEAR = '1' - Clear error / Control reset The signal has an effect in all modes. Depending on whether or not there is an error pending (PSERROR = 1), the signal has two different effects: PSERROR=0, PCCLEAR=1: Control reset PSERROR=1, PCCLEAR=1: Pending error is deleted Slot 2 RMA X4:5 Clear error / Control Reset from BTV06 BSDAT06 = '0' - No action BSDAT06 = '1' - Clear error / Control reset sets PCCLEAR =1 The signal has an effect in all modes. Depending on whether or not there is an error pending (PSERROR = 1), the signal has two different effects: PSERROR=0, PCCLEAR=1: Control reset PSERROR=1, PCCLEAR=1: Pending error is deleted Clear error: A pending error is cleared upon the rising edge of the 'clear error' signal. The NC clears the 'error' signal to indicate that the error has been cleared. The 'error' signal is set again and the error is indicated again if the error still exists. Once an error has been successfully cleared, the advance program interrupted by the error cannot be restarted. The only exception is if the 'reverse program execution required' process parameter has also been set to 'no' and if the axes have measuring reference. If a start is to be possible without measuring reference, the 'reference required' process parameter must also be set to 'no'. When a reverse program is initiated, program segments with reverse vectors will be processed first, followed by the base reverse program (starting from the jump label '.HOME'). Control Reset: A stopped NC program can be aborted by a 'Control-Reset' input. A running spindle is stopped by 'Control reset' (exception: see AxCSPRST with x=axis number of spindle). (TransKit1 sets the AxCSPRST by default to 1: Control reset does not influence the spindle ). Programmed reverse vectors are cleared. The '.HOME' base reverse vector is therefore called when a reverse program is initiated. This executes the base reverse program. Complicated return movements that permit programcontrolled establishment of the readiness to start by programming reverse vectors are not performed. The operator must perform those movements in 'Setup' mode through jog movements. Once it has been ensured that the base reverse program can be executed without interference, the operator may trigger a start of the reverse program and initiate the base reverse program. The following signals and actions are also influenced by a 'Control reset': The 'NC block active' (PSACTIV) status signal is reset

70 TransKit1 Interface Descriptions 7-11 TRANS-01 note Wiring The 'reverse program active' (PSREV) status signal is reset The 'program stopped' (PSSTOP) status signal is reset The 'control voltage interruption' (PSPOWIN) status signal is reset pending M functions are aborted an unconditional stop (M00) is terminated a conditional stop (M001) is terminated M3 spindle CCW rotation is aborted (exception: see AxCSPRST) M4 spindle CW rotation is aborted (exception: see AxCSPRST) The PSREADY signal is set to '1' if the 'homing required' parameter has been set to 'no' messages that have been generated in the NC program are cleared the NC block 'N0001' appears in the position display for the currently selected NC program Zero offsets are switched off the upper limit of the override value is set to 100% G codes are set according to their default values Internal couplings are deactivated (e.g., tapping) event monitoring is de-activated Process acceleration is set to 100% the 'travel to dead stop' state is reset a pending AXD-command from the NC is aborted spindle '1' is used as reference spindle the D corrections are de-activated It was the original signal Restart. The signal function is now different and is used to reset the error in the TransKit1. Slot 2 %Q2.0.4 X4 5 St.1 Control Cable BSDAT06 24V X50 32 C16 #2 0V 33 B16 #1 Slot 1 %I1.0.4 X4 5 Diodes in the terminal St.1 X50:11 #16 A10 PCCLEAR #16 0V X50:33 B16 #1 Connector Signal Function description St.1:C10 Automatic/Manual mode PCMODE1 = 0: Automatic mode PCMODE1 = 1: Manual Mode With the TransKit1 the signal PCMODE0 is not used and has the status 0. Automatic' mode: 'Automatic mode' permits only NC programs to be executed. Moving axes by jog commands is not possible. Advance program:

71 TransKit1 Interface Descriptions The NC advance program is started by a 'start advance program' (PCADV) signal. 2. The 'Program active' (PSACTIV) signal indicates the NC advance program is being executed. The 'Reverse program active' (PSREV) signal remains cleared while an advance program is being executed. The 'ready to start' (PSREADY) signal is canceled when the advance program execution starts. 3. In 'automatic mode', one impulse is sufficient for starting the NC advance program. The start signal may be cleared once the NC program execution has started. The NC program will be completed even if the advance program start signal is no longer applied. 4. The 'Program active' (PSACTIV) signal is cleared when the NC advance program is completed. At the same time, the subsequent NC advance program will have the 'ready to start' (PSREADY) signal assigned. Reverse program: 1. The NC reverse program is started by a 'start reverse program' (PCREV) signal. 2. The 'program active' (PSACTIV) and 'reverse program active' (PSREV) signals indicate the NC reverse program is being executed. The 'ready to start' (PSREADY) signal is canceled at the same time. 3. In 'Automatic' mode, one impulse is sufficient for starting the NC reverse program. The start signal may be cleared once the NC program execution has started. The NC program will be completed even if the reverse program start signal is no longer applied. 4. The 'program active' (PSACTIV) and 'reverse program active' (PSREV) signals are cleared when the NC reverse program is completed. An NC advance program will have the 'ready to start' (PSREADY) signal assigned if reference exists for all the axes after the reverse program has been executed. 'Manual' mode' 'Manual mode permits NC programs to be executed and axes to be moved by jog commands. NC-program operation is the same as in semi-automatic mode, explained below. Advance program: 1. The NC advance program is started by a 'start advance program' (PCADV) signal. 2. The 'Program active' (PSACTIV) signal indicates the NC advance program is being executed. The 'Reverse program active' (PSREV) signal remains cleared while an advance program is being executed. The 'ready to start' (PSREADY) signal is canceled when the advance program starts to be executed. 3. In 'semi-automatic' mode, the NC advance program is executed as long as the advance program start signal is applied. 4. The axes and NC program will be stopped immediately if the start advance signal is removed while the NC advance program is being executed. The interruption is indicated by the 'program stopped' (PSSTOP) signal. 5. A new start advance program signal permits the NC advance program to be resumed from the point of interruption. 6. Restarting the advance program clears the 'program stopped' (PSSTOP) signal. 7. The 'program active' signal is cleared when the NC advance program is completed. At the same time, the 'ready to start' signal will be assigned for a new advance program. 8. The start signal may be cleared when the advance program is completed. Reverse program: 1. The NC reverse program is started by a 'start reverse program' (PCREV) signal. 2. The 'program active (PSACTIV) and 'reverse program active' (PSREV)

72 TransKit1 Interface Descriptions 7-13 signals indicate the NC reverse program is being executed. The 'ready to start' signal (PSREADY) is canceled at the same time. 3. In 'semi-automatic' mode, the NC reverse program is executed as long as the reverse program start signal is applied. 4. The axes and NC program will be stopped immediately if the start reverse program signal is removed while the NC reverse program is being executed. The interruption is indicated by the 'program stopped' (PSSTOP) signal. 5. A new start reverse program signal permits the NC reverse program to be resumed from the point of interruption. 6. Restarting the reverse program clears the 'program stopped' (PSSTOP) signal. 7. The 'program active' signal is cleared when the NC reverse program is completed. At the same time, the 'ready to start' signal will be assigned for an advance program start. 8. The start signal may be cleared when the reverse program is completed. TransKit1 Note1: Through the BTV06 setup configuration it is possible to enable the NC program execution in Manual Mode using the BTV06 L1 and R1 buttons. TransKit1 Note2: All the status signals disussed above with the exception of PSRUN and PSREV are available through the standard output assignment. TRANS-01 note Wiring It was the original signal Auto. The signal functioning is similar but the signal level is reversed. In Trans-01 HI status indicated AUTO mode, while here it indicates MANUAL. Slot 1 %I1.0.2 X4 3 #23 St.1 B10 PCMODE1 Control Cable #23 0V X50:33 B16 #1 Connector Signal Function description St.1:A12 Enable PCENABL = 0: No process enable signal PCENABL = 1: Process enable signal available The process enable signal has an effect in all modes. The 'process enable' signal is required for moving an axis or for executing an NC program. Power remains ON when the process enable signal is removed. An immediate stop is initiated for the process if the process enable signal is removed while an NC program is running. Axis movements are decelerated along a ramp curve, and program execution is interrupted. The NC program can only be restarted after the process enable signal has been applied. The 'start advance program' signal (PCADV) can be used for restarting an interrupted advance program. The 'start reverse program' signal (PCREV) can be used for restarting an interrupted reverse program. If the process enable signal is removed during a jog movement (single axis homing, jogging), the jog process is interrupted and axis movement is decelerated along a ramp.

73 TransKit1 Interface Descriptions 7-14 TRANS-01 note Jog movements can only be continued after the process enable signal has been re-applied. It was the original signal Forward Enable. The signal functioning is similar but motion execution will require an edge at PCADV or PCREV. Wiring Slot 1 %I1.1.5 X3 6 #60 St.1 A12 PCENABL Control Cable #60 0V X50:33 B16 #1 Connector Signal Function description St.1:B12 Advance program (Start) NOTE: By default this external signal is active only in the AUTO mode. It is possible to change the BTV06 setup this way, that the program ADV and REV can be run in MAN mode through the L1 and R1 buttons respectively. PCADV = 0: No advance program start PCADV = 1: Advance program start This control signal has different meanings in the different modes. Requirements for the start of the advance program: Power present No error Process enabling signal issued No reverse program active, and Ready to start 'Automatic' mode A positive edge of the 'Start of advance program' (PCADV) signal starts the advance program when the ready to start signal (PSREADY=1) has been issued. The 'start of advance program' signal can be removed when the advance program is processed. The restart of an interrupted advance program from the currently active block number is also triggered by a positive edge of the 'start of advance program' signal. 'Manual' mode The positive edge of the 'start of advance program' signal (PCADV) starts the advance program. Unlike in 'Automatic' mode, the NC monitors the 'start advance program' signal in the other modes after the program has been started. The advance program is executed as long as the signal is applied. When the signal is removed, active movements are decelerated along a ramp, and program execution is interrupted. A new advance program start restarts program execution. The following conditions interrupt an advance program: Power shutdown

74 TransKit1 Interface Descriptions 7-15 TRANS-01 note Error Process enabling signal removed Stop Changing modes single step mode, and Starting a reverse program It was the original signal Start. The signal functioning is similar. Wiring Slot 2 %Q2.0.2 X4 3 PSMODE1 0V 33 B16 MAN mode selected Control Cable K4 St.1 X V 32 C16 #2 #1 Outputs Q3 3 Output on when L1 (advance) is pressed and MAN mode active 24V 0V K4 K5 Supply BTV06 outputs when MAN mode selected Slot 1 %I1.0.5 X4 6 K5 #14 B12 PCADV #14 Connector Signal Function description St.1:D10 Reverse (homing) program start NOTE: By default this external signal is active only in the AUTO mode. It is possible to change the BTV06 setup this way, that the program ADV and REV can be run in MAN mode through the L1 / R1 buttons respectively. PCREV = 0: No reverse program start PCREV = 1: Reverse program start Requirements for the start of the reverse program: Power present - No error condition exists, and Process enabling signal issued This control signal has different meanings in the different modes. 'Automatic' mode A positive edge of the 'start of reverse program' (PCREV) signal starts the reverse program. A reverse program start may also be initiated while an advance program is being executed or stopped. The 'start of reverse program' signal may be removed when the reverse program is processed. The restart of an interrupted reverse program from the currently active block number is triggered by a positive edge of the 'start of reverse program' signal.

75 TransKit1 Interface Descriptions 7-16 TRANS-01 note Wiring 'Setup' mode A positive edge of the 'start of reverse program' signal starts the reverse program. Unlike in 'Automatic' mode, the NC monitors the 'start reverse program' signal in the other modes after the program has been started. The reverse program is executed as long as the signal is applied. When the signal is removed, active movements are decelerated along a ramp, and program execution is interrupted. Program execution is resumed (restart) when the signal is re-applied. The following conditions interrupt a reverse program: Power shutdown Error - Process enabling signal removed - Stop single step mode, and Changing modes It was the original signal Homing. The signal functioning is similar. Slot 2 %Q2.0.2 X4 3 PSMODE1 MAN mode selected Control Cable K4 X50 St V C16 #2 0V 33 B16 #1 Outputs Q4 4 Output on when R1 (reverse) is pressed and MAN mode active 13 24V 0V 14 K4 K6 Supply BTV06 outputs when MAN mode selected Slot 1 %I1.0.6 X4 7 K6 #15 D10 PCREV #15 Connector St.1:A11 Branching conditions 2 0 Signal PCCOND0 = 0: Condition bit 2 0 inactive PCCOND0 = 1: Condition bit 2 0 active The branching conditions have an effect in all modes. Function description TRANS-01 note Wiring Applying a bit combination to the inputs PCCONDn (n = 0 to 3 for TransKit) satisfies the condition with the corresponding number in the NC program. The condition can be queried in the NC program by means of the allocated NC commands (BES / BEV). The number of the condition is assigned to the inputs as a binary value. The weight of each input follows directly from n to 2^n. It was the original signal Conditional Jump Input 2 0. The signal functioning is similar but uses NC-events in the NC-program.

76 TransKit1 Interface Descriptions 7-17 Slot 1 %I1.1.0 X3 1 #30 St.1 A11 PCCOND0 Control Cable #30 0V X50:33 B16 #1 Connector St.1:B11 Branching conditions 2 1 Signal PCCOND1 = 0: Condition bit 2 1 inactive PCCOND1 = 1: Condition bit 2 1 active The branching conditions have an effect in all modes. Function Applying a bit combination to the inputs PCCONDn (n = 0 to 3 for TransKit) description satisfies the condition with the corresponding number in the NC program. The condition can be queried in the NC program by means of the allocated NC commands (BES / BEV). The number of the condition is assigned to the inputs as a binary value. The weight of each input follows directly from n to 2^n. TRANS-01 note It was the original signal Conditional Jump Input 2 1. The signal functioning is similar but uses NC-events in the NC-program. Wiring Slot 1 %I1.1.1 X3 2 #29 St.1 B11 PCCOND1 Control Cable #29 0V X50:33 B16 #1 Connector St.1:C11 Branching conditions 2 2 Signal PCCOND2 = 0: Condition bit 2 2 inactive PCCOND2 = 1: Condition bit 2 2 active The branching conditions have an effect in all modes. Function Applying a bit combination to the inputs PCCONDn (n = 0 to 3 for TransKit) description satisfies the condition with the corresponding number in the NC program. The condition can be queried in the NC program by means of the allocated NC commands (BES / BEV). The number of the condition is assigned to the inputs as a binary value. The weight of each input follows directly from n to 2^n. TRANS-01 note It was the original signal Conditional Jump Input 2 2. The signal functioning is similar but uses NC-events in the NC-program. Wiring

77 TransKit1 Interface Descriptions 7-18 Slot 1 %I1.1.2 X3 3 #28 St.1 C11 PCCOND2 Control Cable #28 0V X50:33 B16 #1 Connector St.1:D11 Branching conditions 2 3 Signal PCCOND3 = 0: Condition bit 2 3 inactive PCCOND3 = 1: Condition bit 2 3 active The branching conditions have an effect in all modes. Function Applying a bit combination to the inputs PCCONDn (n = 0 to 3 for TransKit) description satisfies the condition with the corresponding number in the NC program. The condition can be queried in the NC program by means of the allocated NC commands (BES / BEV). The number of the condition is assigned to the inputs as a binary value. The weight of each input follows directly from n to 2^n. TRANS-01 note It was the original signal Conditional Jump Input 2 3. The signal functioning is similar but uses NC-events in the NC-program. Wiring Slot 1 %I1.1.3 X3 4 #27 St.1 D11 PCCOND3 Control Cable #27 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:C13 Asynchronous condition (Event) PCEVENT = 0: Asynchronous condition deleted PCEVENT = 1: Asynchronous condition set The PCEVENT signal interrupts any NC program that is running. All moving axes are stopped as quickly as possible. Then a block is started that has been previously defined by means of program control commands (BEV). The NC program is continued with this block. It was the original signal Spindle Enable Manual Mode. This signal is no longer used since the TRANS200 will control the spindle enable.

78 TransKit1 Interface Descriptions 7-19 Slot 1 %I1.1.4 X3 5 #49 St.1 C13 PCEVENT Control Cable #49 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note Wiring Slot 2 St.1:C2 Thrust missing PSTHMIS = 0: The machining torque has not exceeded the pre-selected minimum machining torque (parameter B00.065) during machining. PSTHMIS = 1: The machining torque has exceeded the pre-selected minimum machining torque (parameter B00.065) during machining. The signal is effective in all modes. The 'PSTHMIS' signal indicates that the minimum machining torque (parameter B00.065) has not been exceeded during machining with an active "adaptive feed control" function. The 'PSTHMIS' signal is set, if the minimum machining torque (Parameter B00.065) is not exceeded when the "adaptive feed control" (G25) function is shut down. The 'PSTHMIS' signal is reset, as soon as: the adaptive feed control" function is switched on (G26), the program processing has been completed (RET / BST), any "control reset" has been cleared. The following are possible reasons why the minimum machining torque has not been exceeded: missing work piece Tool breakage incorrect correction data (D corrections) faulty zero offsets It was the original signal Thrust missing. The wiring can remain if the described functionality above is acceptable. %Q2.1.0 X3 1 St.1 #58 C2 Control Cable #58 24V X50 32 C16 #2 0V X50:33 B16 #1 Connector Signal Function description St.1:D2 Excessive Thrust PSEXCTH = 0: The current feed reduction does not exceed the maximum feed reduction (parameter B00.067). PSEXCTH = 1: The current feed reduction does exceed the maximum feed reduction (parameter B00.067). The signal is effective in all modes. The 'PSEXCTH' signal indicates that the maximum feed reduction (Parameter B00.067) has been exceeded during machining with an active "adaptive feed control" function.

79 TransKit1 Interface Descriptions 7-20 The 'PSEXCTH' signal is set, as soon as the current feed reduction exceeds the "maximum feed reduction" (Parameter B00.067) limit value. The 'PSEXCTH' signal is reset, as soon as the current feed reduction falls short of the "maximum feed reduction" (Parameter B00.067) limit value. Note: The NC continues machining even if the current feed reduction exceeds the "maximum speed reduction" (parameter B00.067) limit value. Not until the current feed reduction reaches 100% for more than 20 ms (axis standstill) and the value of the "maximum feed reduction" (Parameter B00.067) limit value is less than 100%, does TRANS200 stop the machining process and generate error message "100% feed axis". The following are possible reasons why the maximum feed reduction has been exceeded: sluggish mechanical system worn-out tool coolant supply interrupted TRANS-01 note Wiring Slot 2 It was the original signal Excessive Thrust. The wiring can remain if the described functionality above is acceptable. %Q2.1.1 X3 2 St.1 #59 D2 Control Cable P2EXCTH #59 24V X50 32 C16 #2 0V 33 B16 #1

80 TransKit1 Interface Descriptions 7-21 Auxiliary functions Note: The auxiliary functions work differently than with the Trans-01. By default, the auxiliary functions o are output at the end of the NC-block o must be acknowledged at the end of the NC-block to continue motion program execution. Based on the machine function to be initiated by an auxiliary functions such as o clamp/unclamp, o coolant on/off, o full depth, o position reached, o the status of the auxiliary functions must be stored (set/reset or latched/unlatched) in the machine PLC program if the function must be retained after their acknowledgement. Below a simplified example on how the state if auxiliary function signals from the Trans200 in the ControlBoxD can be stored in the PLC logic. Additional conditions and interlocks maybe required depending on the specific function to be achieved and situation. Fig : Auxiliary function in PLC program

81 TransKit1 Interface Descriptions 7-22 Connector St.1:A7 Auxiliary function output 400 Signal PSAUX400 = 0: No signaling PSAUX400 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX400 signal can be set by executing NC description auxiliary functions (M400 or MQ400), see separate description. All signaling must be acknowledged via the allocated PCACKN400 signal. The NC program is either interrupted until the acknowledgement is received (M400) or the NC program can request the acknowledgment later (by means of MW400 if NC-program ahead contained MQ400). Renewed signaling via the same output signal is only possible following an acknowledgment. Note: PSAUX400 and PSAUX401 belong to the same group. It means that their use in the NC block is mutually exclusive. TRANS-01 note It was the original signal Auxiliary Function output 0. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. Wiring Slot 2 %Q2.3.0 X1 1 St.1 #31 A7 Control Cable PSAUX400 #31 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:B7 Auxiliary function output 401 Signal PSAUX401 = 0: No signaling PSAUX401 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX401 signal can be set by executing NC description auxiliary functions (M401 or MQ401), see separate description. All signaling must be acknowledged via the allocated PCACKN401 signal. The NC program is either interrupted until the acknowledgement is received (M401) or the NC program can request the acknowledgment later (by means of MW401 if NC-program ahead contained MQ401). Renewed signaling via the same output signal is only possible following an acknowledgment. Note: PSAUX400 and PSAUX401 belong to the same group. It means that their use in the NC block is mutually exclusive. TRANS-01 note It was the original signal Auxiliary Function output 1. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. Wiring

82 TransKit1 Interface Descriptions 7-23 Slot 2 %Q2.3.1 X1 2 St.1 #32 B7 Control Cable PSAUX401 #32 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:C7 Auxiliary function output 404 Signal PSAUX404 = 0: No signaling PSAUX404 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX404 signal can be set by executing NC description auxiliary functions (M404 or MQ404), see separate description. All signaling must be acknowledged via the allocated PCACKN404 signal. The NC program is either interrupted until the acknowledgement is received (M404) or the NC program can request the acknowledgment later (by means of MW404 if NC-program ahead contained MQ404). Renewed signaling via the same output signal is only possible following an acknowledgment. Note: PSAUX404 and PSAUX405 belong to the same group. It means that their use in the NC block is mutually exclusive. TRANS-01 note It was the original signal Auxiliary Function output 2. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. Wiring Slot 2 %Q2.3.2 X1 3 St.1 #33 C7 Control Cable PSAUX404 #33 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:D7 Auxiliary function output 405 Signal PSAUX405 = 0: No signaling PSAUX405 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX405 signal can be set by executing NC description auxiliary functions (M405 or MQ405), see separate description. All signaling must be acknowledged via the allocated PCACKN405 signal. The NC program is either interrupted until the acknowledgement is received (M405) or the NC program can request the acknowledgment later (by means of MW405 if NC-program ahead contained MQ405). Renewed signaling via the same output signal is only possible following an acknowledgment. Note: PSAUX404 and PSAUX405 belong to the same group. It means that their use in the NC block is mutually exclusive. TRANS-01 note It was the original signal Auxiliary Function output 3. The signal functioning

83 TransKit1 Interface Descriptions 7-24 Wiring Slot 2 is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. %Q2.3.3 X1 4 St.1 #34 D7 Control Cable PSAUX405 #34 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:A6 Auxiliary function output 408 Signal PSAUX408 = 0: No signaling PSAUX408 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX408 signal can be set by executing NC description auxiliary functions (M408 or MQ408), see separate description. All signaling must be acknowledged via the allocated PCACKN408 signal. The NC program is either interrupted until the acknowledgement is received (M408) or the NC program can request the acknowledgment later (by means of MW408 if NC-program ahead contained MQ408). Renewed signaling via the same output signal is only possible following an acknowledgment. Note: PSAUX408 and PSAUX409 belong to the same group. It means that their use in the NC block is mutually exclusive. TRANS-01 note It was the original signal Auxiliary Function output 4. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. Wiring Slot 2 %Q2.3.4 X1 5 St.1 #35 A6 Control Cable PSAUX408 #35 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:B6 Auxiliary function output 409 Signal PSAUX409 = 0: No signaling PSAUX409 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX409 signal can be set by executing NC description auxiliary functions (M409 or MQ409), see separate description. All signaling must be acknowledged via the allocated PCACKN409 signal. The NC program is either interrupted until the acknowledgement is received (M409) or the NC program can request the acknowledgment later (by means of MW409 if NC-program ahead contained MQ409). Renewed signaling via the

84 TransKit1 Interface Descriptions 7-25 TRANS-01 note Wiring Slot 2 same output signal is only possible following an acknowledgment. Note: PSAUX408 and PSAUX409 belong to the same group. It means that their use in the NC block is mutually exclusive. It was the original signal Auxiliary Function output 5. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. %Q2.3.5 X1 6 St.1 #36 B6 Control Cable PSAUX409 #36 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:C6 Auxiliary function output 412 Signal PSAUX412 = 0: No signaling PSAUX412 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX412 signal can be set by executing NC description auxiliary functions (M412 or MQ412), see separate description. All signaling must be acknowledged via the allocated PCACKN412 signal. The NC program is either interrupted until the acknowledgement is received (M412) or the NC program can request the acknowledgment later (by means of MW412 if NC-program ahead contained MQ412). Renewed signaling via the same output signal is only possible following an acknowledgment. Note: PSAUX412 and PSAUX413 belong to the same group. It means that their use in the NC block is mutually exclusive. TRANS-01 note It was the original signal Auxiliary Function output 6. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. Wiring Slot 2 %Q2.3.6 X1 7 St.1 #37 C6 Control Cable PSAUX412 #37 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:D6 Auxiliary function output 413 Signal PSAUX413 = 0: No signaling PSAUX413 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX413 signal can be set by executing NC description auxiliary functions (M413 or MQ413), see separate description. All signaling must be acknowledged via the allocated PCACKN413 signal. The NC program is either interrupted until the acknowledgement is received (M413) or the NC program can request the acknowledgment later (by means of

85 TransKit1 Interface Descriptions 7-26 TRANS-01 note Wiring Slot 2 MW413 if NC-program ahead contained MQ413). Renewed signaling via the same output signal is only possible following an acknowledgment. Note: PSAUX412 and PSAUX413 belong to the same group. It means that their use in the NC block is mutually exclusive. It was the original signal Auxiliary Function output 7. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. %Q2.3.7 X1 8 St.1 #38 D6 Control Cable PSAUX413 #38 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:C5 Auxiliary function output 420 Signal PSAUX420 = 0: No signaling PSAUX420 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX420 signal can be set by executing NC description auxiliary functions (M420 or MQ420), see separate description. All signaling must be acknowledged via the allocated PCACKN420 signal. The NC program is either interrupted until the acknowledgement is received (M420) or the NC program can request the acknowledgment later (by means of MW420 if NC-program ahead contained MQ420). Renewed signaling via the same output signal is only possible following an acknowledgment. Note: PSAUX420 and PSAUX421 belong to the same group. It means that their use in the NC block is mutually exclusive. (Functions were intended to be used with PIM option, which is not implemented.) TRANS-01 note It was the original signal BCD 10*4. This function is no longer available since the TransKit1 does not support BCD output. Wiring Slot 2 %Q2.2.6 X1 7 St.1 #52 C5 Control Cable PSAUX420 #52 24V24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:D5 Auxiliary function output 421 Signal PSAUX421 = 0: No signaling PSAUX421 = 1: NC signaling active The signal has an effect in all modes. Function In the NC program, the PSAUX421 signal can be set by executing NC description auxiliary functions (M421 or MQ421), see separate description. All signaling must be acknowledged via the allocated PCACKN421 signal. The NC program is either interrupted until the acknowledgement is received (M421) or the NC program can request the acknowledgment later (by means of

86 TransKit1 Interface Descriptions 7-27 TRANS-01 note Wiring Slot 2 MW421 if NC-program ahead contained MQ421). Renewed signaling via the same output signal is only possible following an acknowledgment. Note: PSAUX420 and PSAUX421 belong to the same group. It means that their use in the NC block is mutually exclusive. (Functions were intended to be used with PIM option, which is not implemented.) It was the original signal BCD 10*8. This function is no longer available since the TransKit1 does not support BCD output. %Q2.2.7 X1 8 St.1 #53 D6 Control Cable PSAUX421 #53 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:D8 Auxiliary function 400 acknowledge PCACKN400 = 0: No acknowledgement PCACKN400 = 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M400 or MQ400 has to be acknowledged via the allocated control signals PCACKN400. Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX400), see separate description. It was the original signal Auxiliary Function output 0 acknowledge. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. Slot 1 %I1.3.0 X1 1 #39 St.1 D8 PCACKN400 Control Cable #39 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note St.1:C8 Auxiliary function 401 acknowledge PCACKN401 = 0: No acknowledgement PCACKN401 = 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M401 or MQ401 has to be acknowledged via the allocated control signals PCACKN401. Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX401), see separate description. It was the original signal Auxiliary Function output 1 acknowledge. The signal functioning is different and the number of the auxiliary function

87 TransKit1 Interface Descriptions 7-28 Wiring changes. The TransKit1 does not monitor the state of the acknowledge signal. Slot 1 %I1.3.1 X1 2 #40 St.1 C8 PCACKN401 Control Cable #40 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:B8 Auxiliary function 404 acknowledge PCACKN404 = 0: No acknowledgement PCACKN404 = 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M404 or MQ404 has to be acknowledged via the allocated control signals PCACKN404. Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX404), see separate description. It was the original signal Auxiliary Function output 2 acknowledge. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. Slot 1 %I1.3.2 X1 3 #41 St.1 B8 PCACKN404 Control Cable #41 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:A8 Auxiliary function 405 acknowledge PCACKN405 = 0: No acknowledgement PCACKN405 = 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M405 or MQ405 has to be acknowledged via the allocated control signals PCACKN405. Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX405), see separate description. It was the original signal Auxiliary Function output 3 acknowledge. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal.

88 TransKit1 Interface Descriptions 7-29 Slot 1 %I1.3.3 X1 4 #42 St.1 A8 PCACKN405 Control Cable #42 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:D9 Auxiliary function 408cknowledge PCACKN408 = 0: No acknowledgement PCACKN408 = 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M408 or MQ408 has to be acknowledged via the allocated control signals PCACKN408 Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX408), see separate description. It was the original signal Auxiliary Function output 4 acknowledge. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. Slot 1 %I1.3.4 X1 5 #43 St.1 D9 PCACKN408 Control Cable #43 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:C9 Auxiliary function 409 acknowledge PCACKN409 = 0: No acknowledgement PCACKN409 = 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M409 or MQ409 has to be acknowledged via the allocated control signals PCACKN409 Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX409), see separate description. It was the original signal Auxiliary Function output 5 acknowledge. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal.

89 TransKit1 Interface Descriptions 7-30 Slot 1 %I1.3.5 X1 6 #44 St.1 C9 PCACKN409 Control Cable #44 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:B9 Auxiliary function 412 acknowledge PCACKN412= 0: No acknowledgement PCACKN412= 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M412 or MQ412 has to be acknowledged via the allocated control signals PCACKN412 Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX412), see separate description. It was the original signal Auxiliary Function output 6 acknowledge. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal. Slot 1 %I1.3.6 X1 7 #45 St.1 B9 PCACKN412 Control Cable #45 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:A9 Auxiliary function 413 acknowledge PCACKN413 = 0: No acknowledgement PCACKN413 = 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M413 or MQ413 has to be acknowledged via the allocated control signals PCACKN413 Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX413), see separate description. It was the original signal Auxiliary Function output 7 acknowledge. The signal functioning is different and the number of the auxiliary function changes. The TransKit1 does not monitor the state of the acknowledge signal.

90 TransKit1 Interface Descriptions 7-31 Slot 1 %I1.3.7 X1 8 #46 St.1 A9 PCACKN413 Control Cable #46 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:A13 Auxiliary function 420 acknowledge PCACKN420= 0: No acknowledgement PCACKN420= 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M420 or MQ420 has to be acknowledged via the allocated control signals PCACKN420 Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX420), see separate description. The signal was not assigned in the original TRANS-01. Slot 1 %I1.2.6 X1 7 #47 St.1 A13 PCACKN420 Control Cable #47 0V X50:33 B16 #1 Connector Signal Function description TRANS-01 note St.1:B13 Auxiliary function 421 acknowledge PCACKN421 = 0: No acknowledgement PCACKN421 = 1: NC signal is acknowledged The signal has an effect in all modes. Signals generated in the NC program by M421 or MQ421 has to be acknowledged via the allocated control signals PCACKN421 Only as a result of the acknowledgment can the NC cancel the relevant output signal (PSAUX421), see separate description. The signal was not assigned in the original TRANS-01. Wiring

91 TransKit1 Interface Descriptions 7-32 Slot 1 %I1.2.7 X1 8 #48 St.1 B13 PCACKN421 Control Cable #48 0V X50:33 B16 #1 Axis #1 functions Axis #1 can be a servo axis. Additional signals for functions such as touch probing, and way points are provided. Note: Axis #1 must not be used as spindle axis since respective signals are not available via connector St.1. Connector Signal Function description TRANS-01 note Wiring X54:1; X54:10 Axis #1 drive ready A1READY = 0: Drive not ready for power on A1READY = 1: Drive ready for power on The signal has an effect in all modes. The signal indicates when the DURADRIVE is ready for switching the 3- phase main power on. When ready, the drive shows Bb on the display and the Bb contact closes. See also Connector X54 Drive #1 Interlock Cable for further details. N/A X54 HDC01.1-AxxxN-SE01-01-FW ControlBoxD X50 0V 11 White 1.0 X1 3 0VDC DURADRIVE #1 24V #83 12 Blue VDCBb Slot 1 X2 %I Interlock Cable IND m Bb ON1 Violet X11 7 ON1 On3 10 Yellow 8 On \ Pink 0V 910 K2:14 9 Green Vpro K2:11 8 Brown 12 ZKS1 \ 6 2 ZKS1 0V 3 4 5

92 TransKit1 Interface Descriptions 7-33 Connector Signal Function description TRANS-01 note Wiring Slot 2 St.1:C3 Axis #1 is homed A1SHOMED = 0 : Axis #1 reference (home) not present A1SHOMED = 1 : Axis #1 is homed This signal tells the PLC whether or not the axis has been homed. With incremental position measuring systems, reference must be reestablished whenever the controller is switched on. This can be done manually for each individual axis using the 'axis homing' signal (AxCHOME) or be programmed via the valid NC reverse program. Single-axis homing of all axes of a process does not make the NC program of that process ready to start. The ready-to-start condition can only be attained by executing a NC reverse program (see signal: 'Ready to start'). The 'axis is homed' signal is used as a validity signal for the waypoint signals of that axis. It was original signal HOME. Note: signal only reflects if Axis #1 is homed. %Q2.2.0 X2 1 St.1 #20 C3 Control Cable A1SHOMED #20 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Function description TRANS-01 note Wiring Connector Signal Function description TRANS-01 note St.1:B14 Axis 1 home switch Wire from the axis home switch (24VDC). The 0VDC External wire of the external power supply must be connected to GND and 0VDC Internal. The switch indicates to the drive that the home switch has reached the home switch cam/dog. It was the original signal Home Limit Switch. See diagram below. St.1:C14 Axis 1 positive overtravel switch Wire from the axis home switch (24VDC). The 0VDC External wire of the external power supply must be connected to GND and 0VDC Internal. The switch indicates to the drive that the hardware overtravel switch has reached the switch cam/dog. It was the original signal - overtravel limit switch. The limit switches are now reversed.

93 TransKit1 Interface Descriptions 7-34 Wiring Connector Signal Function description TRANS-01 note Wiring See diagram below. St.1:D14 Axis 1 negative overtravel switch Wire from the axis home switch (24VDC). The 0VDC External wire of the external power supply must be connected to GND and 0VDC Internal. The switch indicates to the drive that the hardware overtravel switch has reached the switch cam/dog. It was the original signal + overtravel limit switch. The limit switches are now reversed. See diagram below. X #12 #11 #10 St.1 B14 C14 D14 Control Cable #12 #11 #10 Home LS Pos. OT LS Neg. OT LS 0V X50 33 #1 X Blue/ Blk Yell/ Blk Grn/ Blk Wht Interlock Cable INK0209 Complete cable IND3048 X X1 3 DURADRIVE Axis 1 HDC01.1-AxxxN-SE01-01-FW Connector St.1:C12 Axis #1 Probe 1 Signal Probe 1 = depends on the active drive parameter configuration Only effective if the Probe 1 functionality is activated in the digital DURADRIVE amplifier. Note: The Probe function is only available for Axis #1! Function 1. Connections: description The user must connect the external probe (switch type) to the St.1:C12. The probe signal is routed to the high-speed probe input of the digital DURADRIVE Axis #1. The user must also - Connect the Probe signal in parallel to the St.1:C13 wire representing the asynchronous event - Activate the event monitoring -

94 TransKit1 Interface Descriptions Drive setup: The user must configure (edge selection, arming, etc.) for the Probe 1 input using the AXD NC-command, e.g. via the subroutine or reverse (HOME) program. (See blocks N003 to N005 in the attached example. ) Note: The probe used must have a deflection in the direction of probing. The distance of deflection must be large enough so that the motion can be stopped after signal recognition without damaging the probe. If probe will not trigger in the expected area, program should stop (See block N0010 in the attached example) and message can be issued. Example probing subroutine: TRANS-01 note Wiring This functionality did NOT exist with the Trans-01. Caution: The original signal of St.1:C12 was Reverse. This signal is not used anymore. Reverse program execution is triggered through the input St.1:D10 PCREV described before.

95 TransKit1 Interface Descriptions 7-36 ControlBoxD St.1 Control Cable X50 22 #25 C12 Probe 1 #25 X V B16 0V X Blue Wht Interlock Cable INK0209 Complete cable IND3048 DURADRIVE Axis #1 HDC01.1-AxxxN-SE01-01-FW Connector Signal Function description TRANS-01 note Wiring St.1:C4 Axis #1 Real Time Status Bit A1SIDDS = 0: Axis 1 Real-Time status bit is OFF A1SIDDS = 1: Axis 1 Real Time status bit is ON This signal enables the PLC to read a real-time status bit in the drive via the NC. The status that is read from the drive depends on the allocation of an ID number to the real-time status bit in the SERCOS parameters. Please refer to the SERCOS Interface description for a list of the parameters that can be allocated to a real-time bit and for an explanation of the procedure for allocating a parameter to the real-time bit. This function did not exist in the Trans-01. The original signal of St.1:C04 was BCD 10*2 2. This function is no longer available since the TransKit1 does not support BCD outputs. Slot 2 %Q2.2.2 X2 3 St.1 #56 C4 Control Cable A1SIDDS #56 24V X50 32 C16 #2 0V X50:33 B16 #1

96 TransKit1 Interface Descriptions 7-37 Connector St.1:D4 Axis #1 Waypoint 0 Signal A1SWP0 = 0: The active axis position is less than the position defined for the waypoint 0 A1SWP0 = 1: The active axis position is less than the position defined for the waypoint 0 Function The TRANS200 permits up to 8 positions to be entered in the axis description parameters of each axis. Each position (0 to 7) is allocated to a status signal 'AxSWPn' (n = 0-7). Independently of the NC program, the status of the individual signal A1SWP0 shows whether the current axis position is less than or greater than the position that is stored in the associated axis parameter A01.C025. These waypoints permit working area protections to be programmed. TRANS-01 note Wiring Note: The NC always outputs the waypoints, even if the axis has not yet been homed. TRANS200 stores the axis positions when the controller is switched off, and restores them when it is switched on. It can therefore be assumed that, even without homing, the positions may be employed for performing rough monitoring activities using the waypoints. Obviously, this is not true after the machine has been manually manipulated or after new parameters have been loaded. The absolute validity of the waypoints can only be assured by including the 'axis homed' signal (AxSHOMED). Note: Although the TRANS200 permits to use up to 8 waypoints, the TransKit limits them to only two: Waypoint 0 and Waypoint 1. This function did not exist in the Trans-01. Caution: The original signal of St.1:D4 was BCD 10*2 3.. This function is no longer available since the TransKit1 does not support BCD outputs. Slot 2 %Q2.2.3 X2 4 St.1 #57 D4 A1SWP0 Control Cable #57 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:A5 Axis #1 Waypoint 1 Signal A1SWP1 = 0: The active axis position is less than the position defined for the waypoint 1 A1SWP1 = 1: The active axis position is less than the position defined for the waypoint 1 Function The TRANS200 permits up to 8 positions to be entered in the axis description parameters of each axis. Each position (0 to 7) is allocated to a status signal 'AxSWPn' (n = 0-7). Independently of the NC program, the status of the individual signal A1SWP1 shows whether the current axis position is less than or greater than the position that is stored in the associated axis parameter A01.C026. These waypoints permit working area protections to be programmed.

97 TransKit1 Interface Descriptions 7-38 TRANS-01 note Wiring Note: The NC always outputs the waypoints, even if the axis has not yet been homed. TRANS200 stores the axis positions when the controller is switched off, and restores them when it is switched on. It can therefore be assumed that, even without homing, the positions may be employed for performing rough monitoring activities using the waypoints. Obviously, this is not true after the machine has been manually manipulated or after new parameters have been loaded. The absolute validity of the waypoints can only be assured by including the 'axis homed' signal (AxSHOMED). Note: Although the TRANS200 permits to use up to 8 waypoints, the TransKit limits them to only two: Waypoint 0 and Waypoint 1. This function did not exist in the Trans-01. Caution: The original signal of St.1:A5 was BCD 1*2 0. This function is no longer available since the TransKit1 does not support BCD outputs. Slot 2 %Q2.2.4 X2 5 St.1 #50 A5 A1SWP1 Control Cable #50 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:A4 Axis #1 Bus voltage OK Signal UD_OK = 0: DC bus too low. UD_OK = 1: DC bus above the minimum voltage. This signal is effective in all modes Function Once the minimum voltage in the power DC bus is reached, the drive description controller is ready to output power and the UD output is set high. The signal is the condition for system power up. For the safety reasons the power can not be applied to the system until UD_OK = 1 in all connected drives. When TransKit1 works with one drive only, the St1:A4 UD_OK can be connected directly to the St1:D12 PCUDRDY. (see note on electrical drawing BE2000 sheet 05/12). In described case there is no need to transfer this signal to the PLC and back. If TransKit1 has two drives connected, it is absolutely necessary to send both signals UD_OK to the PLC. PLC is then responsible for issuing the PCUDRDY back to the TransKit. (See: Drive DC-Bus voltage ready for wiring diagram) TRANS-01 note It was signal BCD output 10*2 0. This function is no longer available since the TransKit1 does not support BCD output. Wiring #54

98 TransKit1 Interface Descriptions 7-39 Axis #2 functions Axis 2 can be a servo axis or a spindle axis. Note: If spindle axis functionality is required, Axis #2 must be used as the spindle axis since respective signals are provided via St.1. Connector Signal Function description TRANS-01 note Wiring X55:1; X55:10 Axis #2 drive ready A2READY = 0: Drive not ready for power on A2READY = 1: Drive ready for power on The signal has an effect in all modes. The signal indicates when the DURADRIVE is ready for switching the 3-phase main power on. When ready, the drive shows Bb on the display and the Bb contact closes. See also Connector X55 Drive #2 Interlock Cable for further details. N/A X55 HDC01.1-AxxxN-SE01-01-FW ControlBoxD X50 0V 11 White 1.0 X1 3 0VDC DURADRIVE #2 24V 12 Blue VDC Slot 1 X2 %I Interlock Cable IND m 16 K2:14 K2: \ 9 8 Violet Yellow Pink Green Brown X Bb Bb ON1 ON1 On3 12 On4 6 0V Vpro ZKS1 \ ZKS1 0V

99 TransKit1 Interface Descriptions 7-40 Connector Signal Function description TRANS-01 note Wiring Slot 2 St.1:D1 Axis #2 homed A2SHOMED = 0 : Axis #2 is not referenced (homed) A2SHOMED = 1 : Axis #2 is referenced (homed) The NC employs this signal to tell the PLC whether or not the axis has been homed. With incremental position measuring systems, reference must be reestablished whenever the controller is switched on. This can be done manually for each individual axis using the 'axis homing' signal (AxCHOME) or be programmed via the valid NC reverse program. Single-axis homing of all axes of a process does not make the NC program of that process ready to start. The ready-to-start condition can only be attained by executing an NC reverse program (see Process signals: 'Ready to start'). Caution: It was the original signal +/- 15 OK. Wiring in the machine control panel must be modified! %Q2.2.1 X2 2 St.1 #8 D1 A2SHOMED Control Cable #8 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Function description TRANS-01 note Wiring Connector Signal Function description TRANS-01 note Wiring Connector Signal Function description TRANS-01 note Wiring St.1:A15 Axis 2 home switch Wire from the axis home switch (24VDC). The 0VDC External wire of the external power supply must be connected to GND and 0VDC Internal. The switch indicates to the drive that the home switch has reached the home switch cam/dog. Did not exist with TRANS-01. See diagram below. St.1:B15 Axis 2 positive overtravel switch Wire from the axis position limit switch (24VDC). The 0VDC External wire of the external power supply must be connected to GND and 0VDC Internal. The switch indicates to the drive that the hardware overtravel switch has reached the switch cam/dog. Did not exist with TRANS-01. See diagram below. St.1: C15 Axis 2 negative overtravel switch Wire from the axis position limit switch (24VDC). The 0VDC External wire of the external power supply must be connected to GND and 0VDC Internal. The switch indicates to the drive that the hardware overtravel switch has reached the switch cam/dog. Did not exist with TRANS-01. See diagram below.

100 TransKit1 Interface Descriptions 7-41 #61 X50 25 St.1 A15 Control Cable #61 Home LS #63 24 B15 #63 Pos. OT LS #62 23 C15 #62 Neg. OT LS 0V X50 33 #1 X Blue/ Blk Yell/ Blk Grn/B lk Wht Interlock Cable INK0209 Complete cable IND3048 X X1 3 DURADRIVE Axis 2 HDC01.1-AxxxN-SE01-01-FW Connector Signal Function description St.1:B2 Axis #2 at commanded speed A2N_CMD = 0: Axis 2 (spindle) not at commanded speed A2N_CMD = 1: Axis 2 (spindle) at commanded speed The signal is effective in all modes. The signal is set if the difference between the actual velocity value and the velocity command value is within a programmed velocity window. List of the influencing SERCOS parameters: Parameters Velocity window Actual velocity value Velocity command value SERCOS ident No. S S S TRANS-01 note Note: The signal is only valid for digital main spindle drives. This signal did not exist with the TRANS01. Caution: The original signal of St.1:B2 was Brake release. This function is no longer necessary since the motor brake is directly controlled from the DURADRIVE. If this signal was previously used, control cabinet has to be rewired. Wiring

101 TransKit1 Interface Descriptions 7-42 Slot 2 %Q2.1.7 X3 8 St.1 #13 B2 Control Cable A2N_CMD #13 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Function description St.1:B5 Axis #2 spindle in position A2SINPOS = 0: Spindle not positioned A2SINPOS = 1: Spindle has attained position This signal is effective in all modes The A2SINPOS signal is issued if, with respect to the position command value, the actual position value is within the positioning window after an 'Mx19' has been processed. List of the related Axis #2 SERCOS parameters: Parameters SERCOS ident No. Positioning window S Position command value S TRANS-01 note Wiring Note: The signal is only valid for digital main spindle drives. Caution: It was signal BCD output 1*2 1. This function is no longer available since the TransKit1 does not support BCD output. Slot 2 %Q2.2.5 X2 6 St.1 #51 B5 Control Cable A2SINPOS #51 24V X50 32 C16 #2 0V 33 B16 #1 Connector Signal Function description TRANS-01 note Wiring St.1:B1 Axis #2 Spindle speed Nmin attained A2SN_MIN = 0: Spindle speed Nmin not yet attained A2SN_MIN = 1: Spindle speed Nmin attained This signal is effective in all modes The signal is A2SN_MIN is set when the actual velocity value is inside the standstill window specified in the drive of axis #2. List of the related Axis #2 SERCOS parameters: Parameters SERCOS ident No. Standstill window S Note: The 'AxSN_MIN' signal does not fulfill the personal safety requirements. The signal is only valid for digital main spindle drives. Caution: It was signal Brake Control 2. The motor brake is directly controlled by the DURADRIVE. If this signal was previously used, control cabinet has to be rewired.

102 TransKit1 Interface Descriptions 7-43 Slot 2 %Q2.1.6 X3 7 St.1 #3 B1 Control Cable A2SN_MIN #3 24V X50 32 C16 #2 0V 33 B16 #1 Connector St.1:B4 Axis #2 Bus voltage OK Signal UD_OK = 0: DC bus too low. UD_OK = 1: DC bus above the minimum voltage. This signal is effective in all modes Function Once the minimum voltage in the power DC bus is reached, the drive description controller is ready to output power and the UD output is set high. The signal is the condition for system power up. For the safety reasons the power can not be applied to the system until UD_OK = 1 in all connected drives. When TransKit1 works with one drive only, the St1:A4 UD_OK can be connected directly to the St1:D12 PCUDRDY. (see note on electrical drawing BE2000 sheet 05/12). In described case there is no need to transfer this signal to the PLC and back. If TransKit has two drives connected, it is absolutely necessary to send both signals UD_OK to the PLC. PLC is then responsible for issuing the PCUDRDY back to the TransKit1. (See: Drive DC-Bus voltage ready for wiring diagram) TRANS-01 note It was signal BCD output 10*2 1. This function is no longer available since the TransKit1 does not support BCD output. Wiring #55 Spare wires of the connector St.1

103 TransKit1 Interface Descriptions Connector RX and TX SERCOS fiber optic These connectors are for the SERCOS fiber optic connection to the DURADRIVE(s). These fiber optic cables (IKO0982 and IKO085) are preinstalled when ordering a complete TransKit1 assembly. Fig : SERCOS drive interface cable wiring TX of ControlBox RX of ControlBox The cable from TX (transmit) of the ControlBox represents the SERCOS light output that connects to X21 RX of the first DURADRIVE. From the first DURADRIVE connector X20 TX another fiber optic cable is connected back to RX (receive) of the ControlBox, unless a second DURADRIVE is installed. If latter, the cable returns from X20 TX of the second DURADRIVE. Both drives are connected between X20 TX and X21 RX with a third SERCOS cable.

104 TransKit1 Interface Descriptions Connector X54 and X55 DURADRIVE interlock cable Overview Hardware interlocking signals are connected to the ControlBoxC and ControlBoxD via connectors X54 (DURADRIVE #1 left) and X55 (DURADRIVE #2 right). X54 X55 Fig : DURADRIVE Interlock cable wiring The one end of the interlock cable IND3048 connects to ControlBox connector X54 or X55, and the other end to the Phoenix terminal blocks that are inserted into the DURADRIVE connectors X1, X3 and X11.

105 TransKit1 Interface Descriptions 7-46 Connector X54 Drive #1 Interlock Cable The TransKit1 uses a single cable per drive for interlocking. The cable has a connector at the ControlBox and is connected to X1, X3 and X11 in the DURADRIVE as shown below. For details on limit switch connection refer to St.1 connector details. The signal UD is providing feedback to the ControlBox if the drive is powered up. For further details on DURADRIVE functions, please refer to Project Planning Manual DURADRIVE Drive Controllers with degree of protection IP 65 DOK-DURADR-HDC01.1****-PR02-EN-P; Note: ControlBoxD The Local E-stop can be added in the field if necessary. The modification should be done in such way, that the IP65 enclosure rating is maintained. Please contact Bosch Rexroth if for any reason the user must make modification to this wiring. Interlock Cable IND m X50 0V #83 24V #101 X White 1.0 Blue 1.0 X1 3 1 HDC01.1-AxxxN-SE01-01-FW 0VDC 24VDC DURADRIVE #1 PCESTAT %I Local E-Stop K A1CREADY %I PCPOWON St.1:B X50:10 K2 21 #12 20 #10 19 # Jumper if no E-stop K2:14 K2: Blue/Blk Yel/Blk Green/Blk Red Red/Blk Black Violet Yellow Pink Green Brown X \ 11 6 X Home LS + O.T. LS - O.T. LS Probe 1 UD OK E-Stop Bb Bb ON1 ON1 On3 On4 0V +24Vpro ZKS1 \ ZKS1 5 0V Note: The jumpers (red) are directly installed on the DURADRIVE connectors. Fig : Interlock cable wiring X54 - axis 1

106 TransKit1 Interface Descriptions 7-47 Connector X55 Drive #2 Interlock Cable The TransKit1 uses a single cable per drive for interlocking. The cable has a connector at the ControlBox and is connected to X1, X3 and X11 in the DURADRIVE as shown below. For details on limit switch connection refer to St.1 connector details. The signal UD is providing feedback to the ControlBox if the drive is powered up. For further details on DURADRIVE functions, please refer to Project Planning Manual DURADRIVE Drive Controllers with degree of protection IP 65 DOK-DURADR-HDC01.1****-PR02-EN-P; Note: The Local E-stop can be added in the field if necessary. The modification should be done in such way, that the IP65 enclosure rating is maintained. Please contact Bosch Rexroth if for any reason the user must make modification to this wiring. Interlock Cable IND m ControlBoxD X50 0V #83 24V #101 X White 1.0 Blue 1.0 X1 3 1 HDC01.1-AxxxN-SE01-01-FW 0VDC 24VDC DURADRIVE #2 PCESTAT %I Local E-Stop K A2CREADY %I PCPOWON St.1:B K3 X50:10 25 # # # Jumper if no E-stop K3:14 8 K3:11 Blue/Blk Yel/Blk Green/Blk Red Red/Blk Black Violet Yellow Pink Green Brown X \ 11 6 X Home LS + O.T. LS - O.T. LS Probe 1 UD OK E-Stop Bb Bb ON1 ON1 On3 On4 0V +24Vpro ZKS1 \ ZKS1 5 0V Note: The jumpers (red) are directly installed on the DURADRIVE connectors. Fig : Interlock cable wiring X55 - axis #2

107 TransKit1 Interface Descriptions PIM Function External Tool Correction In the final revision of the TransKit1 the PIM function has not been implemented. The signals PSAUX420 and PSAUX421 together with appropriate acknowledgements PCACKN420 and PCACKN421 were freed to be used as regular auxiliary functions. X53 Serial Port pins 7.6 Connector X10 Serial port for programming Technical data Behind a dust cover, the 15pin Sup-D connector X53 provides a serial interface programming port. The type of connection (RS232C or RS485) is chosen with the cable using the Bosch Rexroth SIS setup. Fig : X53 connector serial interface pin assignment X53 as RS232C For a single point RS232 connection use cable IND5009(613220). Note: The ControlBoxD internal connection between X53 socket and TRANS200 programming port X10 is made with either universal serial cable without termination AE1103 (613198) for RS232 communication, or AE1107 (613337) cable for RS485 configuration. The later includes termination resistors on the control side. Both cables are included in the ControlBoxD delivery, so the change can be done in the field. Fig : X53 connector RS232C serial interface pin assignment

108 TransKit1 Interface Descriptions 7-49 X53 as RS485 Fig : X53 connector RS232C serial connection to PC The RS485 bus permits the daisy-chain connection of up to 32 ControlBox systems to a single PC for centralized programming, monitoring and troubleshooting. A RS485 repeater should be used between number 16 and 17 to strengthen (repeat) the signal. The RS485 bus cable should be shielded and twisted in pairs. The crosssection should be a minimum of 0.22mm², the surge impedance Ohm. The shield is provided on both ends of the transmission link. If ground-potential bonding currents may occur, one end is grounded directly, the other end via a 15nF capacitor. For RS485 communication the first and last connector must contain a terminator circuit as shown below: Fig : X10 connector RS485 termination This is achieved with the ControlBoxD internal connection between X53 port and the TRANS200 programming port X10. The RS485 cable AE1107 (613337) contains the terminating switch in the control side plug. The switch has to be set into ON position to activate the termination.

109 TransKit1 Interface Descriptions 7-50 Fig : Example - RS485 Bus Choosing the RS232C or RS485 cable The internal serial communication of the ControlBoxD is wired for RS232C from the factory. The user can convert to using RS485 by selecting the mode in the PPC-R (Trans200) via S1 and replacing the RS232 cable AE1103 (connected to X10 of TRANS200) with the RS485 cable AE1107 (contains the switch in one connector). Plug the RS485 connector (with the switch) into the X10 port at the PPC-R card and the other end into the X53 plug at the bottom of the ControlBoxD. Note: When switching to RS485 communication the termination resistor must be activated at the cable connector plugged into the LAST TRANS200 of the RS485 bus! Note: The dust cover must be closed if no cable is connected to the serial programming port of the ControlBoxD. Only IP65 rated connectors must be used for permanent serial connection. {Use cables IND5009 (613220) and IND5008 (613199)}

110 TransKit1 Interface Descriptions 7-51 TRANS200 X10 PC serial port settings RS232C/RS485 at TRANS200 in ControlBoxD The serial PC communication default settings are for RS232C: - 01, controller address (TRANS200) Baudrate - Even parity The serial PC communication default settings are for RS485: - 01, controller address (TRANS200) Baudrate To modify these settings, press S1 (see figure below) and follow the menu instructions for modifying the serial communication settings : Modifying serial communication selection.

111 TransKit1 Interface Descriptions Connector X20 Ethernet port for programming Ethernet networking overview If the ControlBoxD is purchased with the Ethernet communication option, the RJ45 connector X20 can be used for connection to the programming PC running WinTrans software. Fig : Example Laptop Ethernet connection Fig : Example Ethernet Bus

112 TransKit1 Interface Descriptions 7-53 Note: The dust cover must be closed if no cable is connected. Only IP65 rated connectors must be used for permanent Ethernet connection. Also a dummy RJ45 Ethernet plug must be inserted into X20 if the dust cover remains open. Ethernet SWITCH 10/100 Address selection via S1 and H1 X20 X20 X20 IND5007 X20 UDS-10 Station: Machine Sta1L Sta1R Sta5L Staxy c Product: PC UDS-10 UDS-10 UDS-10 UDS-10 c Ethernet setup Address IP: xx Sub-net: (Mode)/Port: xx Baudrate: Flow: I/F Mode: - 4C 4C 4C 4C c TRANS200 setup Address: xx Serial: - RS232C RS23C RS232C RS232C Baudrate: : Example ControlBoxD with Ethernet networking IND5007 cable The complete cable IND5007/000.6 is used to connect the DB25 serial port of the Lantronix UDS converter to the PROG port (X10) of the PPC-R card (Trans200). Setup of Ethernet Converter Ethernet Serial converter hardware The Ethernet option is accomplished by use of the Lantronix UDS device server. The input side the UDS (factory default: 5001, , 00, 4C) is connected to the Ethernet and the output to the PPC- R card using a serial port X10 (factory default: RS232C, , Even).

113 TransKit1 Interface Descriptions 7-54 Fig : Lantronix UDS connections Ethernet Serial converter setup Step 1 The Lantronix UDS Serial-Ethernet device server must be programmed by the user. The following steps must be performed on the PC that is used with WinTrans software and that is connected to Ethernet: Install the Device Installer software provided with the TransKit1 or ControlBox. Step 2 Connect the PC (with active Ethernet TCP/IP setup) and the ControlBox (of the TransKit1) via Ethernet cables to an Ethernet Switch (HUB). Then start the DeviceInstaller program on the PC. (You can also use crossed Ethernet cable to connect to single device w/o hub.) Press the search button (left large icon) to find connected UDS-10 devices. After the scan all available UDS-10 devices appear showing their default address. Note: It may be necessary to perform this setup one UDS-10 at a time to prevent duplicate IP addresses in the network. Step 3 Select the desired device and click the IP address button. Enter the desired unique IP address of the UDS-10. This address must match the

114 TransKit1 Interface Descriptions 7-55 address entered in the System Configurator software for the TRANS200 controller to which the UDS-10 is connected to. Select the PC-network class the same like in other UDS-10 and the machine PC (BTV). Press the Set IP Address button to activate the IP address in the UDS-10. To check that the UDS-10 device contains the new IP address, press the Ping button and check that the UDS-10 is responding. If the device is responding, document the IP-address for the ControlBox of the TransKit1. Repeat the Step 3 if the UDS-10 does not respond and assure that no duplicate IP addresses are used and the chosen common Network Class. Step 4 To confirm the serial port settings of the UDS-10, select the desired device and click the configuration button (tools). Then click the Telnet to Device to open the dialog. After the dos-box opens press <Enter> to continue and the following menu appears:

115 TransKit1 Interface Descriptions 7-56 In the top the currently active serial port settings are listed. Press <1> and <Enter> to modify the settings. Enter only data for: Baudrate: I/F Mode: 4C ;for RS232C Flow: 00 Port: <5xxxx> ;must match the Mode entry in the System Configurator (see below) Activate with 9 to save and press <Enter>. Close the Lantronix software when all devices are done.pc TRANS200 System Configurator setup Step 1 System Configurator If the TransKit1 (specifically its ControlBox) was ordered with the Ethernet communication option the user must first enable the TCP/IP before defining the TRANS200 systems in the System Configurator software. After installing the WinTrans software on that PC, open the following file on the PC using Notepad (pure) text editor:..:\program Files\Indramat\MTGUI\BASICDATA\RESOURCE\SYSCON.INI NOTE: Do not modify or delete any data in this file except what is explained below. Search for [TRA200-R] and add the string,tcp to V24 as shown below. Then save the data and close the file.

116 TransKit1 Interface Descriptions 7-57 Step 2 System Configurator On the PC start the System Configurator and define one TRANS200 control per TransKit1 ControlBox. Double click the icon to start the System Configurator. Then enter a new TRANS200 or select an existing TRANS200 that represents the desired TRANS200 in the TransKit1 ControlBox. Go through the wizard until the setup of the communication is prompted. Either double-click new or the existing CommAddr for the device (not used with another device).now select TCP and enter the Channel which is the <IP address> and Mode which is the <port> address of the UDS-10 converter mounted in the ControlBox of the TransKit1. To test the connection to the TRANS200 you must also match the TRANS200 device address in the System Configurator setup and the TRANS200 hardware (PPC-R) located in the ControlBox. The Ping button can be used to verify the Ethernet IP connection if the device address, Channel / IP address and Mode / Port are set identical. Fig : Example Ethernet configuration of TRANS200 on PC side

117 TransKit1 NC setup NC setup 8.1 TRANS200 TRANS200 - Training The user of the TransKit1 or ControlBoxC and ControlBoxD should attend training courses offered by Bosch Rexroth for the TRANS200 motion controller. Please contact Bosch Rexroth Electric Drives and Controls or a representative for available training courses. Note: Being unfamiliar with the TRANS200 control system may result in potentially costly startup delays. TRANS200 - Documentation The user can obtain the latest Documentation CD from Bosch Rexroth or purchase printed manuals via the BRC representative. Note: Even though the TRANS200 of the ControlBoxD uses version 23VRS software and firmware, the documentation of version 22VRS can also be used if no documentation for 23VRS is available. Hardware components: Software:

118 TransKit1 NC setup 8-2 Commissioning : TRANS200 - WinTrans software The user must purchase and use the WinTrans software SWA-TRA200-T11-23VRS-MS-CD650 (PN ) to commission the ControlBoxD of the TransKit1 solution. This software must be installed on a PC (laptop or machine PC) and works under the PC operating system Windows 2000 (SP2 or higher) or Windows XP (SP 2 or higher). TRANS200 Parameter adaptation The TRANS200 used in the ControlBoxD is provided with default parameter sets for single and dual axis configurations. Parameter set and IO configuration are pre-loaded if the ControlBoxD is ordered as a finished kit, or they can be loaded from the provided Floppy Disk.

119 TransKit1 NC setup 8-3 Note: The user will need to use the WinTrans software (on a PC) to finalize o the axis setup (e.g., axis name/meaning, axis type linear/rotary, etc.) o process definitions, feeds and speed o D-correction setup o auxiliary function setup so they match the desired machine configuration. This setup should occur during the preparation phase to minimized delays during the startup. Further documentation required for this process: MTC200/TRANS200 Parameter Description Application Manual DOK-CONTRL-PAR*DES*V22-AW01-EN-P TRANS200 - NC-programming Compared to the single axis TRANS-01 controller, the multi-axis TRANS200 has a more comprehensive G-code instruction set combined with high-level commands. These commands are described in detail in the documentation: TRANS200 NC Programming Instructions Application Manual DOK-TRA200-NC**PRO*V22-AW01-EN-P (PN ) Use the above documentation for creation of NC-programs. Note: Application of the described NC-functions (G-codes, D- corrections, Auxiliary functions, etc.) is limited by the interface configuration (connector St.1) and axis configuration as well as the setup in the parameter set.

120 TransKit1 NC setup 8-4 The WinTrans software offers the beginner a NC-programming assistant that provides clear text dialog for NC-block creation with integrated help.

121 TransKit1 Operation Operation The TransKit1 with ControlBoxD can be configured with a BTV06 HMI that allows axis operation in manual machine mode. Diagnostic information and help is available at any time. The user can edit Zero Offsets, NC-variables, NC-Events and tool offset data permitting fast and convenient process related optimization. 9.1 ControlBoxD - BTV06 HMI button description HMI screens L1 and R1 PB for MANual program control PB and LEDs for MANual operation Softkey Text and Softkeys Numerical and navigation Fig. 9-1: BTV06 HMI Overview MAN/ JOG Indicator shows if manual operation mode was selected via the respective signal on connector St.1. Light OFF Automatic mode active The indicators AXIS1+, AXIS1, AXIS2+, AXIS2 and RUN/ACTIVE indicate axis movement and that the NC program is active and running. Light ON Manual mode active This mode permits axis jogging via the PBs AXIS1+, AXIS1, AXIS2+, AXIS2. If activated in the setup of BTV06 HMI, NC program execution is possible by pressing the PB L1 (forward execution) or PB R1 (reverse program).

122 TransKit1 Operation 9-2 AXIS1 + AXIS2 + AXIS1 AXIS2 Light OFF Light ON PB pressed The respective axis is not moving in the positive or negative direction. Axis is moving in respective direction. Axis is jogged at preset speed when manual operation mode is active. RUN/ ACTIVE Light OFF` Light ON PB pressed The NC program /. NC block is not active. The NC program / NC block is active. No function CLEAR ERROR Light OFF Light ON PB pressed No error active. Error active. Control Reset aborting the active NC program if NO error is active. Clear Error if an error is active. L1 PB pressed If manual mode active (MAN/JOG =ON) the NC program is executed (forward) while L1 and MAN/JOG is simultaneously pressed. (Can be disabled through the BTV06 setup) R1 PB pressed If manual mode active (MAN/JOG =ON) the Reverse NC program is executed while R1 and MAN/JOG is simultaneously pressed. (Can be disabled through the BTV06 setup) F1 F8 PB pressed Activates the menu described in the respective softkey name that is displayed in the lowest line of the display. HELP PB pressed Displays the brief help for the active screen if the text HELP is shown in the upper left corner. Main Menu PB pressed Calls the Main Menu screen NC-Functions. PB pressed Used to scroll up/down through the screen if more information is available than can be displayed. Also used to page forward/backward through tables. ESC PB pressed This key will cancel a function, exit windows and help screens. OK PB pressed This key is used to confirm prompts and conclude entries.

123 TransKit1 Operation 9-3 The numerals, cursor keys printed on the BLUE background are normally active when the button is pressed. The <Shift>-key (arrow to upper left) can be pressed and held while pressing a button with characters printed on the GREEN background to enter character information. Specific characters are entered by pressing the button multiple times while holding the <Shift>-key.

124 TransKit1 Operation BTV06 HMI - screen description The BTV06 HMI of the ControlBoxD provides all necessary screens for station operation. Special emphasis was put on minimizing the key stokes to reach information. This section describes these screens. Screen Areas Help is available Screen Name Operation Mode Diagnostic message Screen content Soft-Key description

125 TransKit1 Operation 9-5 Main Menu NC-Functions Fig 9-1A: NC-function screen Automatic Mode The NC-Functions screen is displayed at power up or when the is pressed. Main Menu The top line indicates that help information is available by pressing the <HELP>-key. The active operating mode is displayed in the upper right corner. In the second line the currently active diagnostic message is displayed. Axis position data can be displayed as Machine (M) or Program (P) coordinates as selected in the SETup menu (<F8>). The screen shows the commanded, actual and programmed end position, The current and next NC-block are displayed in the block below, providing the user with the NC-program information currently being executed. Fig 9-1B: Help of NC-function screen Automatic Mode

126 TransKit1 Operation 9-6 Fig 9-1C: NC-Status screen Fig 9-1D: Help - NC-Status screen Fig 9-1E: NC-function screen Manual Mode

127 TransKit1 Operation 9-7 Fig 9-1F: NC-block / program display Fig 9-1G: Help for NC-block / program display Fig 9-1H: NC-variable list display

128 TransKit1 Operation 9-8 Fig 9-1J: Help for NC-variable list display Fig 9-1K: Setup of NC-variable Lists NC-Event Status display The screen contains two separate windows: First one shows if the Asynchronous Event (EVENT 0) has been activated Second one shows the number of currently active synchronous events (1 to 15) Additionally it is possible to assign short event description through the modifications in the BTV06 event setup screen. The description will display on the screen together with the event number.

129 TransKit1 Operation 9-9 Fig 9-1L: Help for NC-Event Status display Fig 9-1M: Zero Offsets display Fig 9-1N: Offsets display

130 TransKit1 Operation 9-10 Fig 9-1P: Setup of Offsets display Fig 9-1Q: D-corrections (Tool corrections) screen Fig 9-1R: Help for D-corrections (Tool corrections) display

131 TransKit1 Operation 9-11 Fig 9-1S: Setup D-corrections (Tool corrections) display Fig 9-1T: TK1 Components display Fig 9-1U: Setup - Axis configuration screen

132 TransKit1 Cables and Accessories Cables and Accessories 10.1 Selection List of Connectors and Ready-Made Cables Ordering of ready made cables AE (PN ) ControlBoxD internal RS232C cable For connection between connector PPC-R X10 and X53 (IP67) in the housing. Note: fixed length 0.6m (2 feet). Connector Rexroth cable Connector AE1103 AE (PN ) RS485 cable for internal ControlBox connection between connector PPC-R X10 and X53 in the housing. Switch should be set to "1" on the first and the last unit in the RS485 net. If more than 16 units has to be interconnected (32 units maximum) the bus amplifier must be used between device 16 and device 17. Note: fixed length 0.6m (2 feet). AE1107 INS0439/L IND5008 (PN ) ControlBoxD - RS485 cable For external linking of multiple ControlBox systems via IP67 rated connector plugging into X53 of the ControlBox. IND5008/xxx.x Note: Max. RS485 bus cable length is 400m.. IND5009 (PN ) ControlBoxD - RS232 cable For connection of PC (using 15-pin D-sub connector) to X53 of the ControlBox for programming. Note: Max. cable length is 15 m (45 feet). IND5009/xxx.x

133 TransKit1 Cables and Accessories 10-2 Ordering of ready made cables Connector Rexroth cable Connector IND5007 (PN ) Lantronix UDS or UDS to PPC-R X10 (Trans200). Note: Standard length is 0.6m (2 Feet). 25 pin male IND5007/000.6 INS0439/L0 IND3048 (PN ) ControlBoxD DURADRIVE (HDC) interlocking cable. Note: Standard length is 1.5m (5 feet). IND3048/001.5 IKB0015 (PN ) ControlBoxD conection between Trans200 X16 and BTV06 COM1 IKB0015/000.6

134 TransKit1 Cables and Accessories Accessories The switch box PSS-T10 (PN ) and the ready-made cable IND3052 (2 meter long) can be purchased for purpose of training, engineering and debugging. The cable directly plugs into the St.1 connector of the ControlBoxD. The switch box allows the insertion of label strips. The label strips for the ControlBoxD connector St.1 are displayed below. POWEN POWER N=CMD N<MIN A1 WP0 A1 WP1 LO-PIM HI-PIM READY Act/Run A1 Ref A2 Ref Sp_Pos ThMis ThExc ERROR Mc400 Mc401 Mc404 Mc405 Mc408 Mc409 Mc412 Mc413 PowEN PowON MAN. E-Stop CLR ADV REV STOP Cond0 Cond1 Cond2 Cond3 Event Enable A1 HSw A1 -OT A1 +OT Probe1 A1_UD A2 HSw A2 -OT A2 +OT PIM_LO PIM_HI Ma400 Ma401 Ma404 Ma405 Ma408 Ma409 Ma412 Ma413