Rexroth TRANS 200 Motion Control System

Transcription

1 Industrial Hydraulics Electric Drives and Controls Linear Motion and Assembly Technologies Pneumatics Service Automation Mobile Hydraulics Rexroth TRANS 200 Motion Control System R Edition 01 Project Planning Manual

2 About this Documentation Motion Control System Title Type of Documentation Rexroth TRANS 200 Motion Control System Project Planning Manual Document Typecode Internal File Reference Document Number B314-01/EN Purpose of Documentation This documentation describes the startup of the control system TRANS 200. Record of Revisions Description Release Date Notes B314-01/EN Valid from version 23 Copyright 2003 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Published by Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 D Lohr a. Main Telephone +49 (0)93 52/40-0 Tx Fax +49 (0)93 52/ Dept. BRC/ESM5 (ML) Dept. BRC/ESM6 (DiHa) Note This document has been printed on chlorine-free bleached paper.

3 Motion Control System Contents I Contents 1 Introduction Purpose of Documentation Structure of the Instructions Important Directions for Use Appropriate Use Introduction 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 Brief Description of the Components TRANS 200 System Overview Brief Description PPC-R0x.2N Input/Output Modules RECO Drive Systems Diax DuraDrive REFUDRIVE Cable Specifications Serial Connection Field Bus Connection SERCOS Connection Teleservice Commissioning of the TRANS Hardware Preparation

4 II Contents Motion Control System Electrical Connection / Peripherals Additional Modules Basic Settings (Device Address, Transmission Mode, Transmission Rate) Communication Commissioning of the TRANS Hardware Overview of Functions and Additional Information User Management Firmware Handling F2 Select Control F3 Configuration (Creation of Parameter Files / Download F8 - Creation of the Field Bus Configuration / Download F4 - Creation of an NC Program / Download of an NC Program Function blocks / PLC Interface Diagnosis Diagnosis Display "H1" Meaning of the Status Indications List of System Error Messages Commissioning the Drives with DriveTop Overview and Additional Information General Information on Drive Parameters Communication Structure Preparation Address Allocation and Connection Establishment of a Connection between Control and Drives Loading Basic Parameters Application-Dependent First-Time Setup Operating Mode and Application Profile Drive Controller Operating Mode Selection Scaling and Units Gear, Mechanical Error Handling of the Supply Module Error Handling, Drive EMERGENCY STOP Function Position Limit Values Other Limits Position Control Loop Monitoring Setting the Control Loop Creation of the Reference Setting the Absolute Measure Homing Index 8-1

5 Motion Control System Contents III 9 Service & Support Helpdesk Service-Hotline Internet Vor der Kontaktaufnahme... - Before contacting us Kundenbetreuungsstellen - Sales & Service Facilities

6 IV Contents Motion Control System

7 Motion Control System Introduction Introduction 1.1 Purpose of Documentation These instructions are intended to provide the customer easier access to the control architecture of the TRANS 200. Commissioning of the controller is explained. Commissioning starts with the electrical connection of the hardware module. In this regard, the additional documents concerning the provided modules are mentioned. After hardware connection, the system is initialized with the basic settings of the module (e.g. device address, baud rate, communication mode); then, the parameters and the I/O configuration are set, and an NC program is created and downloaded. The chapters are designed in such a manner that the reader only needs to go through those which appear relevant for the respective application. Each chapter is independent, and reference to other chapters is only made to intensify the explanations. The functions described in this documentation are not to be understood as a warranty of certain controller characteristics. This documentation describes the characteristic functions of the controller; details are subject to changes between two releases. These instructions have been written with a focus on practicability, intelligibility and compactness. We appreciate any constructive comments, suggestions and other ideas on how to improve this documentation and we hope you ll find the following chapters rewarding and worth your while. 1.2 Structure of the Instructions Chapter 01 Chapter 02 Chapter 03 Chapter 04 Chapter 05 Chapter 06 Chapter 07 This chapter contains information regarding handling and use of the instructions, as well as details on further reading. This chapter contains general information on intended and on nonintended use. This chapter contains safety information for electrical drives and controllers. This chapter contains a short description of the hardware components used in these "First Steps". This chapter describes the preparations for commissioning the hardware and the TRANS 200 controller. This chapter explains the diagnosis potential of the system and explains the diagnosis messages which may be displayed. This chapter explains the consequences and processes during the commissioning of drives with the "DriveTop" tool.

8 1-2 Introduction Motion Control System

9 Motion Control System Important Directions for Use Important Directions for Use 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.

10 2-2 Important Directions for Use Motion Control System 2.2 Inappropriate Use Using the TRANS 200 outside of the above-referenced areas of application or under operating conditions other than described in the document and the technical data specified is defined as inappropriate use". TRANS 200 may not be used if they are subject to operating conditions that do not meet the above specified ambient conditions. This includes, for example, operation under water, in the case of extreme temperature fluctuations or extremely high maximum temperatures or if Bosch Rexroth has not specifically released them for that intended purpose. Please note the specifications outlined in the general Safety Guidelines!

11 Motion Control System 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 in order to 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 or 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)

12 3-2 Safety Instructions for Electric Drives and Controls Motion Control System 3.3 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

13 Motion Control System Safety Instructions for Electric Drives and Controls General Information Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before starting up the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe operation of this equipment. Only persons who are trained and qualified for the use and 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 the documentation of the product with regard to the use of the delivered components contains only examples of applications and suggestions. The machine and installation manufacturer must make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements. 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.

14 3-4 Safety Instructions for Electric Drives and Controls Motion Control System 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.

15 Motion Control System 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! Ÿ Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain or repair this equipment. Ÿ Follow general construction and safety regulations when working on high voltage installations. Ÿ Before switching on power the ground wire must be permanently connected to all electrical units according to the connection diagram. Ÿ 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. Ÿ 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. Ÿ The following should be observed with electrical drive and filter components: Ÿ 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. Ÿ Never touch the electrical connection points of a component while power is turned on. Ÿ Install the covers and guards provided with the equipment properly before switching the equipment on. Prevent contact with live parts at any time. Ÿ 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. Ÿ Electrical components with exposed live parts and uncovered high voltage terminals must be installed in a protective housing, for example, in a control cabinet.

16 3-6 Safety Instructions for Electric Drives and Controls Motion Control System 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! Ÿ Connect the electrical equipment, the housings of all electrical units and motors permanently with the safety conductor at the ground points before power is switched on. Look at the connection diagram. This is even necessary for brief tests. Ÿ 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. Ÿ Use a copper conductor with at least 10 mm² cross section over its entire course for this safety conductor connection! Ÿ 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 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! Ÿ 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. Ÿ 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.

17 Motion Control System Safety Instructions for Electric Drives and Controls Protection Against Dangerous Movements 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 devices defective components software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. 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.

18 3-8 Safety Instructions for Electric Drives and Controls Motion Control System DANGER Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ÿ Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. Unintended machine motion is possible if monitoring devices are disabled, bypassed or not activated. Ÿ Pay attention to unintended machine motion or other malfunction in any mode of operation. Ÿ Keep free and clear of the machine s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine s range of motion: - use safety fences - use safety guards - use protective coverings - install light curtains or light barriers Ÿ Fences and coverings must be strong enough to resist maximum possible momentum, especially if there is a possibility of loose parts flying off. Ÿ 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. Ÿ Isolate the drive power connection by means of an emergency stop circuit or use a starting lockout to prevent unintentional start. Ÿ 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. Ÿ Secure vertical axes against falling or dropping after switching off the motor power by, for example: - mechanically securing the vertical axes - adding an external braking/ arrester/ clamping mechanism - ensuring sufficient equilibration of the vertical axes The standard equipment motor brake or an external brake controlled directly by the drive controller are not sufficient to guarantee personal safety!

19 Motion Control System Safety Instructions for Electric Drives and Controls 3-9 Ÿ 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 Ÿ 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! Ÿ Persons with heart pacemakers, hearing aids and metal implants are not permitted to enter the 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. Ÿ 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. Ÿ 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.

20 3-10 Safety Instructions for Electric Drives and Controls Motion Control System 3.9 Protection Against Contact with Hot Parts CAUTION Housing surfaces could be extremely hot! Danger of injury! Danger of burns! Ÿ Do not touch housing surfaces near sources of heat! Danger of burns! Ÿ After switching the equipment off, wait at least ten (10) minutes to allow it to cool down before touching it. Ÿ 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! Ÿ Observe general installation and safety instructions with regard to handling and mounting. Ÿ Use appropriate mounting and transport equipment. Ÿ Take precautions to avoid pinching and crushing. Ÿ Use only appropriate tools. If specified by the product documentation, special tools must be used. Ÿ Use lifting devices and tools correctly and safely. Ÿ For safe protection wear appropriate protective clothing, e.g. safety glasses, safety shoes and safety gloves. Ÿ Never stand under suspended loads. Ÿ Clean up liquids from the floor immediately to prevent slipping.

21 Motion Control System Brief Description of the Components Brief Description of the Components 4.1 TRANS 200 System Overview Brief Description The TRANS 200 is a high-performance distributed axis control system in RECO format to be installed in a control cabinet. This system is able to control a maximum of 4 interpolating axes and 3 spindles. The system communicates with the master PLC system via a configurable field bus interface. It behaves like a field bus slave; thus, it can be very easily integrated into field bus topologies. One PLC can control several distributed TRANS 200 systems. Their number depends on the type of field bus used and on the PLC. The traversing movement is commissioned and programmed independently of the PLC programming. All traversing instructions are programmed in the TRANS 200; the movement is controlled by the PLC by means of single binary signals. TRANS200_SPS.jpg Fig. 4-1: TRANS 200 system overview TRANS 200 system overview Not only simple traversing instructions, but also more complex handling instructions can be realized with the integrated technology and geometry functions. distributed axis motion for a maximum of 4 digital axes and 3 spindles, INTERBUS, ControlNet, Profibus or DeviceNet field bus interface, "SERCOS interface" drive interface, serial interface (RS232/RS485) for commissioning and programming, freely programmable traversing program, point-to-point movements, linear and circular interpolation, spindle orientation (M19), incremental and absolute displacement measuring systems, 2 ms SERCOS cycle time, and extensive library of technology and geometry functions. The programming and diagnosis functions of the TRANS 200 are executed using a standard PC or notebook.

22 4-2 Brief Description of the Components Motion Control System Mini control panel BTV06 or handheld device BTC06 is available for local monitoring of the controller. In BTx mini control panels, the following functions are available: Control panel function (operation panel, jogging axis) for BTC06 only Read/write NC data (D corrections, NC variables, offsets) NC screen (control of speeds and positions) Further information can be found in Section 5.1 or in the documentation listed below. Additional Documentation Type of documentation Designation DOC-SUPPL*-BTV06.1****-PR02-EN-P Mini control panel BTV06 DOK-SUPPL*-BTC06******-PR03-EN-P Mini control panel BTC06 DOK-SUPPL*-SCM*PROG*V4-AW01-EN-P Screen Manager DOK-SUPPL*-SCM*BEDIEN*-AW04-EN-P Screen Manager Fig. 4-2: Documentation directory for mini control panels BTV06 / BTC06 / Screen Manager WinTRANS system overview WinTRANS is a software package for Windows NT 4.0 and can be installed on any standard PC. Scope of functions: Tool for commissioning and parameterizing the control and the drive systems Diagnosis of control data, such as axis positions, current traversing commands, and status of control signals Creation of traversing programs Entry of variables, corrections, offsets, etc. Configuration of the field bus interface and diagnosis of the field bus data Additional Documentation Type of documentation Designation DOK-CONTRL-MTGUI***V22-AW01-EN-P MTGUI Operator Interface Fig. 4-3: Documentation directory for WinTRANS

23 Motion Control System Brief Description of the Components 4-3 Operating Modes The TRANS 200 supports 3 operating modes which can be activated completely independently of the connected PLC but which can alternatively be completely controlled by the PLC. Automatic mode Semiautomatic mode Set-up mode In the "Automatic" mode, traversing programs are processed automatically until a programmed STOP is reached. Traversing programs are tested with this operating mode. The processing of the traversing programs can be controlled manually. The machine is set up with this operating mode. In the "Set-up" mode, individual axis movements can be triggered manually; traversing programs can be processed as in the "Semiautomatic" mode. Range of Functions Axes/spindles The TRANS 200 supports a maximum of 4 axes and 3 spindles. Possible configurations: 4 linear axes and 3 spindles or 4 rotary axes and 3 spindles or a combination of the two maximum possibilities, whereby the maximum number of 4 linear/rotary axes must not be exceeded. NC program Events Variables Corrections Zero offset Home position Technology NC programs according to DIN66025 / ISO Draft 6983/2. A traversing program can comprise up to 500 traversing commands. By means of events, the traversing program can be directly synchronized with machine states without any additional PLC programming. A total of 31 synchronous events and 1 asynchronous event is available. By means of variables, traversing programs can be programmed through variables that can be changed by the PLC and through non-fixed positions or feed rates. A total of 80 NC variables is available. The traversing movements are automatically adjusted to the respective tool dimensions by means of 30 tool corrections. The D corrections can be altered with the PLC via the multiplex channel. Zero offsets permit the shifting of the workpiece zero point within the machine coordinate system. The home position can be defined by a reference cycle. A number of technology functions can be called up directly in the traversing program, such as Adaptive Depth, Adaptive Feed, Tapped Hole, etc.

24 4-4 Brief Description of the Components Motion Control System 4.2 PPC-R0x.2N The TRANS 200 controller system uses the universal hardware module PPC-R0x.2N-N-**-FW (See below for a detailed type number code.) This module is in RECO format. Additional Documentation Type of documentation Designation DOK-CONTRL-PPC-R0*.2**-PR03-EN-P Description of hardware: PPC- R0*.2 (Project Planning Instructions) Fig. 4-4: Documentation directory of PPC-R0*.2 Fig. 4-5: PPC-R01.2N-N-S1-FW PPC-R.bmp Special features and deviations in the TRANS 200 are described in the following.

25 Motion Control System Brief Description of the Components 4-5 Design The TRANS 200 uses both designs PPC-R01.2 (narrow design) and PPC-R02.2 (wide design). The narrow design can be extended by means of a PC104 plug-in card and requires 1 slot in the RECO module rack. The slot for extensions (PC104 slot) can be equipped either with an INTERBUS card, a ControlNet adapter class or a Profibus card. For the corresponding type number codes, see Section 4.2 "Hardware Type Key". The wide PPC-R02.2 design is used only if a mini control panel (BTC06 / BTV06) and a field bus switch are used simultaneously. It can be extended by means of 3 PC104 plug-on cards and requires 2 slots in the RECO module carrier. Serial Interfaces (X10 / X16) An operation computer can be connected via the first serial interface X10. The transmission methods "RS232" and "RS485" are supported. With the S1 pushbutton (Config button; for description of the setup, see Chapter 5), the device address, the transmission mode and the transmission rate can be set. In the TRANS 200, mini control panel BTV06 or handheld BTC06 can be connected to the second serial interface X16. The S1 button can be used to enable the interface (menu item M7) and change the transfer rate (menu item M8). A more detailed description can be found in Chapter 5. BT Bus The TRANS 200 does not support the BT bus. Digital Inputs and Outputs (Terminal Strip X1) Inputs I1 to I3 and outputs Q1 and Q2 are reserved for diagnosis and maintenance by Customer Service. They must not be connected. Their significance can change completely between two versions or releases. The other contacts must be connected according to the instructions. For a detailed description and the power data, see the section "Commissioning the TRANS 200 Hardware Preparation". Hardware Options The TRANS 200 does not require a backup battery. Likewise, no PMM card (4 M byte buffered SDRAM) is necessary.

26 4-6 Brief Description of the Components Motion Control System Hardware Type Keys The following table contains the type keys of the PPC-R01.2 Short text column Example: PPC - R01. 2N - N - S1 - FW 1. Product group 1.1 PPC = PPC 2. Housing design 2.1 for RECO unit = R 3. Series = Design = 2 5. RAM module MB module = A 5.2 not equipped = N 6. Other design 6.1 none = N 7. Configuration 7.1 Serial Rexroth Indramat interface (SIS) = S1 (or according to application) 8. Firmware 8.1 Designation that firmware must be ordered as a seperate subitem = FW PPC_R01_Type.fh7 Fig. 4-6: Hardware type keys for PPC-R01.2N-N-XX-FW When the PPC-R0*.2 is used in connection with the TRANS 200 Motion Control System, the configuration (see point 7 of the above type keys) also covers the following options: Device with Serial Bosch Rexroth Interface (SIS) Fig. 4-7: PPC-R01.2N-N-S1-FW PPC-R01.2N-N-S1-FW.jpg

27 Motion Control System Brief Description of the Components 4-7 Device with INTERBUS Slave Fig. 4-8: PPC-R01.2N-N-B2-FW Type key of the narrow model: PPC-R01.2N-N-B2-FW Type key of the wide model: PPC-R02.2N-N-NN-B2-NN-FW PPC-R01.2N-N-B2-FW.jpg Device with ControlNet Adapter Class Fig. 4-9: PPC-R01.2N-N-L2-FW Type key of the narrow model: PPC-R01.2N-N-L2-FW Type key of the wide model: PPC-R02.2N-N-L2-NN-NN-FW Device with Profibus Slave PPC-R01.2N-N-L2-FW.jpg Fig. 4-10: PPC-R01.2N-N-P2-FW Type key of the narrow model: PPC-R01.2N-N-P2-FW Type key of the wide model: PPC-R02.2N-N-NN-P2-NN-FW PPC-R012N-N-P2_FW.bmp

28 4-8 Brief Description of the Components Motion Control System Device with DeviceNet Slave Fig. 4-11: PPC-R01.2N-N-V2-FW Type key of the narrow model: PPC-R01.2N-N-V2-FW Type key of the wide model: PPC-R02.2N-N-V2-NN-NN-FW 4.3 Input/Output Modules RECO02.2 PPC-R01.2N-N-V2-FW.jpg RECO module racks are available with 1, 2, or 4 slots. The 2- and 4-slot module racks can be extended to up to 16 slots by connecting several module racks. As an alternative to the field bus adapters (SERCOS or INTERBUS), the slots can be equipped with RECO modules. Additional Documentation Type of documentation Designation DOK-CONTRL-RECO02.2***-PRJ1-EN-P Description of RECO02.2 hardware (project planning document of the input-output unit) DOK-CONTRL-RECO02.2***-FK01-EN-P Description of RECO02.2 hardware (description of the function of the input-output unit) Fig. 4-12: Documentation directory for input/output modules RECO02.2 The following modules are available for application in transfer machines with TRANS 200: Type Designation Material No. RMB Module rack with 1 slot RMB Module rack with 2 slots RMB Module rack with 4 slots RME DC024 Input module with 16 inputs RME DC024 Input module with 32 inputs RME AC115 Input module with 16 inputs RMA DC Output module with 16 outputs RMA DC Output module with 32 outputs RMA AC Output module with 16 outputs RMA RE Output module with 16 relay outputs Fig. 4-13: Available RECO modules

29 Motion Control System Brief Description of the Components Drive Systems Diax 04 With the Diax 04 intelligent digital drive family, Bosch Rexroth has introduced a new era of production automation. High power density, extensive functions and high flexibility are the most prominent features of this innovative drive solution. Thanks to its excellent performance data and the solutions to the specific problems of this branch, Diax 04 is cut out for almost all applications where production processes with a power consumption of 3.5 kw to 75 kw are to be automated efficiently and with high precision. The graphic set-up program DriveTop will guide you quickly and securely through all the set-up steps on the controller or PC terminal. Because of the wide range of motors of various designs and dimensions, the Diax 04 will adapt to a large number of different mechanical and economic situations: DIAX04.jpg Fig. 4-14: Diax 04 Drive solution with high demands for precision and dynamics Applications with main spindles and servos Rotary direct drives in synchronous or asynchronous technology Linear synchronous or asynchronous motors The Diax 04 drive family is equipped with the SERCOS digital drive interface; thus, it can be easily connected to the TRANS 200. For more information on the Diax 04 drive family, see the corresponding drive documentation. Drive Configuration The following table contains the released Bosch Rexroth drive system which can be operated with the TRANS 200. Supply module Control module (axis) Control module (spindle) HVR / HVE Diax 04 (servo) with SSE firmware (max. 4 linear or rotary axes) Fig. 4-15: TRANS 200 drive configuration Diax 04 (spindle) with SHS firmware (max. 3 spindles)

30 4-10 Brief Description of the Components Motion Control System DuraDrive With the DuraDrive digital drive family, Bosch Rexroth has created a drive amplifier family that can be connected directly to the machine due to protection class IP65. The excellent performance data to a large degree correspond to those of the Diax 04 drive family. This permits a wide range of applications of the DuraDrive drive family. The graphic set-up program "DriveTop" is also available to set the parameters of the drives. DURADRIVE.jpg Fig. 4-16: DuraDrive Applications with main spindles and servos Rotary direct drives in synchronous or asynchronous technology Linear synchronous or asynchronous motors IP65-protected drive amplifiers for direct connection to the machine Suitable for highly dynamic and highly precise NC interpolation applications The built-in power pack permits direct connection to the power supply Performance range from 1.6 kw to 15kW The DuraDrive drive family is also equipped with the SERCOS digital drive interface; thus, it can be easily connected to the TRANS 200. For more information on the DuraDrive drive family, see the corresponding Drive Documentation.

31 Motion Control System Brief Description of the Components 4-11 REFUDRIVE With the frequency converters of the RD51/RD52 compact device series, Bosch Rexroth provides an especially flexible and economic solution in the power range between 1.5 and 400 kw. The possibility of selecting between the two control procedures VFC (voltage frequency control) and FVC (flux vector control) satisfies all demands, from a simple spindle drive up to a highly dynamic positionable spindle. The VFC control procedure is used in the RD51 variant, while the RD52 variant uses the FVC control procedure; in this way, this drive is suitable for positionable spindles. PMK2173_3R.jpg Fig. 4-17: REFUDRIVE Applications with main spindles and servos Positionable spindle Power range between 1.5 kw and 400 kw The REFUDRIVE RD51/RD52 drive family is also available with the SERCOS digital drive interface, which allows the drives to be easily connected to the MotionControl TRANS 200. Therefore, they possess the advantages of a digital drive. For more information on the REFUDRIVE RD51/RD52 drive family, see the corresponding drive documentation.

32 4-12 Brief Description of the Components Motion Control System 4.5 Cable Specifications Serial Connection With the serial connection between plug X10 and the PC, communication can be established by means of the set-up tool "WinTRANS". The communication parameters can be parameterized via the S1 pushbutton (see Chapter 5). Transmission modes RS232 and RS485 are available. Connection of RS232 For connection to the PPC-R0x.2, cable set IKB0012 (material No.: ) is available. PPC (X10, X16) terminal / PC 15 pin D-subminiature, connector 9-pin D-subminiature, bushing signal TxD RxD SGND connector housing pin Fig. 4-18: IKB0012 pin signal RxD TxD RTS CTS SGND DTR DSR connector housing Sy7pr057.fh7 RS485 Connection WinTRANS is able to communicate with several PPC-R0x.2s via an RS485 interface. RS485 cable Bus termination 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 equipotential bonding currents may occur, one end is grounded directly, the other end via a 15nF capacitor. Bus termination is to be provided at both ends of the bus. If one bus end is provided by means of an RS485 coupler, it may be possible to add the bus termination within the coupler. The power supply of the bus termination can also come from the PPC- R0x.2.

33 Motion Control System Brief Description of the Components V 390 W RS W RS485- GND 390 W 0 V Sy7pr111.fh7 Fig. 4-19: Bus termination To connect the bus to the PPC-R0x.2, Bosch Rexroth offers a connector with which the bus termination can be alternatively implemented. Designation Material No. RS485 plug INS0619/K Fig. 4-20: Plug for RS485 connection Field Bus Connection INTERBUS Bosch Rexroth provides a cable for connecting the INTERBUS. The cable listed below has a straight plug or bush on both ends. The connection is listed by UL and CSA. The cable color corresponds to IAONA for field buses (purple). Designation Material No. INTERBUS cable IKB Fig. 4-21: Cable for INTERBUS connection ControlNet Bosch Rexroth does not provide any connecting cable for ControlNet. If you require cable sets, cable accessories and cable specifications, please contact Allen-Bradley (Rockwell Automation). Profibus Bosch Rexroth provides two cables for connecting the Profibus. Both cable types are listed in the following table; they can be selected according to the required use. Profibus cable (basic cable with two plugs) Profibus cable (extension with one plug) Fig. 4-22: Cable for Profibus connection Designation Material No. IKB IKB

34 4-14 Brief Description of the Components Motion Control System SERCOS Connection Due to the use of optical fibers, the data transmission is absolutely immune against electromagnetic interferences that can occur in a rough industrial environment. LWL Leitung 2,2 mm Fibre optic cable 2,2 mm LWL Leitung 6,0 mm Fibre optic cable 6,0 mm SERCOSKabel.eps Sercoskabel.eps Fig. 4-23: SERCOS fiber optic cable Description Application Order No. Mat. No. Optical fiber cable 2.2 mm Optical fiber cable 6.0 mm Connection among the drives short links Connection of drives and controller long links Fig. 4-24: Order numbers for SERCOS fiber optic cable IKO0982 *) IKO0985 *) *) different material numbers according to the respective length The connection has a ring design. This means that one SERCOS fiber optic cable is required for each drive. The cables are available in sets and in user-defined lengths. 4.6 Teleservice Overview New possibilities in modern information and communication technology are causing a change of structure within the industry in the field of customer service. By using the add-on "Teleservice" (separate ordering required!), you can access, diagnose and maintain remotely located computers all from your location in the company. In addition to a substantial reduction in costs, this also results in an improvement in service efficiency; this in turn is of benefit both to the manufacturer and to the operator. Using modern communication media such as the Internet together with normalized communication mechanisms, connections can be made world-wide using Teleservice.

35 Motion Control System Brief Description of the Components 4-15 Performance features There is a powerful program for the remote control of the PC system for the TRANS 200 system. The system has the following features: integrated Web server on the control unit, remote control via Web browser per ActiveX Control (no client installation required!), high speed by means of data compression, file synchronization, audio support, record/playback function for logging, powerful script language for automated processes, and configurable security levels. For more information, see the documentation listed below. Additional Documentation Type of documentation Designation DOK-CONTRL-TELESER*V02-AW01-EN-P Teleservice / remote diagnosis (application manual) Fig. 4-25: Documentation directory for remote diagnosis Installation Detailed installation instructions can be found in the additional documentation.

36 4-16 Brief Description of the Components Motion Control System

37 Motion Control System Commissioning of the TRANS Commissioning of the TRANS Hardware Preparation Electrical Connection / Peripherals In this chapter, the electrical installation and the potential extensions are discussed, and the sequence of hardware commissioning is explained. For additional information on specific topics, see the corresponding chapters of this documentation. The supply voltage is connected according to the following wiring diagram. For the application in transfer machines, the watchdog connection (terminals 8 and 9 ready-for-operation contact) must be integrated into the EMERGENCY STOP sequence. When the firmware identifies internal faults or does not function properly, the potential-free contact of the watchdog will open. For more detailed information, please see the documentation on PPC-R0*.2 hardware. X PPC-R Dig. output 1 Dig. output 2 Dig. input 1 Dig. input 2 Dig. input 3 24V external 0V external Bb Power pack +24VDC 2x0.75 mm Bb +24VDC -15 /+20% 0V 11 0V Grounding bolt PPC-R_AnX1.FH7 Fig. 5-1: Power supply connection

38 5-2 Commissioning of the TRANS 200 Motion Control System General Cable cross-section for feeding the supply voltage 0.75 mm 2 to 1.5 mm 2 Mounting in the control cabinet With module rack RMB02.2 on top-hat rail TS 35 x 27 x 15 Protection type IP 20, EN60529 Relative humidity 5 85%, noncondensing (operation) 5 95%, noncondensing (transport) Atmospheric pressure kpa Operating temperature - ambient From 0 C to 45 C Storage and transport temperature From 25 C to 70 C Housing dimensions (W x H x D) 41.5 x 192 x 150 Weight 1.1 kg Fig. 5-2: General technical data Power Supply Power supply / rated voltage 24V DC 15%, +20% according to EN : 1994 AC component 5% of the rated voltage Absolute limits 19.2 to 30 V DC, ripple included Maximum power consumption, PPC-R A (+ power supply for I/O modules of up to 2.6A) Fig. 5-3: Power supply Watchdog Relay (Ready-for-Operation contact) Watchdog relay Make-contact element V n=24v, I max=150ma Fig. 5-4: Watchdog WARNING Components can be damaged! Ÿ The plugs and modules may only be connected or disconnected when not under power! Additional Documentation Type of documentation Designation DOK-CONTRL-PPC-R0*.2**-PR03-EN-P Description of hardware module PPC-R01.2N-N-XX-FW Fig. 5-5: Documentation directory

39 Motion Control System Commissioning of the TRANS Additional Modules Presently, the slot for extensions (PC104 slot) can be equipped with an INTERBUS, a ControlNet adapter or a Profibus. You can find corresponding type keys in section "PPC-R01.2N". The RECO module rack is available with 1, 2, or 4 slots and can be extended to a maximum of 16 slots by connecting several module racks. Only the module racks with 2 and 4 slots can be connected. As an alternative to the field bus adapters, the slots can be equipped with RECO modules. For a detailed description of the modules, see the documentation mentioned in the following or section "Input/Output Modules RECO02.2". Additional Documentation Type of documentation Designation DOK-CONTRL-RECO02.2***-PRJ1-EN-P SERCOS input/output unit RECO02.2 (project planning manual for the input/output units) DOK-CONTRL-RECO02.2***-FK01-EN-P SERCOS input/output unit RECO02.2 (description of the function of the input/output units) Fig. 5-6: Documentation directory Basic Settings (Device Address, Transmission Mode, Transmission Rate) S1 Menu The basic settings of the hardware module are provided in the so-called S1 menu. Using the S1 pushbutton (also see documentation "PPC- R0*.2"), the following values can be indicated and shown in display H1: M00: device type, M02: firmware identification string / date, M03: device address, M04: transmission mode of serial interface X10, M05: transmission rate of serial interface X10, M07: activation of the BTx interface, and M08: transmission rate of serial interface X16 (BTx interface).

40 5-4 Commissioning of the TRANS 200 Motion Control System Fig. 5-7: Position S1 pushbutton / H1 display Trans_H1_S1.bmp Furthermore, the system faults of the controller are shown in the display. The much more frequent process malfunctions can only be indicated using the multiplex channel or the "WinTRANS" operating interface. After the firmware has successfully run up, "bb" (ready for operation) appears in the display. If this message does not appear, an error message is issued. For the explanations of the malfunctions, please refer to section "Diagnosis". If the settings are to be checked or changed, proceed as follows: When the key is pressed for a long time (> 1s), the menu opens from the "bb" display or from a system error message (e.g. "S061" No PSM module). When the key is pressed for a short time, you can scroll through the menu. The menu options are listed in the table below. If you want to edit a selected menu point, open the editing mode by pressing the key for a long time. The menu options can be selected by pressing the key for a short time and then stored by pressing the key for a long time. If no entry is made in a menu option for longer than 5 seconds, the selection will go back to the menu options. If no entry is made here either for more than 20 seconds, the display will return to bb. The data selected before will not be saved.

41 Motion Control System Commissioning of the TRANS Following is an overview of the supported menu items: Short key press Selectable menus (display in window) Selectable menu items Firmware ID M0: TRANS 200 None Hardware ID M1: Not used None Firmware ID M2: Firmware string / date None Device address M3: Device address 0-63 Port A: Transmission mode M4: Port A mode RS232 / RS485 Port A: Transmission rate M5: Port A baud rate 9K6 / 19K2 / 38K4 / 57K6 / 115K Port B: Activation M7: Port B activation Off / BTx Port B: Transmission rate M8: Port B baud rate 38K4 / 57K6 / 115K Long key press (editing mode) Long key press (data are saved) or, after 5s, the display returns to "Mx"; the changes are not saved! Fig. 5-8: Function table of S1 pushbutton The default setting for menu item M08 (baud rate of port B) should be retained in any case. Future applications with mini control panels will support higher transmission rates. Existing mini control panels support a baud rate of only 38.4 kbaud. The mini control panels are commissioned and programmed according to the corresponding instructions that can be found in the documentation listed below. Additional Documentation Type of documentation Designation DOK-SUPPL*-SCM*BEDIEN*-AW04-EN-P Description of use for mini control panels Fig. 5-9: Documentation directory Addressing Each TRANS 200 can be assigned a device address between 0 and 63. Thus, up to 32 Bosch Rexroth devices of the types "TRANS 200" and "MTC 200" can be centrally visualized and administrated via the RS485 protocol. However, if more than 16 devices are connected to one network, an amplifier should be used for 16 additional devices.

42 5-6 Commissioning of the TRANS 200 Motion Control System Communication Drive Communication The drives communicates with the TRANS 200 via a fiber optic ring (TX: transmitter / RX: receiver). The drive interface is a SERCOS interface. Each drive in the ring must have a unique drive number between 1 and 7. PC Communication A serial connection between the HMI PC (e.g. notebook) and the TRANS 200 (15-pin Sub D bush X 10) is established. Operating modes "RS232" and "RS485" are supported. The transmission rates can be configured as well. The configuration can be effected by means of the S1 pushbutton on the hardware and via the PC system configurator. RS232 The RS232 connection is the simpler connection to the PPC. It requires merely a peer-to-peer connection. RS232-Verbindung.bmp Fig. 5-10: RS232 connection Communication is set up via cable IKB0012. For more information, see Section 4.5. RS485 With the RS485 connection, up to 32 devices can be connected. For connection to the PC (notebook), a converter from RS232 to RS485 is required. For this purpose, we recommend the Phoenix Contact PSM-V24/RS485- P/BB interface converter. When using the interface converter, make sure the following data are set in the system configuration scheme: transmission mode: RS485 polarity: LOW (otherwise, no connection to the interface converter can be made) Settings on the interface converter or the TRANS 200 Switch on the interface converter to DTE Required settings on the TRANS 200 (device address, transmission mode, transmission rate)

43 Motion Control System Commissioning of the TRANS Note: If a repeater is used in the RS485 transfer pathway, the transfer rate should not be set higher than 57 kb. Transfer errors occur more often at higher transfer rates. Fig. 5-11: RS485 cabling RS485-Verbund.bmp For detailed information on the cable types, please refer to Section 4.5, "Cable Specification / Serial Connection". If the interface converter described above and bus plug INS0619/K01 (available from Bosch Rexroth AG) are used, an adapter plug for connecting the RS485 bus and the interface converter is required. The adapter plug must be assigned as follows: 9-pin plug 15-pin plug Designation Pin No.: 3 Pin No.: 4 RS485+ Pin No.: 8 Pin No.: 5 RS485 - Pin No.: 5 Pin No.: 7 SGND Pin No.: 5 Pin No.: 10 SGND Pin No.: 6 Pin No.: 12 +5V Fig. 5-12: Adapter plug If a 9-pin plug is used in place of bus plug INS0619/K01, the adapter plug is not needed. The assignment is as described above; however, an additional connection between pins 7 and 9 must be provided for the bus termination.

44 5-8 Commissioning of the TRANS 200 Motion Control System PLC communication The PLC interface is available in the following versions: 1. RECO I/O (integrated bus) For more detailed information, please refer to Section 4.3 or the documentation on RECO modules. 2. INTERBUS slave (PC104 module) 3. ControlNet Adapter Class (PC104 module) 4. Profibus slave (PC104 module) 5. DeviceNet slave (PC104 module) Fig. 5-13: Topology field bus / TRANS 200 / drives TRANS_Topologie.bmp The data width and the assignment of the interface are adjustable in the I/O configuration scheme / field bus configuration scheme. For more detailed information on the I/O configuration scheme, also see section "I/O Configurator", p

45 Motion Control System Commissioning of the TRANS Commissioning of the TRANS 200 Commissioning of the control system not only involves commissioning of the hardware module; the firmware must be parameterized as well. In the following chapter, parameterization and setting of the software is described. The individual steps should be taken in the sequence described in the following. The individual steps are described in more detail in other documents which are mentioned at the respective location. Hardware Before starting the WinTRANS interface and making the corresponding settings, the hardware must be correctly wired. The following sketch indicates the connections between the TRANS 200 and the peripherals. Übersicht_T200.bmp Fig. 5-14: TRANS 200 wiring Connections: X1 Hardware power supply X10 Connection to PC / notebook IKB0012 X16 Connection to mini control panel IKB0015 TX/RX SERCOS connection to the drives IKO0982 / IKO0985 In addition to these hardware connections, the following settings must be made on the PPC-R0x.2: device address, baud rate and communication mode. The settings must be made both in the system configurator and on the PPC-R0x.2; they must agree. If a mini control panel is connected, its communication parameters must also be checked if a connection cannot be made using the default parameters (also see section "Basic Settings (Device Address, Transmission Mode, Transmission Rate)", p. 5-3).

46 5-10 Commissioning of the TRANS 200 Motion Control System Overview of Functions and Additional Information WinTRANS is a graphic user interface for the family of TRANS 200 devices. It is primarily intended for commissioning, maintenance and service purposes. Fig. 5-15: TRANS 200 main screen Overview of Functions: TRANS_Hauptmenue.bmp With F2 "Select Control", a device defined via the system configuration scheme can be selected. To handle machine parameters (system parameters, process parameters, axis parameters and drive parameters), activate function F3 "Configuration". To write new NC programs, select function F4, "NC Program". For this purpose, an NC assistant is provided. To view data, select F5 "NC Screen": Online device screen with position indication NC block indication Spindle and feed indication Active G codes and M codes Processing / administration of NC variables, NC events, D corrections, offsets To view signal states or to assign (force) a certain value to signals, select function F6 "Watch+Force". With F7 "Control Panel", individual axes can be moved manually and NC programs can be started in automatic mode. With F8 "I/O Config.", the field bus type to be used, the RECO I/O modules, the assignment of the interface signals, and the multiplex channels are configured. To install a new firmware version, start "Commissioning\Setup \Firmware handling". User management is activated in "Commissioning\Setup\User management".

47 Motion Control System Commissioning of the TRANS Additional Documentation Type of documentation Designation DOK-CONTRL-MTGUI***V22-AW01-EN-P MTGUI Operator Interface DOK-CONTRL-PAR*DES*V23-AW01-EN-P Description of TRANS 200 parameters Fig. 5-16: Documentation directory System Requirements The user interface is installed according to the corresponding installation instructions. However, the minimum requirements of the PC hardware should be observed: Minimum requirement: PC with Pentium 133 MHz, 64 MB RAM Windows NT 4.0 (Service Pack >= 5) Serial interface for online operation Internet Explorer >4.01 Additional Documentation Type of documentation Designation DOC-CONTRL-INS*BOF*V22-AW01-EN-P Installation Instructions Fig. 5-17: Documentation directory User Management User management ensures that only authorized personnel have access to protected functions (and program parts). Before a protected function is executed, the user must register with User Management. To log in, the name and a password are entered. The name identifies and the password authorizes the user. After registration has been completed, User management will decide on the basis of the rights of the registering user whether the selected function may be executed or not. During the first registration after a new installation, the password for the supervisor is determined. The identification data for the first registration are as follows: Name: "Supervisor Password: "123" After the first registration, the password must be changed. Furthermore, User management should be activated by all means to protect the functions concerned. For an extensive description of User management, please refer to the documentation listed in the following.

48 5-12 Commissioning of the TRANS 200 Motion Control System Additional Documentation Type of documentation Designation DOK-CONTRL-SETUP***V22-AW02-EN-P Setup Fig. 5-18: Documentation directory Firmware Handling When the hardware is delivered, the current firmware is installed. After ramp-up of the controller, the following messages may be indicated in the "H1" display: "dl" There is no firmware in the controller. The controller is ready to download firmware. "S17" Ramp-up of the controller has been successfully completed, the firmware has been initialized, and no parameters are available on the controller (the memory is empty!). The control system is waiting for correct parameters. "S24" Ramp-up of the controller has been successfully completed, the firmware has been initialized, and no valid parameters are available on the controller (the memory content is invalid!) The control system is waiting for correct parameters. "bb" Ramp-up of the motion control has been successfully completed, parameters and firmware are OK. After initialization of the TRANS 200, the drive can likewise ramp up to "bb" if the parameters conform to the drive constellation. For further information on the error messages, please refer to Chapter 6. A firmware download is generally required only after changing/updating the version. If a firmware download is nevertheless desired, it is carried out using the "Commissioning" menu: in the menu bar under "Commissioning" in the "Setup" directory. Firmware can only be downloaded by authorized qualified staff; the access rights are controlled by User management. If the user is authorized to perform actions in this menu, the proper menu "Firmware Handling" will become available after successful entry of user name and password. The following menu is self-explanatory and guides the user through the selected function. Additional Documentation Type of documentation Designation DOK-CONTRL-SETUP***V22-AW02-EN-P Setup Fig. 5-19: Documentation directory

49 Motion Control System Commissioning of the TRANS Firmware Type Keys / Potential Configurations The following table shows the type keys for the firmware and software components available for the TRANS 200. This table provides the order information for the TRANS 200 system. The type keys for the software are shown thereafter. Firmware configuration Available hardware Comments FWA-PPCR0*-T01-23VRS-NN-S1NNNN PPC-R01.2N-N-S1-FW Standard version with serial interface FWA-PPCR0*-T01-23VRS-NN-B2XXXX PPC-R01.2N-N-B2-FW or PPC-R02.2N-N-NN-B2-NN-FW FWA-PPCR0*-T01-23VRS-NN-L2XXXX PPC-R01.2N-N-L2-FW or PPC-R02.2N-N-L2-NN-NN-FW FWA-PPCR0*-T01-23VRS-NN-P2XXXX PPC-R01.2N-N-P2-FW or PPC-R02.2N-N-NN-P2-NN-FW FWA-PPCR0*-T01-23VRS-NN-V2XXXX PPC-R01.2N-N-V2-FW or PPC-R02.2N-N-V2-NN-NN-FW Version with INTERBUS slave Version with ControlNet Adapter Class Version with Profibus slave Version with DeviceNet slave Software configuration Comments SWA-TRA200-T01-23VRS-NN-C1,44 Firmware of the CNC runtime system available on diskette SWA-TRA200-T11-23VRS-MS-CD650 User interface software on CD SWL-TRA200-T11-23VRS-MS License agreement of the software of the operator interface Fig. 5-20: Available configurations

50 5-14 Commissioning of the TRANS 200 Motion Control System The following figure shows the type keys of the software: Short text column Example: F W A - P P C R 0 * - T R R V R S - N N - 1. Product group 1.1 Firmware... = FW Software... = SW 2. Class 2.1 Product (devices)... = A 3. Product name 3.1 e.g. controller ID 4. Firmware type (alphanumeric) 4.1 e.g. Trans for Reco = TRR 5. Firmware version ( ) 5.1 e.g = Firmware character 6.1 Test version = T 6.2 Standard (full version) = V 7. Firmware release level (update) ( ) 7.1 Release level (the currently valid level is = level of the parts list is supplied automatically) = RS 7.2 Specific release level, e.g = Language (for abbreviations see INN 09.04, Part 1) 8.1 e.g. German = DE 8.2 multilingual = MS 8.3 Language independant = NN 9. Product name, continued (field 3) 9.1 Not applicable if not used 9.2 Disk with 1,44 MB storage = C1, CD with 650 MB storage = C650 Re: 2. Assembly.....= B Components..= C Data carrier... = D Re: 3. PSM01*......= PSM01* Control Net.. = CNS01* Interbus.... = IBS03* Trans = TRA200 PPC-R0*-2N.. = PPCR01* Fig. 5-21: Software type keys Re: 4. Trans200 for Reco = TRR Boot Loader Machine Tool..= BLM PC104-Control Net = PHL PC104-Interbus = PHB TypenschlFWA.FH7

51 Motion Control System Commissioning of the TRANS F2 Select Control The "Select Control" menu item is called with the <F2> key. Select Control is used to select a specific control from the available controls. The machine tool interface that appears on the screen is then always based on the selected control. In the TRANS 200, no processes can be selected because work is carried out with only one process. Steuerungsauswahl.bmp Fig. 5-22: Select Control (TRANS 200) Controls Processes Info... The first list displays all configured controls and contains the following columns: K: The head-end control is indicated by an X. L: An X indicates the local control; no entry means that the control has been removed. Control name, device name Status: Device status (OK, System failure, Download, Failure, No connection) Controls that cannot be selected, e.g. due to an error, are displayed in italics. The selected control is highlighted in bold print. All other controls are displayed in normal print. The second list shows the processes of the highlighted control unit. The list contains two columns: Process name Status (OK, Failure) The currently selected process is displayed in bold. The highlighted control and the highlighted process are selected when the user presses "OK". The dialog box is closed. The selected control can then be further processed. The <Info...> button opens another dialog box, which provides information about the highlighted control. Number of the PC to which the control is assigned Local device address

52 5-16 Commissioning of the TRANS 200 Motion Control System Device type FarDevice address F3 Configuration (Creation of Parameter Files / Download The creation and download of a set of parameters is part of the initialization of the control software. A valid set of parameters is created by means of the F3 function key: "Configuration". A new set of parameters can be created under "Machine parameters" via the "New" button. In this menu, an upload is possible as well, i.e. a set of parameters available on the control is loaded to the operator interface. After that, this set of parameters can be further processed. When a new set of parameters is created, the individual parameters are preassigned a default value so that the values do not necessarily have to be adapted. The default values (= 0) of the traversing range limits must be adapted to allow for traversing (exception: rotary axes!). The designations stand for the following parameters: Main group Parameter Value Basic definitions Max. tool path feed rate Max. tool path acceleration Basic position required Reference required D corrections D-correction admissible Max./min length of the D- corrections SERCOS interface SERCOS axes from 1 to max. 7 Fig. 5-23: Parameter table for machine parameters Fig. 5-24: "Machine parameter" menu parameter01.bmp

53 Motion Control System Commissioning of the TRANS List of Parameters Under the menu item "SERCOS interface", you can configure the connected SERCOS axes. You obtain the corresponding menu via the "New" button. The parameters are likewise preassigned default values. For a detailed description of parameter handling, please refer to the description in "WinTRANS Motion Control Software". The exact description of the parameters is to be found in the documentation "Description of Parameters". Commissioning the drives is described in detail in Chapter 7; the respective drive documentation should be consulted as well. Loading Parameters Start the parameter download with the "F7" key. After a successful parameter download, the connected axes should ramp up in the SERCOS phase 4 "bb" if the connected axes are supported by the created parameter file. During the first parameter download, ensure that the option "Download SERCOS parameters" is deactivated. Otherwise, an error message indicating that no SERCOS parameters exist will be issued. Additional Documentation Type of documentation Designation DOK-CONTRL-PAR*MAN*V22-AW01-EN-P Parameter handling DOK-CONTRL-PAR*DES*V23-AW01-EN-P Description of TRANS 200 parameters Fig. 5-25: Documentation directory F8 - Creation of the Field Bus Configuration / Download The TRANS 200 provides for a multitude of interface signals which can be determined by means of the I/O configurator. Furthermore, the I/O configurator determines with which I/O medium (field bus or RECO) the TRANS 200 interface signals are to be accessed. The I/O configurator can be started from the main WinTRANS menu as follows: Press the <F8: IO Config.> button or activate using the mouse. or Select the menu point "IO Configurator" in the "Commissioning" menu. Field Bus Configurator To create an I/O configuration, the corresponding I/O channel and the data width must first be determined in the field bus configurator (see the figure below). The I/O channel (INTERBUS, ControlNet, RECO-I/O, Profibus) is determined in the scroll menu "IO medium". The data width of the inputs and outputs is determined as described in point 1 in the figure below. These values show how many inputs and outputs can be configured. The total width of the I/O configuration is represented once more in point 2 in the figure below. The total data width of the field bus channel with the multiplex channel included can be seen in point 3 in the figure below. Either 1 or 2 multiplex channels can be configured.

54 5-18 Commissioning of the TRANS 200 Motion Control System Fig. 5-26: Field bus configurator T200IOC_FieldbusInfo.bmp With the "Swapping" function, the created I/O configuration is adapted to the data structure of the PLC. The function allows for an exchange of the data bytes and words on the bus, or depending on the data type the consideration of the addressing used by the respective PLC. I/O Configurator After determination of the data width in the field bus configurator, the inputs and outputs can be determined. By way of example, the configuration of inputs is described in the following figure. The outputs are configured in the same way as the inputs. Fig. 5-27: Editing inputs T200IOC_EditInputs.bmp For easier creation of the I/O configuration, a template containing the most important signals is offered. The template can be adapted individually to the given application. The template can be selected in the "I/O Configurator" under "File New".

55 Motion Control System Commissioning of the TRANS Loading of the IO Configuration After completion of the I/O configuration, it can be loaded to the control system via the download function (F7). The interface signals take effect immediately. Additional Documentation Type of documentation Designation DOK-TRA200-IO*CPAN*V23-PR01-EN-P IO Configuration/Watch+Force/ Control Panel DOK-TRA200-SPS*COM*V23-PR01-EN-P Description of interface / field bus interface (description of the PLC interface) Fig. 5-28: Documentation directory F4 - Creation of an NC Program / Download of an NC Program Overview The NC program assistant, which can be called using "F4: NC program", is a tool for generating NC programs. It supports the user in the creation of consistent NC programs with the correct syntax. The NC assistant provides for the creation of new NC sets as well as for the editing of existing NC sets. Here, the user is guided through various entry dialogs: The G and M commands etc. are made easier to understand by a comment or by illustrations: e.g. G1, linear interpolation. The user is offered only admissible and sensible function combinations - G1 and G0, for example, preclude each other in an NC set; with G0, G61 is not available because exact positioning etc. is generally applicable with G0The user is guided through all the possible components of an NC block. The sequence of the parts in the NC sets is standardized. Consistency and correct syntax are ensured for each NC block. Fig. 5-29: NC program assistant TRA_NC-ASS2.jpg

56 5-20 Commissioning of the TRANS 200 Motion Control System Note: The NC program assistant should preferably be operated with the mouse. Creation of an NC Program The NC assistant guides the user through several steps to create an NC program. The menus for creation of an NC program are listed in the following. Not all the steps must be followed to create a functioning NC program. Step 1: NC Program Step 2: Function Step 3: Spindle 4. Step: M functions 5. Step: Tool 6. Step: Command In the first step, the assistant dialog box shows the NC program; the commands for handling the NC program are activated via the F keys or the menu bar. In the second stop, the main function of an NC set is entered. The main functions are: Interpolation types (G0 / G1 / G2 / G3) Dwell time (G4) Tapping without compensating chuck (G63 / G64) Homing (G74) Traveling against dead stop / release of initial axis stress (G75 / G76) This step comprises the spindle functions, including the speed and/or position for 3 spindles. In this screen, M functions can be added to an NC set. M functions (auxiliary functions) M400 to M431 enable the TRANS 200 to trigger program-controlled PLC actions. D corrections are programmed using the Tool step. This step comprises functions that control the flow of the NC program. They include the following functions: Branches (BST / BRA / BEQ / BNE / etc.) Events (BES / BEV / CEV / etc.) Control commands (DCD / ITM / ODT / etc.) 7. Step: Label 8. Step: Zero offsets 9. Step: Comment In this step, a new label can be created or an existing one deleted. The NC assistant makes sure that no multiple labels are created, i.e. that each label name is unique in the NC program. Zero offsets are programmed here. With a zero offset, the origin of an axis of coordinates related to the machine zero can be shifted. The TRANS 200 provides for the zeros G50 / G51 / G52 / G54 - G59 In this step, a comment on an NC set can be entered. There are two comment types: User comment (the comment is inserted into the current set display) NC note (indicated in the diagnosis menu of the user surface). Loading an NC Program After termination and saving of an NC program (these are likewise menuguided actions!), the automatic download of the NC program is activated. In the overview for NC programs, the NC program just created and downloaded is marked by "CNC".

57 Motion Control System Commissioning of the TRANS Additional Documentation Type of documentation Designation DOK-CONRTL-NC*PSYS*V23-AW01-EN-P NC programming system DOK-TRA200-NC**PRO*V23-AW01-EN-P NC programming instructions for the TRANS 200 Fig. 5-30: Documentation directory Function blocks / PLC Interface Bosch Rexroth provides function blocks for control systems from thirdparty suppliers. The function blocks provide for sequential communication to the connected TRANS 200 via field bus, check the time flow, and, if applicable, signal communication errors to the PLC application The following function blocks are available: MUX_READ (function block for the read request) MUX_WRITE (function block for the write request) The function blocks are available for the following PLC manufacturers and field buses: Field bus V21 V22 (expanded MUX) Interbus Bosch Rexroth ISP200 Not available. Schneider Electric TSX Premium ControlNet Rockwell Automation - ControlLogix Schneider Electric TSX Premium Not available. Profibus Not available. Not available. DeviceNet Not available. Not available. Fig. 5-31: Availability of function blocks Additional Documentation Type of documentation Designation DOK-TRA200-SPS*COM*V23-PR01-EN-P Description of interface / field bus interface (description of the PLC interface) Fig. 5-32: Documentation directory

58 5-22 Commissioning of the TRANS 200 Motion Control System

59 Motion Control System Diagnosis Diagnosis 6.1 Diagnosis Display "H1" 6.2 Meaning of the Status Indications The PPC-R module is equipped with a 4-character alphanumerical indication display. Here, the test and initialization steps are displayed during boot-up; serious errors are shown during operation. During initialization, a run-up of figures is shown. If errors occur during that phase (self-test faults), the figure will be static or will flash: -1 to -10 As soon as the CNC firmware becomes active, the display indicates the diagnosis INIT During that time, the recognition of the optional modules as well as further initialization and tests take place. Subsequently, any errors are indicated in a flashing mode as system errors in the following format: Snnn S: System error nnn: 3-figure, decimal error number. As soon as the TRANS 200 is ready for operation, the display will indicate the diagnosis bb If major errors occur during operation, they will be indicated as system errors, as described above. Generally, system errors can only be remedied by a reset (disconnecting and connecting the TRANS 200, pressing the S2 key or performing a softreset via the operator interface). Note: Diagnosis signals and minor faults not requiring any reset are not indicated via the alphanumerical display. They can be indicated only via the multiplex channel or the operator interface. The following additional messages can be shown in the display: PF "Power Fail" the power supply of the hardware is switched off or has failed. The firmware saves the data to the PSM module before the power supply drops below the required value. dl "Download" the display flashes when the flash loader is active. A list of the numbers of system errors and a brief description of their causes and remedies follows. For some system errors, further information is available through an operator interface or the multiplex channel (additional information). Example: n case of a "Power On Self Test" fault, additional information on the fault type (RAM fault / co-processor fault etc.) and the location of fault is available.

60 6-2 Diagnosis Motion Control System Note: Many system errors will prevent the field bus from being started. In such a case, the multiplex channel and, accordingly, the diagnosis option via the PLC will not be available. List of System Error Messages 002 Error during Initialization of TRANS 200 Important software components of the TRANS 200 are missing or are not functioning! Remedy: Trigger a reset. Replace the TRANS 200 firmware module (PSM01.1). Contact the Bosch Rexroth customer service department. 003 CPU Time Monitoring Two software components of the TRANS 200 no longer run synchronously. Remedy: Trigger a reset. Replace the TRANS 200 firmware module (PSM01.1). Contact the Bosch Rexroth customer service department. 004 Power Fail Interrupt The operating voltage of the TRANS 200 has fallen to 18V or below for a short time. Remedy: Trigger a reset. Make sure that the power supply of the TRANS 200 is adequately dimensioned. Check if other consumers connected to the same power supply require high peak currents for short times. Do not simultaneously connect several consumers with high start-up current requirements. 007 Software Version Error Two software components of the TRANS 200 are not compatible. Additional information: Information on the components and version identifications. Remedy: Replace the TRANS 200 firmware module (PSM01.1). Contact the Bosch Rexroth customer service department. 008 Unsuccessful Self-Test of the Motion Control The self-test of a component of the TRANS 200 was unsuccessful. Additional information: Information on the system that recognized the fault, and on the type of self-test fault. Remedy: Replace the TRANS 200 module. Contact the Bosch Rexroth customer service department.

61 Motion Control System Diagnosis Invalid Data Memory of the TRANS 200 The data in the memory of the TRANS 200 is invalid. Possible causes: The TRANS 200 is operated for the first time and has not yet been parameterized. An older firmware version was updated. The module PSM01.1 is faulty. Remedy: Load the following data in the given sequence into the TRANS 200: 1. Machine parameter (if the device does not jump to "bb", first press Reset, then download the additional data) 2. IO configuration 3. NC programs 4. Zero offsets If the error occurs repeatedly, replace module "PSM01.1" and inform customer service. 023 Incomplete Set of Parameters in the TRANS 200 The machine parameters filed in the TRANS 200 are incomplete. Possible causes: The transmission of a set of parameters was interrupted manually or by a transmission error. Remedy: Re-transmit the set of parameters. 024 Invalid Data Memory in the TRANS 200 The data in the memory of the TRANS 200 are no longer valid. Possible causes: The TRANS 200 is operated for the first time and has not yet been parameterized. An older firmware version was updated. The module PSM01.1 is faulty. Remedy: Load the following data in the given sequence into the TRANS 200: 1. Machine parameter (if the device does not jump to "bb", first press Reset, then download the additional data) 2. IO configuration 3. NC programs 4. Zero offsets If the error occurs repeatedly, replace module "PSM01.1" and inform customer service.

62 6-4 Diagnosis Motion Control System 028 Invalid Parameter Version After the TRANS 200 operating software is replaced with another version, the data that are currently in the TRANS 200 parameter set can no longer be processed. Remedy: Continue work with the original operating software by re-importing it into the TRANS 200. Re-import the parameter set into the TRANS Data memory full after parameter transmission The user data memory in the TRANS 200 is full. No additional data can be stored. This concerns NC programs, offset banks, parameters, and IO configurations. Remedy: The memory requirements must be reduced by: deleting comments in "( )" and user messages in "[ ]" from NC programs, deleting NC program instructions that are not needed. 033 Error during initialization of APR Firmware component "Axis processor" of the TRANS 200 could not be correctly initialized. Remedy: Trigger a reset. If the error occurs repeatedly, replace the memory module (PSM01.1) and inform customer service. 034 APR Time Monitoring Firmware component "Axis processor" of the TRANS 200 reports a system fault! Remedy: Trigger a reset. If the error occurs repeatedly, replace the memory module (PSM01.1) and inform customer service. 035 The APR does not respond Firmware component "Axis processor" of the TRANS 200 does not react. Remedy: Trigger a reset. If the error occurs repeatedly, replace the memory module (PSM01.1) and inform customer service. 036 The APR was not recognized. Firmware component "Axis processor" of the TRANS 200 was not recognized. Remedy: Trigger a reset. If the error occurs repeatedly, replace the memory module (PSM01.1) and inform customer service. 037 Ring for digital drives not yet closed The SERCOS fiber optic ring between the TRANS 200 and the associated drive amplifiers is not yet closed. Remedy: Check whether all fiber optic plug-in connections were made properly and whether all drive amplifiers are switched on.

63 Motion Control System Diagnosis Error during initialization of IOM Firmware component "IO Mapper" of the TRANS 200 could not be correctly initialized. Remedy: Trigger a reset. If the error occurs repeatedly, replace the memory module (PSM01.1) and inform customer service. 050 The IOM does not respond Firmware component "IO Mapper" of the TRANS 200 does not react. Remedy: Trigger a reset. If the error occurs repeatedly, replace the memory module (PSM01.1) and inform customer service. 051 IOM Time Monitoring Firmware component "IO Mapper" of the TRANS 200 reports a system fault! Remedy: Trigger a reset. If the error occurs repeatedly, replace the memory module (PSM01.1) and inform customer service. 052 Invalid IOM Configuration The IO configuration of the TRANS 200 is invalid. Remedy: Load the valid configuration into the TRANS Memory Module "PSM01.1" has been Removed In addition to the operating software, memory module "PSM01.1" also contains the user data and internal states of the TRANS 200 that must be retained when the TRANS 200 is switched off. Modifications that are made when the module has been removed are not saved. Therefore, the TRANS 200 must be operated only with the module attached. Remedy: Equip the TRANS 200 assembly with a "PSM01.1" memory module and then trigger a reset. 063 IO Interface of TRANS 200 Inactive The RECO connection is not yet operative. This message should disappear automatically after a few seconds. Remedy: If the message doesn t disappear automatically, trigger a reset. If the error occurs repeatedly, replace memory module "PSM01.1" and inform customer service. 082 Malfunction of the Field Bus Connection Group message for fatal faults in the operation of the field bus connection. Remedy: Trigger a reset. If the error occurs repeatedly, replace the field bus module or memory module "PSM01.1" and contact customer service.

64 6-6 Diagnosis Motion Control System

65 Motion Control System Commissioning the Drives with DriveTop Commissioning the Drives with DriveTop 7.1 Overview and Additional Information Complete commissioning of a Diax 04-AC servo drive within the TRANS 200 system with all necessary parameters and settings is a demanding task and requires profound knowledge of drive engineering. In commissioning these high-quality drive systems, command of basic physical correlations, insight into the technology of the type of application, and of course experience are of great importance. In this connection, please observe the chapter "Safety Information for Electrical Drives and Control Systems" in Chapter 3 or in the Drive Function Description. Fig. 7-1: Diax 04 DIAX04.jpg For more information on this topic, please refer to the two sets of documents "Diax 04 Drive with Servo Function" with the document designation DOK-DIAX04-SSE-02VRS**-61M1-EN-P and "Diax 04 AC Main Spindle Drive" with the document designation DOK-DIAX04-SHS- 02VRS**-62M1-EN-P.

66 7-2 Commissioning the Drives with DriveTop Motion Control System Introduction This chapter offers an overview of the functions of a Diax 04 drive by means of a very simple and easily understandable example. By way of the commissioning software "DriveTop", the most important parameters and their functions are clearly described. In creating this documentation, a drive training device with 4 Diax 04 drives and the following configuration was used: Axis SERCOS address Axis meaning Motor encoder (feedback) S 4 Main spindle Relative transmitter (HSF single turn) X 1 Linear axis Absolute transmitter (HSF multi-turn) Y 2 Linear axis Absolute transmitter (HSF multi-turn) Z 3 Linear axis Absolute transmitter (HSF multi-turn) Fig. 7-2: Drive configuration Based on this configuration, commissioning of the system by way of the linear X axis is performed. This example is provided to help the reader with the introduction to the high-efficiency "DriveTop" tool. 7.2 General Information on Drive Parameters Communication with the drive is implemented using SERCOS parameters. They are used to set the functions, parameterize the control settings, operate drive functions and commands, and transmit desired and actual values cyclically or as required. Here, there are S and P parameters with the following significance, clearly identified by their ID number: S parameters for SERCOS parameters. These are specified in the SERCOS protocol definition (standard: EN 61491); this is an international standard and thus does not depend on the manufacturer. Example: S P parameters for product- or manufacturer-specific parameters. They are the drive manufacturer s own specification; special meanings are defined which are not applicable with other manufacturers. Example: P We have learned from experience not to overstrain and thus confuse beginners in this field with a vast number of drive parameters and their meanings. For this reason, we intentionally do without the massive "parameter accumulation" usually to be found in drive documentation. Only the functionality of the drives is explained to the reader of these Commissioning Instructions; their respective parameters, as applicable, can be found in the Descriptions of Functions if required.

67 Motion Control System Commissioning the Drives with DriveTop 7-3 Communication Phases When the drives are activated, 5 SERCOS communication phases are run through at first; these are briefly explained in the following table: Phase Brief Description P0 Master (motion control) attempts to close the SERCOS ring P1 Addressing of all stations P2 Parameterization mode P3 Cyclic parameterization and check P4 Cyclic operation Fig. 7-3: SERCOS communication phases Note: Except for some special cases, writing of parameters is only possible in communication phase 2, i.e. in the parameterization mode. 7.3 Communication Structure Bosch Rexroth provides the comfortable, extensive "DriveTop" software for commissioning and diagnosing the drives. The connection between DriveTop and the drive controller is made via the interface software "WinTRANS": Fig. 7-4: Starting "DriveTop" Parameter_DriveTop.bmp Using the "F3: Configuration" key or in the menu bar "Commissioning/ Configuration", you can open the parameter menu as shown in the figure above. By entering the corresponding parameter menu, you can activate the "DriveTop" software tool via "F8: Edit". Note: The active set of parameters (marked "CNC"!) must be used. The "DriveTop" tool functions only in online mode.

68 7-4 Commissioning the Drives with DriveTop Motion Control System 7.4 Preparation Address Allocation and Connection Some preparations must be made before setting up the drives. 1. All drives must be correctly installed and connected. 2. Allocate a unique address to each drive, starting with 1; address 0 is reserved for the drive master (control). The maximum address is 7. The address is set by means of the two address rotary switches on the SERCOS interface module (type - DSS2.1) of the drive amplifier. The address to be set is determined as the total of the two numbers, which are weighted differently: Low switch: set number x 1 High switch: set number x Close the SERCOS ring. Make sure that the polarity of the fiber optic cables is correct. Tx: Transmit Rx: Receive Fig. 7-5: SERCOS topology 4. Check the emergency stop chain. Sercostopologie.bmp

69 Motion Control System Commissioning the Drives with DriveTop Establishment of a Connection between Control and Drives After all necessary preparations have been taken, now start "DriveTop" as described above. After the start and successful ramp-up of "DriveTop", the editor will show the following screen: Fig. 7-6: Main "DriveTop" menu Hauptmenü_DriveTop.bmp 7.6 Loading Basic Parameters With the function "Load basic parameters", default controller parameters (factory-set standard values for rough, but mostly stable operation) can be loaded into the drive. The following settings are made: The velocity and acceleration values are set to low values. Position limits and the emergency stop are deactivated. The operative mode "Velocity Regulation" is activated and all optional functions are deactivated. By means of the control loop parameter, controller parameters compatible with the used motor type are set; these work for most of the applications. The basic parameters are loaded via the menu: <File> <Load basic parameters> Note: Loading of the basic parameters will overwrite existing values by default settings! Therefore, it is advisable to save the existing parameters before loading the basic parameters. If parameters change when firmware is replaced, the drive will likewise prompt the operator to load basic parameters by indicating PL.

70 7-6 Commissioning the Drives with DriveTop Motion Control System 7.7 Application-Dependent First-Time Setup By way of example, a first-time setup with standard settings is performed for a Diax 04 drive as a linear axis with absolute transmitter. 1. Start the commissioning assistant via the menu: <Setup> <Setup drive> An assistant will support you during setup and guide you through some dialog fields. Basic parameters and the most significant settings are explained in the following. Note: When you click the entry space of each parameter with the right mouse button, you can view the maximum admissible value in the popup menu under <Parameter Info>. On switching over to SERCOS phase 4, the parameters are checked for validity. Operating Mode and Application Profile We start by setting the type of operation and the application profile. 1. As the drive in this case is a positionable linear drive, the operation type "Position Control" must be set. The corresponding application profile in this case is a "Linear axis with absolute motor transmitter" since the drive has an HSF Multiturn (absolute transmitter). 2. Basic parameters and the most significant settings are explained in the following. Fig. 7-7: Operating mode and application profile dt_erstinbetrieb_1.pcx To start parameterization, change to the parameterization phase (SERCOS Phase 2). Sometimes, the following error will appear after this action:

71 Motion Control System Commissioning the Drives with DriveTop 7-7 Fig. 7-8: Parameter error P Confirm this error with <Cancel>. dt_fehler_p187.pcx Note: By clicking the right mouse button, you can switch over the SERCOS phases at any time through a popup menu. Drive Controller Axis designation The dialog field "Drive controller" shows general information, e.g. firmware version, controller type, and motor type. For better orientation, you can assign an identification to the axis here. dt_antriebsregelgerät_1.pcx Fig. 7-9: Drive controller Then confirm with <Next>

72 7-8 Commissioning the Drives with DriveTop Motion Control System Operating Mode Selection In the dialog field "Operating mode selection" which then appears, set the main operating mode and 3 secondary operating modes. In our example, we operate the drive in Position lode lagless with one motor encoder (encoder 1). Note: In the TRANS 200 control system, the main operating mode and the 1 st secondary operating mode is written by the control, which is also responsible for switching between these modes. The user must not make any entries here! Fig. 7-10: Operating mode selection Then confirm with <Next>. dt_betriebsartenauswahl.pcx

73 Motion Control System Commissioning the Drives with DriveTop 7-9 Scaling and Units "Scaling" is an important part of commissioning. It defines the physical unit and the conversion factor for the transfer of data. Our drive is operated according to the following figure. Via a ball roller spindle or a gear unit, the rotary motion of the motor is transformed into a translatory traveling motion of a linear slide. dt_wichtung_maßeinheiten.pcx Fig. 7-11: Scaling and units Via the <Advanced> button, you can open another dialog field where special parameters may be entered for scaling. Fig. 7-12: Scaling advanced settings dt_wichtung_erweitert.pcx Do not change any of these entries, but press the <Close> button; then confirm with <Next>.

74 7-10 Commissioning the Drives with DriveTop Motion Control System Gear, Mechanical Feed constant Data reference Entry of the maximum traversing range is compulsory; for the case of over-range, the indication of either a warning or an error can be set. Since our drive configuration is a test structure, we will leave all default values unchanged. If the motion of the linear slide is implemented by a gear unit, enter the gear ratio here. The so-called "feed constant" indicates the way the linear slide will travel in one revolution with a gear ratio of 1:1. If, for example, the value of 10 mm is entered here, an existing slide will travel 10 mm with one 360 revolution of the drive. Accordingly, the feed constant is the leadscrew pitch. Furthermore, you have the option to parameterize the axis as a modulo axis so that the position is set to zero again when a defined path has been realized. This in an important function in rotary axes. All data, such as the gear ratio, feed constant, and other information, refer to a load and are considered automatically in the axis movement. Fig. 7-13: Gear, mechanical Then confirm with <Next>. dt_getriebe_mechanisch.pcx

75 Motion Control System Commissioning the Drives with DriveTop 7-11 Error Handling of the Supply Module The desired reaction of the drive in case of an error (drive error, control error, EMERGENCY STOP etc.) and the type of remedial action for the arising danger must be defined. In this case, the supply and control modules can show several reactions. In our example, please leave the necessary parameters of the supply modules at their preset default values. Note: In this connection, please note the drive diagnosis description "Diax 04 Drive with servo function", documentation number DOK-DIAX04-SSE-02VRS**-FKB1-EN-P. Fig. 7-14: Error handling of supply module Then confirm with <Next>. dt_fehlerreaktion_versorgung.pcx Error Handling, Drive The reaction of the drive to any occurring error should be determined and parameterized according to the respective application. With Velocity command value equals zero, the drive is slowed down to a standstill immediately if there is sufficient intermediate circuit voltage. If, however, Switch off current is set for errors, the drive slowly loses momentum and slows down. In some cases, Return traverse movement into a safe position is required as well. Note: In this connection, please note the drive diagnosis description "Diax 04 Drive with servo function", documentation number DOK-DIAX04-SSE-02VRS**-FKB1-EN-P.

76 7-12 Commissioning the Drives with DriveTop Motion Control System EMERGENCY STOP Function Fig. 7-15: Error handling of drive Then confirm with <Next>. dt_fehlerreaktion_antrieb.pcx As an option, an E-stop switch (EMERGENCY STOP, protective doors, etc.) can be activated. Since there is no such device in our example, we deactivate this E-stop signal. Fig. 7-16: EMERGENCY STOP function Then confirm with <Next>. dt_not_stop_funktion.pcx

77 Motion Control System Commissioning the Drives with DriveTop 7-13 Position Limit Values With "Position limit monitoring", you can activate traversing range limits by means of a software-based process (software position switch). Here, the traversing range is measured and controlled by the transmitters. The movement of the slide can likewise be controlled and the drive can be stopped if necessary via a travel range limit switch installed externally on the axis. Here, too, both parameters are deactivated. dt_antriebsbegrenzungen.pcx Other Limits Fig. 7-17: Position limit values Then confirm with <Next> In setting the limits, the project planning documents for the respective drive must be observed. The permissible values and nominal data for all existing drives and types are listed there. Velocity limit Acceleration limit Torque/force limit The "Bipolar velocity limit" provides the maximum permissible velocity of the drive. This prevents unintentional entry of speed values that are too high. If the nominal value exceeds this limit, the speed will be limited and a warning will be indicated. Please observe that here again, all data refer to the load or a linear slide respectively. Here, the "Bipolar jerk and acceleration limits" refer only to the reaction drive stop and are not significant otherwise. With an AC synchronous motor with permanent magnets, the following context is applicable: M = K M: Torque K m: Torque constant I: Stator current Fig. 7-18: Motor equation of a synchronous motor with permanent magnets m I

78 7-14 Commissioning the Drives with DriveTop Motion Control System Standstill current This name indicates that the limitation of the torque directly affects the torque-forming current. The maximum admissible standstill current I dn serves as a reference value, i.e. it corresponds to a value of 100%. Proceeding from this current, the continuous torque at standstill M dn can be determined. The maximum effective peak current I max is defined by any demagnetizing of the rare-earth magnets of the rotor occurring when currents are too strong. This peak current I max determines the maximum input value of the parameters Bipolar torque/force limit and Torque/force peak limit. Accordingly, both parameters can be used to limit the peak current I max. Note: The maximum input values are calculated in the drive when switching to SERCOS parameter phase 4. For this purpose, all motor-specific limits are read from the data memories and are considered in the calculation. Fig. 7-19: Other Limits Then confirm with <Next>. dt_antriebsbegrenzungen_sonstige.pcx

79 Motion Control System Commissioning the Drives with DriveTop 7-15 Position Control Loop Monitoring The position control loop monitoring function is provided for the diagnosis of errors in the position control loop. A model actual position is used to monitor the position control loop. This model actual position is constantly compared to the real actual position considered in the control. If the deviation is greater than the value of the monitoring window, an error is generated. We leave the default setting unchanged. Setting the Control Loop Fig. 7-20: Control loop monitoring Then confirm with <Next>. dt_regelkreisüberwachung.pcx In this dialog field, control parameters of the cascade control loop can be changed and optimized for the respective type of application. Bootstrap When initially operating a control device with the connected motor, the motor will be identified by the control device (read-out of the feedback memory). Here, the control device compares the parameter "Motor type", which is read out of the motor feedback data memory, to the value of the parameter "Connected motor type" stored in the firmware on a PCMCIA card. If there is a difference between the two parameters, an error is generated, and UL will be indicated in the diagnosis indication of the drive. The control parameters can be set back to their default values at any time. To do so, activate the button <Set standard values> in the dialog field that appears. This corresponds to the "Bootstrap" command (S ). Note: Bootstrapping is also possible at any time via the menu <Parameter> <Control loop> <Control loop setting> menu. From there, you can open the same dialog field.

80 7-16 Commissioning the Drives with DriveTop Motion Control System Fig. 7-21: Control loop setting 7.8 Creation of the Reference Setting the Absolute Measure dt_regelkreiseinstellung.pcx Then confirm with <Next>. Now open the dialog field "Friction compensation", where no changes will be made. Thus, confirm with <Next>. When commissioning an absolute measurement system, such as a multiturn motor transmitter, the actual position of the system will first indicate an arbitrary value which does not refer to the machine zero point. Contrary to non-absolute measurement systems, absolute measurement systems create their reference only once the first time that an axis is commissioned. Using the command "Set absolute measurement", the actual position of the measurement system can be set to the desired value in reference to the machine zero point. When absolute measures are set, the current position of the drive or the slide is accepted as final. Now, the drive will know its absolute position even after failure of the power supply, since it is stored permanently in the non-volatile feedback memory. Note: This command can be performed at any time in the menu <Drive functions> <Set reference/absolute measure>.

81 Motion Control System Commissioning the Drives with DriveTop 7-17 Since we are commissioning a linear axis with an absolute transmitter, the following dialog field will appear: Fig. 7-22: Setting the absolute measure Then confirm with <Next>. dt_refer_absmaßsetzen.pcx Homing If a drive has an incremental transmitter, such as a single-turn motor transmitter, its position will no longer be known after starting. Then the coordinate system of the measurement system will no longer correspond to the machine coordinate system. Using the command "Drive-controlled homing", the measuring reference between the drive measurement system and the machine coordinate system is established. Drive-controlled homing means that the drive automatically approaches a reference point at a direction, velocity and acceleration that can be uniquely defined by parameters. This reference point may be a cam on the drive, an existing reference switch, a zero reference mark, or a space marker on an external measurement system. Now, the next dialog box "Homing" will be displayed instead of the dialog field "Set absolute data".

82 7-18 Commissioning the Drives with DriveTop Motion Control System Fig. 7-23: Homing Terminate commissioning by clicking the button <Exit>. dt_referenzieren.pcx Note: For trouble-shooting, please note the drive diagnosis description "Diax 04 Drive with servo function", documentation number DOK-DIAX04-SSE-02VRS**-FKB1-EN-P.