Rexroth IndraMotion MLC03VRS Function Modules

Transcription

1 Electric Drives Linear Motion and Hydraulics Assembly Technologies Pneumatics Service Rexroth IndraMotion MLC03VRS Function Modules R Edition 01 Functional Description

2 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Title Type of Documentation Document Typecode Internal File Reference Purpose of Documentation Record of Revision Rexroth IndraMotion MLC03VRS Function Modules Functional Description DOK-IM*MLC-FM******V03-FK01-EN-P RS-81a7223f48889a4b0a6846a000f1576e-1-en-US-4 The documentation describes the function modules supported by the IndraMotion starting from version MLC03VRS: CrossComm (CFL01.1-Q2), cross communication SERCOS II SERCOS II (CFL01.1-Q2), control communication SERCOS II SERCOS III (CFL01.1-R3), control communication SERCOS III SERCOS III C2C (CFL01.1-R3), cross communication SERCOS III SRAM (CFL01.1-Y1), 8 MBYTE Ram PLS (CFL01.1-Q2), camshaft gear Fast I/O (CFL01.1-E2), fast inputs/outputs DeviceNet/M (CFL01.1-V1), DeviceNet master Profibus/M (CFL01.1-P1), profibus master Edition Release Date Notes B319-01/EN MLC03VRS Copyright Validity Published by Note 2007 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Bosch Rexroth AG Bgm.-Dr.-Nebel-Str Lohr a. Main, Germany Phone +49 (0)93 52 / 40-0 Fax +49 (0)93 52 / Department BRC/EAY2 (KW) The documentation has been printed on chlorine-free bleached paper.

3 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Table of Contents Bosch Rexroth AG I/IV Table of Contents 1 Important Directions for Use Appropriate Use Introduction Areas of Use and Application Inappropriate Use Safety Instructions for Electric Drives Safety Instructions - General Information Using the Safety Instructions and Passing them on to Others How to Employ the Safety Instructions Explanation of Warning Symbols and Degrees of Hazard Seriousness Hazards by Improper Use Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts and Housings Protection Against Electric Shock by Protective Extra-Low Voltage Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Protection Against Contact with Hot Parts Protection During Handling and Mounting Battery Safety Protection Against Pressurized Systems Page 3 SERCOS interface in the versions SERCOS II and SERCOS III SERCOS III (CFL01.1-R3), Control Communication SERCOS III Function Module (CFL01.1-R3) Addressing of the SERCOS III Function Module (CFL01.1-R3) Project Planning of SERCOS III (CFL01.1-R3) in the MLC Project Creation of the SERCOS III Function Module (CFL01.1-R3) SERCOS II (CFL01.1-Q2), Control Communication SERCOS II Function Module (CFL01.1-Q2) Addressing of the SERCOS II Function Module (CFL01.1-Q2) Project Planning of SERCOS II (CFL01.1-Q2) in the MLC Project Creation of the SERCOS II Function Module (CFL01.1-Q2) SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Overview MLC-Link - Structuring Examples SERCOS III C2C (CFL01.1-R3), MLC Cross-Communication, SERCOS III SERCOS III C2C Function Module (CFL01.1-R3)... 26

4 II/IV Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Table of Contents Page General, SERCOS III C2C (CFL01.1-R3) Addressing of the SERCOS III C2C Function Module (CFL01.1-R3) MLC Network, SERCOS III C2C (CFL01.1-R3), as Line or Ring Project Planning of MLC Network, SERCOS III (CFL01.1-R3), in the MLC Project Creation of the SERCOS III C2C Function Module (CFL01.1-R3) Configuration of the Network and the Network Participants, SERCOS III C2C (CFL01.1-R3) Configuration of the Link Axes, SERCOS III (CFL01.1-R3) MLC Network - Online Acceptance of Data of the Network Master for the Network Slaves, SERCOS III C2C (CFL01.1-R3) Parameters for the MLC Network, SERCOS III C2C (CFL01.1-R3) Diagnostic Messages for the MLC Network, SERCOS III C2C (CFL01.1-R3) MLC Network, SERCOS III C2C (CFL01.1-R3) - PLC Components MLC Network, SERCOS III C2C (CFL01.1-R3) - Binary PLC Outputs in the MLC Network / Binary MLC Network Inputs MLC Network, SERCOS III C2C (CFL01.1-R3) - Binary PLC Inputs in the MLC Network / Binary States in the MLC Network MLC Network, SERCOS III C2C (CFL01.1-R3) - Mode of Operation of Synchronous Network Inputs MLC Network, SERCOS III C2C (CFL01.1-R3) - Redundancy and Error Tolerance MLC Network, SERCOS III C2C (CFL01.1-R3) - Configuration Examples MLC Network, SERCOS III C2C (CFL01.1-R3) - Configuration Examples, Modular Structure MLC Network, SERCOS III C2C (CFL01.1-R3) - Configuration Examples, Rotary Printing with two Productions (Modified Web Guide Rollers) CrossComm (CFL01.1-Q2), MLC Cross-Communication, SERCOS II CrossComm Function Module (CFL01.1-Q2) General, CrossCom (CFL01.1-Q2) Addressing of the Function Module, CrossComm (CFL01.1-Q2) MLC Network as Single and Double Ring, CrossComm (CFL01.1-Q2) Optical Adjustment of the Ring(s), CrossComm (CFL01.1-Q2) Project Planning of the MLC Network, CrossComm (CFL01.1-Q2), in the MLC Project Creation of the Function Module, CrossComm (CFL01.1-Q2) Configuration of the Network and the Network Participants, CrossComm (CFL01.1-Q2) Configuration of the Link Axes, CrossComm (CFL01.1-Q2) MLC Network - Online Acceptance of Data of the Network Master for the Network Slaves, Cross Comm (CFL01.1-Q2) Parameters for the MLC Network, CrossComm (CFL01.1-Q2) Diagnostic Messages for the MLC Network, CrossComm (CFL01.1-Q2) MLC Network, CrossComm (CFL01.1-Q2) - PLC Components MLC Network, CrossComm (CFL01.1-Q2) - Binary PLC Outputs in the MLC Network / Binary MLC Network Inputs MLC Network, CrossComm (CFL01.1-Q2) - Binary PLC Inputs in the MLC Network / Binary MLC Network Status MLC Network, CrossComm (CFL01.1-Q2) - Mode of Operation of Synchronous Network Inputs MLC Network, CrossComm (CFL01.1-Q2) - Redundancy and Error Tolerance MLC Network, CrossComm (CFL01.1-Q2), Double Ring, Error-Free MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Primary Ring (Single Error)... 75

5 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG III/IV Table of Contents Page MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Secondary Ring (Single Error) MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Primary and Secondary Ring Between Two Neighbored Network Participants (Double Error) MLC Network, CrossComm (CFL01.1-Q2), Restitution of the Double Ring, Error-Free MLC Network, CrossComm (CFL01.1-Q2) - Configuration Examples MLC Network, CrossComm (CFL01.1-Q2) - Configuration Examples, Modular Structure MLC Network, CrossComm (CFL01.1-Q2) - Configuration Examples, Rotatory Printing with Two Productions (Changed Web Guide Roller) SRAM Module (CFL01.1-Y1) - Memory Expansion for the MLC L General Addressing of Function Module SRAM (CFL01.1-Y1)Addressing of Function Module SRAM (CFL01.1-Y Creating the Function Module SRAM (CFL01.1-Y1) Battery Battery Buffering Battery Monitoring Battery Exchange PLS (CFL01.1-N1) - Camshaft Gear PLS (CFL01.1-N1) Function Module - General Operating Principle of the Hardware-Based PLS Addressing of the PLS Function Module (CFL01.1-N1) Project Planning of the PLS Function Module (CFL01.1-N1) Project Planning of a PLS Function Module (CFL01.1-N1) Creation and Deletion of the PLS Function Module (CFL01.1-N1) Configuration of a Camshaft Gear (Overall Overview Dialog) Configuration of a Camshaft Gear (Detail View Dialog) Configuration of a Camshaft Gear (Reference Axis Context Menu) Configuration of a Camshaft Gear (Error Reaction Context Menu) Going Online Parameterization SPS Post-Processing of the Camshaft Gear Data Fast I/O Function Module CFL01.1-E Hardware Description Project Planning of the Fast I/O (CFL01.1-E2) in the MLC Project Creation of Fast I/O (FM1) Object in the Project Configuration of Fast IO DeviceNet Master Function Module CFL01.1-V Hardware Description Project Planning of the DeviceNet Master CFL01.1-V1 in the MLC Project Creation of DeviceNet/M Object (CFL01.1-V1) in the Project Configuration of Master-Specific Settings

6 IV/IV Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Table of Contents Page Insertion of DeviceNet Slaves Configuration of DeviceNet Slaves General Configuration of the I/O Connection of a DeviceNet Slave Profibus-DP Master Function Module CFL01.1-P Hardware Description Planning of the Profibus-DP Master CFL01.1-V1 in the MLC Project Creation of Profibus/M Object (COM-DPM) in the Project Configuration of Master-Specific Settings Insertion of Profibus DP Slaves Configuration of Profibus DP Slaves Insertion of Modules in Profibus DP Slave Configuration of Modules of a Profibus DP Slave Service and Support Helpdesk Service Hotline Internet Helpful Information Index

7 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 1/156 Important Directions for Use 1 Important Directions for Use 1.1 Appropriate Use Introduction Rexroth products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability. WARNING Personal injury and property damage caused by inappropriate use of the products! 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 Areas of Use and Application 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 Rexroth products, make sure that all the pre-requisites 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. The IndraControl of Rexroth and its function modules are suitable for motion/ logic applications. The IndraControl and its function modules may only be used with the accessories and parts specified in this document. If a component has not been specifically named, then it may not be either mounted or connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant function descriptions. IndraControl and its function modules have been developed for use in single or multiple-axis drives and control tasks. To ensure an application-specific use, the machine operator and visualization panels are available with differing equipment and different interfaces. Typical applications of IndraControl and its function modules are: [Handling and assembly systems] [Packaging and foodstuff machines] [Printing and paper processing machines]

8 2/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Important Directions for Use 1.2 Inappropriate Use [Machine tools] IndraControl and its function modules may only be operated under the assembly, installation and ambient conditions as described here (temperature, system of protection, humidity, EMC requirements, etc.) and in the position specified. Using IndraControl and its function modules 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". IndraControl and its function modules 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 Rexroth has not specifically released them for that intended purpose. Please note the specifications outlined in the general safety instructions!

9 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 3/156 Safety Instructions for Electric Drives 2 Safety Instructions for Electric Drives 2.1 Safety Instructions - General Information Using the Safety Instructions and Passing them on to Others Do not attempt to install or commission this device without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation prior to working with the device. If you do not have the user documentation for the device, contact your responsible Bosch Rexroth sales representative. Ask for these documents to be sent immediately to the person or persons responsible for the safe operation of the device. If the device is resold, rented and/or passed on to others in any other form, these safety instructions must be delivered with the device in the official language of the user's country. WARNING Improper use of these devices, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in material damage, bodily harm, electric shock or even death! Observe the safety instructions! How to Employ the Safety Instructions Read these instructions before initial commissioning of the equipment in order to eliminate the risk of bodily harm and/or material damage. Follow these safety instructions at all times. Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings provided in this documentation. Read the operating, maintenance and safety instructions in your language before commissioning the machine. If you find that you cannot completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation, as well as care in operation and maintenance, are prerequisites for optimal and safe operation of this device. Only assign trained and qualified persons to work with electrical installations: Only persons who are trained and qualified for the use and operation of the device may work on this device or within its proximity. The persons are qualified if they have sufficient knowledge of the assembly, installation and operation of the product, as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they must be trained, instructed and qualified to switch electrical circuits and devices on and off in accordance with technical safety regulations, to ground them and to mark them according to the requirements of safe work practices. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer.

10 4/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Safety Instructions for Electric Drives Follow all safety regulations and requirements for the specific application as practiced in the country of use. The devices have been designed for installation in industrial machinery. The ambient conditions given in the product documentation must be observed. Only use safety-relevant applications that are clearly and explicitly approved in the Project Planning Manual. If this is not the case, they are excluded. Safety-relevant are all such applications which can cause danger to persons and material damage. The information given in the documentation of the product with regard to the use of the delivered components contains only examples of applications and suggestions. The machine and installation manufacturer must make sure that the delivered components are suited for his individual application and check the information given in this documentation with regard to the use of the components, make sure that his application complies with the applicable safety regulations and standards and carry out the required measures, modifications and complements. Commissioning of the delivered components is only permitted once it is sure that the machine or installation in which they are installed complies with the national regulations, safety specifications and standards of the application. Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the section on EMC in the respective documentation (Project Planning Manuals of components and system). The machine or installation manufacturer is responsible for compliance with the limiting values as prescribed in the national regulations. Technical data, connection and installation conditions are specified in the product documentation and must be followed at all times. National regulations which the user must take into account European countries: according to European EN standards United States of America (USA): National Electrical Code (NEC) National Electrical Manufacturers Association (NEMA), as well as local engineering regulations regulations of the National Fire Protection Association (NFPA) Canada: Canadian Standards Association (CSA) Other countries: International Organization for Standardization (ISO) International Electrotechnical Commission (IEC) Explanation of Warning Symbols and Degrees of Hazard Seriousness The safety instructions describe the following degrees of hazard seriousness. The degree of hazard seriousness informs about the consequences resulting from non-compliance with the safety instructions:

11 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 5/156 Safety Instructions for Electric Drives Warning symbol Signal word Danger Degree of hazard seriousness acc. to ANSI Z Death or severe bodily harm will occur. Warning Caution Death or severe bodily harm may occur. Minor or moderate bodily harm or material damage may occur. Fig.2-1: Hazard classification (according to ANSI Z 535) Hazards by Improper Use DANGER High electric voltage and high working current! Risk of death or severe bodily injury by electric shock! Observe the safety instructions! DANGER Dangerous movements! Danger to life, severe bodily harm or material damage by unintentional motor movements! Observe the safety instructions! WARNING High electric voltage because of incorrect connection! Risk of death or bodily injury by electric shock! Observe the safety instructions! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Observe the safety instructions! Hot surfaces on device housing! Danger of injury! Danger of burns! Observe the safety instructions! CAUTION CAUTION Risk of injury by improper handling! Risk of bodily injury by bruising, shearing, cutting, hitting or improper handling of pressurized lines! Observe the safety instructions!

12 6/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling of batteries! Observe the safety instructions! 2.2 Instructions with Regard to Specific Dangers Protection Against Contact with Electrical Parts and Housings This section concerns devices and drive components with voltages of more than 50 Volt. Contact with parts conducting voltages above 50 Volts can cause personal danger and electric shock. When operating electrical equipment, it is unavoidable that some parts of the devices conduct dangerous voltage. DANGER High electrical voltage! Danger to life, electric shock and severe bodily injury! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain and repair this equipment. Follow general construction and safety regulations when working on power installations. Before switching on the device, the equipment grounding conductor must have been non-detachably connected to all electrical equipment in accordance with the connection diagram. Do not operate electrical equipment at any time, even for brief measurements or tests, if the equipment grounding conductor is not permanently connected to the mounting points of the components provided for this purpose. Before working with electrical parts with voltage potentials higher than 50 V, the device must be disconnected from the mains voltage or power supply unit. Provide a safeguard to prevent reconnection. With electrical drive and filter components, observe the following: Wait 30 minutes after switching off power to allow capacitors to discharge before beginning to work. Measure the electric voltage on the capacitors before beginning to work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Do not remove or plug in connectors when the component has been powered. Install the covers and guards provided with the equipment properly before switching the device on. Before switching the equipment on, cover and safeguard live parts safely to prevent contact with those parts. A residual-current-operated circuit-breaker or r.c.d. cannot be used for electric drives! Indirect contact must be prevented by other means, for example, by an overcurrent protective device according to the relevant standards. Secure built-in devices from direct touching of electrical parts by providing an external housing, for example a control cabinet.

13 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 7/156 Safety Instructions for Electric Drives For electrical drive and filter components with voltages of more than 50 volts, observe the following additional safety instructions. DANGER High housing voltage and high leakage current! Risk of death or bodily injury by electric shock! Before switching on, the housings of all electrical equipment and motors must be connected or grounded with the equipment grounding conductor to the grounding points. This is also applicable before short tests. The equipment grounding conductor of the electrical equipment and the devices must be non-detachably and permanently connected to the power supply unit at all times. The leakage current is greater than 3.5 ma. Over the total length, use copper wire of a cross section of a minimum of 10 mm 2 for this equipment grounding connection! Before commissioning, also in trial runs, always attach the equipment grounding conductor or connect to the ground wire. Otherwise, high voltages may occur at the housing causing electric shock Protection Against Electric Shock by Protective Extra-Low Voltage Protective extra-low voltage is used to allow connecting devices with basic insulation to extra-low voltage circuits. All connections and terminals with voltages between 5 and 50 volts at Rexroth products are PELV systems. 1) It is therefore allowed to connect devices equipped with basic insulation (such as programming devices, PCs, notebooks, display units) to these connections and terminals. WARNING High electric voltage by incorrect connection! Risk of death or bodily injury by electric shock! If extra-low voltage circuits of devices containing voltages and circuits of more than 50 volts (e.g. the mains connection) are connected to Rexroth products, the connected extra-low voltage circuits must comply with the requirements for PELV. 2) Protection Against Dangerous Movements Dangerous movements can be caused by faulty control of connected motors. Some common examples are: improper or wrong wiring of cable connections incorrect operation of the equipment components wrong input of parameters before operation malfunction of sensors, encoders and monitoring devices defective components software or firmware errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. 1) "Protective Extra-Low Voltage" 2) "Protective Extra-Low Voltage"

14 8/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Safety Instructions for Electric Drives The monitoring in the drive components will normally be sufficient to avoid faulty operation in the connected drives. Regarding personal safety, especially the danger of bodily harm and material damage, this alone cannot be relied upon to ensure complete safety. Until the integrated monitoring functions become effective, it must be assumed in any case that faulty drive movements will occur. The extent of faulty drive movements depends upon the type of control and the state of operation.

15 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 9/156 Safety Instructions for Electric Drives DANGER Dangerous movements! Danger to life, risk of injury, severe bodily harm or material damage! Ensure personal safety by means of qualified and tested higher-level monitoring devices or measures integrated in the installation. These measures have to be provided for by the user according to the specific conditions within the installation and a hazard and fault analysis. The safety regulations applicable for the installation have to be taken into consideration. Unintended machine motion or other malfunction is possible if safety devices are disabled, bypassed or not activated. To avoid accidents, bodily harm and/or material damage: Keep free and clear of the machine s range of motion and moving parts. Possible measures to prevent people from accidentally entering the machine s range of motion: use safety fences use safety guards use protective coverings install light curtains or light barriers Fences and coverings must be strong enough to resist maximum possible momentum. Mount the emergency stop switch in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the device if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a safety related starting lockout to prevent unintentional start. Make sure that the drives are brought to a safe standstill before accessing or entering the danger zone. Additionally secure vertical axes against falling or dropping after switching off the motor power by, for example: mechanically securing the vertical axes, adding an external braking/ arrester/ clamping mechanism or ensuring sufficient equilibration of the vertical axes. The standard equipment motor brake or an external brake controlled directly by the drive controller are not sufficient to guarantee personal safety! Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: maintenance and repair work cleaning of equipment long periods of discontinued equipment use Prevent the operation of high-frequency, remote control and radio equipment near electronics circuits and supply leads. If the use of such devices cannot be avoided, verify the system and the installation for possible malfunctions in all possible positions of normal use before initial startup. If necessary, perform a special electromagnetic compatibility (EMC) test on the installation.

16 10/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Safety Instructions for Electric Drives Protection Against Magnetic and Electromagnetic Fields During Operation and Mounting Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious personal danger to those with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with heart pacemakers and metal implants are not permitted to enter following areas: Areas in which electrical equipment and parts are mounted, being operated or commissioned. Areas in which parts of motors with permanent magnets are being stored, repaired or mounted. If it is necessary for somebody with a pacemaker to enter such an area, a doctor must be consulted prior to doing so. The noise immunity of present or future implanted heart pacemakers differs greatly so that no general rules can be given. Those with metal implants or metal pieces, as well as with hearing aids, must consult a doctor before they enter the areas described above. Otherwise health hazards may occur Protection Against Contact with Hot Parts CAUTION Hot surfaces at motor housings, on drive controllers or chokes! Danger of injury! Danger of burns! Do not touch surfaces of device housings and chokes in the proximity of heat sources! Danger of burns! Do not touch housing surfaces of motors! Danger of burns! According to the operating conditions, temperatures can be higher than 60 C, 140 F during or after operation. Before accessing motors after having switched them off, let them cool down for a sufficiently long time. Cooling down can require up to 140 minutes! Roughly estimated, the time required for cooling down is five times the thermal time constant specified in the Technical Data. After switching drive controllers or chokes off, wait 15 minutes to allow them to cool down before touching them. Wear safety gloves or do not work at hot surfaces. For certain applications, the manufacturer of the end product, machine or installation, according to the respective safety regulations, has to take measures to avoid injuries caused by burns in the end application. These measures can be, for example: warnings, guards (shielding or barrier), technical documentation Protection During Handling and Mounting In unfavorable conditions, handling and mounting certain parts and components in an improper way can cause injuries.

17 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 11/156 Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling! Bodily injury by bruising, shearing, cutting, hitting! Observe the general construction and safety regulations on handling and mounting. Use suitable devices for mounting and transport. Avoid jamming and bruising by appropriate measures. Always use suitable tools. Use special tools if specified. Use lifting equipment and tools in the correct manner. If necessary, use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Do not stand under hanging loads. Immediately clean up any spilled liquids because of the danger of skidding Battery Safety Batteries consist of active chemicals enclosed in a solid housing. Therefore, improper handling can cause injury or material damage. CAUTION Risk of injury by improper handling! Do not attempt to reactivate low batteries by heating or other methods (risk of explosion and cauterization). Do not recharge the batteries as this may cause leakage or explosion. Do not throw batteries into open flames. Do not dismantle batteries. When replacing the battery/batteries do not damage electrical parts installed in the devices. Only use the battery types specified by the manufacturer. Environmental protection and disposal! The batteries contained in the product are considered dangerous goods during land, air, and sea transport (risk of explosion) in the sense of the legal regulations. Dispose of used batteries separate from other waste. Observe the local regulations in the country of assembly Protection Against Pressurized Systems According to the information given in the Project Planning Manuals, motors cooled with liquid and compressed air, as well as drive controllers, can be partially supplied with externally fed, pressurized media, such as compressed air, hydraulics oil, cooling liquids and cooling lubricating agents. Improper handling of the connected supply systems, supply lines or connections can cause injuries or material damage.

18 12/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Safety Instructions for Electric Drives CAUTION Risk of injury by improper handling of pressurized lines! Do not attempt to disconnect, open or cut pressurized lines (risk of explosion). Observe the respective manufacturer's operating instructions. Before dismounting lines, relieve pressure and empty medium. Use suitable protective equipment (for example safety goggles, safety shoes, safety gloves). Immediately clean up any spilled liquids from the floor. Environmental protection and disposal! The agents used to operate the product might not be economically friendly. Dispose of ecologically harmful agents separately from other waste. Observe the local regulations in the country of assembly.

19 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives 3 SERCOS interface in the versions SERCOS II and SERCOS III Subject to the SERCOS interfaces available onboard IndraControl L40.2: SERCOS II, fiber optic cable, double / single ring IndraControl L65.1: SERCOS III, Ethernet CAT5 cable, ring/line (as of MLC 04VRS) Type Material number Control communication Cross-communication SERCOS II R911,170,009 SERCOS II (CFL01.1-Q2) CrossComm (CFL01.1-Q2) SERCOS III C2C SERCOS III R911,170,008 SERCOS III (CFL01.1-R3) (CFL01.1-R3) Fig.3-1: For Details, See Use of function modules SERCOS III (CFL01.1-R3), Control Communication, page 15, SERCOS II (CFL01.1-Q2), Control Communication, page 19, SERCOS III C2C (CFL01.1-R3), MLC Cross-Communication, SERCOS III, page 26, CrossComm (CFL01.1-Q2), MLC Cross-Communication, SERCOS II, page 52, The following configurations are available: Bosch Rexroth AG 13/156 SERCOS interface in the versions SERCOS II and SERCOS III L40 two function modules are made available, which mutually secure the other type of communication or which allow a cross-communication in one way or the other. Konfiguration OnBoard 1. Module 2. Module Function Function Function 1. Module 2. Module A - - Control comm. - - B SERCOS II - Control Crosscomm. comm. - C SERCOS III - Disabled Control comm. - D SERCOS II SERCOS II Version not supported E SERCOS II SERCOS III Version not supported F SERCOS III SERCOS II Disabled Control Crosscomm. comm. G SERCOS III SERCOS III Disabled Control Crosscomm. comm.

20 14/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS interface in the versions SERCOS II and SERCOS III L65 As of MLC 04VR S Control comm. Cross-comm. Fig.3-2: 1. Module 2. Module A - - Function OnBoard Control comm. Control comm. Function 1. Module Function 2. Module - - G SERCOS II SERCOS II Disabled Control communication Control comm. - - Konfiguration B SERCOS III - Crosscomm. C SERCOS II - Disabled Control comm. D SERCOS III SERCOS III Version not supported E SERCOS III SERCOS II Version not supported F SERCOS II SERCOS III Version not supported Crosscomm. Cross-communication Configuration possibilites for SERCOS II and SERCOS III function modules

21 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 15/156 SERCOS III (CFL01.1-R3), Control Communication 4 SERCOS III (CFL01.1-R3), Control Communication 4.1 SERCOS III Function Module (CFL01.1-R3) With the help of the SERCOS III function module (CFL01.1-R3), it is possible to connect SERCOS III drives to the IndraMotion MLC 40.2 equipped with an onboard SERCOS II interface. The function module can be ordered under the material number: R In comparison with SERCOS II, the following features have been added: the connection is made via Ethernet CAT5 cables instead of fiber optic cables, a higher data rate, 100 Mbaud. The module for the control communication must always be plugged in before the cross-connection module. Currently, the drive control communication is only available for IndraDrive as of Version Addressing of the SERCOS III Function Module (CFL01.1-R3) Front View On the basis of the front view of the SERCOS III function module, the configuration of the line and ring is indicated. Options of Configuration Fig.4-1: Front view of the SERCOS III function module (CFL01.1-R3) A maximum of 4 function modules can be connected to an MLC. The following options are possible regarding SERCOS II and SERCOS III function modules:

22 16/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III (CFL01.1-R3), Control Communication L40 L65 with MLC 04VRS MC CC Fig.4-2: Configuration OnBoard 1. module 2. module Function Function Function 1. module 2. module A - - MC - - B SERCOS II - MC CC - C SERCOS III - deactivated MC - D SERCOS II SERCOS II variant is not supported E SERCOS II SERCOS III variant is not supported F SERCOS III SERCOS II deactivated MC CC G SERCOS III SERCOS III deactivated MC CC A - - MC - - B SERCOS III - MC CC - C SERCOS II - deactivated MC - D SERCOS III SERCOS III variant is not supported E SERCOS III SERCOS II variant is not supported F SERCOS II SERCOS III variant is not supported G SERCOS II SERCOS II deactivated MC CC Master communication Cross communication Configuration options of SERCOS II and SERCOS III function modules. Connection of the Function Module to the MLC During startup, the control locates the SERCOS modules which can be pluged in to location 2 and 4. The order is important for the function. The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.4-3: Addressing of function modules on an IndraControl Connection Displays The MLC must be disconnected from the power supply, before a function module can be attached. An active SERCOS III control communication is indicated with the LEDs L (green) or S (yellow), LINK / ACTIVITY. 4.3 Project Planning of SERCOS III (CFL01.1-R3) in the MLC Project Creation of the SERCOS III Function Module (CFL01.1-R3) In order to be able to configure the drive control communication with the help of SERCOS III (CFL01.1-R3), the "SERCOS III" device must be created under MLC. This can be done in two ways:

23 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 17/156 SERCOS III (CFL01.1-R3), Control Communication 1. When an MLC is created, the wizard offers the connection of function modules in dialog 3, configuration. Here, the SERCOS III module can be selected. Fig.4-4: Insertion of a SERCOS III function module via the wizard 2. Drag the "SERCOS III (CFL01.1-R3)" device from "FM" group of the library onto the MLC... Fig.4-5: Dragging of the module...and "let it drop" between Profibus and SERCOS. Fig.4-6: Insertion of the module These settings can only be made in the offline mode.

24 18/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III (CFL01.1-R3), Control Communication The SERCOS III function module is thus integrated in the MLC project. Fig.4-7: SERCOS III function module prepared for configuration By analogy with the SERCOS II drives, a SERCOS III drive is to be dragged onto the SERCOS folder and to be dropped there.

25 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 19/156 SERCOS II (CFL01.1-Q2), Control Communication 5 SERCOS II (CFL01.1-Q2), Control Communication 5.1 SERCOS II Function Module (CFL01.1-Q2) With the help of the SERCOS II function module (CFL01.1-Q2), it is possible to connect SERCOS II drives to the IndraMotion MLC 65.1 equipped with an onboard SERCOS II interface. IndraMotion MLC 65.1 is available as of MLC 04VRS. The function module can be ordered under the material number: R The module for the control communication must always be plugged in before the cross-connection module. Ring The SERCOS II drives are to be connected to the primary ring of the function module via fiber optic cables. 5.2 Addressing of the SERCOS II Function Module (CFL01.1-Q2) Front View On the basis of the front view of the SEROCS II function module, the configuration (primary ring; the secondary ring is switched off in this operating mode) is indicated. Options of Configuration Fig.5-1: Front view of the SERCOS II function module (CFL01.1-Q2) A maximum of 4 function modules can be connected to an MLC. The following options are possible regarding SERCOS II and SERCOS III function modules:

26 20/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS II (CFL01.1-Q2), Control Communication L40 L65 with MLC 04VRS MC CC Fig.5-2: Configuration OnBoard 1. module 2. module Function Function Function 1. module 2. module A - - MC - - B SERCOS II - MC CC - C SERCOS III - deactivated MC - D SERCOS II SERCOS II variant is not supported E SERCOS II SERCOS III variant is not supported F SERCOS III SERCOS II deactivated MC CC G SERCOS III SERCOS III deactivated MC CC A - - MC - - B SERCOS III - MC CC - C SERCOS II - deactivated MC - D SERCOS III SERCOS III variant is not supported E SERCOS III SERCOS II variant is not supported F SERCOS II SERCOS III variant is not supported G SERCOS II SERCOS II deactivated MC CC Master communication Cross communication Configuration options of SERCOS II and SERCOS III function modules. Connection of the Function Module to the MLC During startup, the control locates the SERCOS modules which can be pluged in to location 2 and 4. The order is important for the function. The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.5-3: Addressing of function modules on an IndraControl Connection Displays Distortion Displays FOC Ports Connection Displays The MLC must be disconnected from the power supply, before a function module can be attached. An active MLC ring is displayed on the CFL01.1-Q2 by means of the LEDs Ma (green). By means of the distortion displays of the CFL01.1-Q2 (red LEDs Er-P), error primary ring, the quality of the optical signal received can be checked. X7S1 is the transmitter, X7S2 the receiver port of the primary ring. An active SERCOS II control communication is indicated by means of the LED Ma (green).

27 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 21/156 SERCOS II (CFL01.1-Q2), Control Communication 5.3 Project Planning of SERCOS II (CFL01.1-Q2) in the MLC Project Creation of the SERCOS II Function Module (CFL01.1-Q2) In order to be able to configure the drive control communication with the help of SERCOS II (CFL01.1-Q2), the "SERCOS II" device must be created under MLC. This can be done in two ways: 1. When an MLC is created, the wizard offers the connection of function modules in dialog 3, configuration. Here, the SERCOS II module can be selected. Fig.5-4: Insertion of a SERCOS II function module via the wizard 2. Drag the "SERCOS II (CFL01.1-Q2)" device from the "FM" group of the library onto the MLC... Fig.5-5: Dragging of the module...and "let it drop" on the MLC.

28 22/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS II (CFL01.1-Q2), Control Communication Fig.5-6: Insertion of the module These settings can only be made in the offline mode. The SERCOS II function module is thus integrated in the MLC project. Fig.5-7: SERCOS II function module prepared for configuration A SERCOS II drive is to be dragged onto the SERCOS folder and to be dropped there.

29 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives 6 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication 6.1 Overview The present documentation gives an overview of the use of the function modules CrossComm (CFL01.1-Q2), SERCOS II, fiber optic cable rings, and CrossCommunication, SERCOS III C2C (CFL01.1-R3) in connection with Rexroth IndraMotion MLC. In MLC-Link - Structuring Examples, page 23, the motivation for cross-communication is explained. The examples are applicable to both versions. The other topics are given in the table. Topic CrossComm SERCOS III C2C (CFL01.1-Q2) (CFL01.1-R3) General Page 52 Page 26 Project planning in IW Page 57 Page 31 Parameter Page 68 Page 40 Diagnostics Page 68 Page 41 PLC support Page 69 Page 43 Redundancy and error tolerance Page 74 Page 48 Configuration examples Page 78 Page 48 Fig.6-1: Guide for both forms of realization 6.2 MLC-Link - Structuring Examples A link capable MLC-Control transfers cyclical the positions of local axes in the MLC-Link as master axis to all link participants. Each MLC administrates maximum two master axes from the pool of the 16 local axes. Many applications can be realized with a drive ring. However, there are also applications which require a more complex system with several drive rings or controls. Below are examples of use from the printing machine sector: Bosch Rexroth AG 23/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Several Master Axes In a system, several master axes are defined (e.g., for several webs or productions in a printing machine). Local axes of a link participant should be assignable to the different master axes arbitrarily.

30 24/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-2: Print machine with 2 master axes for the production - section-oriented topology Fig.6-3: Print machine with 7 master axes and 2 production master axes - section-oriented topology

31 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 25/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Modular Configuration Fig.6-4: Print machine with 7 master axes, thereof 2 production master axes - module-oriented topology With modular configuration of a system for different processing stations one drive ring is intended. All axes in the system should follow the same master axis. High System Load Fig.6-5: Modular configuration with multiple drive rings The number of the projected axes or the demanded functional range (high activity in the SERCOS-synchronous PLC-Task) cannot be administered by a MLC. The local axes are distributed to several drive rings, however, must follow the same master axis.

32 26/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-6: Example for the configuration at high system load 6.3 SERCOS III C2C (CFL01.1-R3), MLC Cross-Communication, SERCOS III SERCOS III C2C Function Module (CFL01.1-R3) General, SERCOS III C2C (CFL01.1-R3) In order to be able to distribute the master axis positions of different MLC controls to any local axes in different drive rings, the MLC controls are combined to form an MLC network. A cross-communication in this network allows the distribution of the configured master axes positions on selected local link axes in different controls. In addition to the MLC function module "CrossComm" (CFL01.1-Q2), SERCOS II, the interconnection of the MLC controls can also be carried out with the help of the SERCOS III C2C (CFL01.1-R3) function module. The function module can be ordered under the material number: R In comparison with SERCOS II, the following features have been added: the connection is made via Ethernet CAT5 cables instead of fiber optic cables a higher data rate, 100 Mbaud In order to be able to use SERCOS III for the control communication and crosscommunication of an IndraMotion MLC 40.2, the function modules must be arranged as follows:

33 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 27/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-7: SERCOS III for control communication and cross-communication The module for the control communication must always be plugged in before the cross-connection module. Max. 64 MLCs in a Network Max. 128 Master Axes in a Network Cycle Time that can be Selected in the Network Currently, the drive control communication is only available for IndraDrive as of Version 4. For the cross-communication, the data of SERCOS II are achieved again: With the help of the SERCOS III C2C function module (CFL01.1-R3), up to 64 MLC controls can be combined to one MLC network. For each MLC, the actual positions of up to two local axes can be published in the MLC network. In a network with a maximum of 64 network participants, a maximum of 128 different master positions are thus available. The network cycle time can be preset with three different values. The real maximum number of participants and master axes supported in the MLC network also depends on this presetting. Preset cycle time Number of participants Number of master axes 2 ms ms ms Fig.6-8: Typical network cycle times with SERCOS III C2C (CFL01.1-R3) The actually achievable cycle time considerably depends on the fact how many drives were activated in the individual drive rings and which functionalities were enabled in the individual controls.

34 28/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication The interconnection time must be identical with the Sercos cycle time. The network cycle time must be adjusted in the same way for all controls in the MLC network. The cycle time in the network ring and in the drive ring of each network participant must be identical. Line or Ring The MLC network can be operated as line or ring, respectively. In case of a line, the master must be situated at the beginning or the end of the line. In case of a ring structure, the master can take any position within in the ring. The ring offers the following advantages from now on increased error tolerance, since e.g. a failure of the transmission distance between two MLCs is tolerated. increased availability, since e.g., in case of a switched-off control, the cross-communication can be held up with the remaining drive rings. Addressing of the SERCOS III C2C Function Module (CFL01.1-R3) Front View On the basis of the front view of the SERCOS III C2C function module, the configuration of the line and ring is indicated. Options of Configuration Fig.6-9: Front view of the SERCOS III C2C function module (CFL01.1-R3) A maximum of 4 function modules can be connected to an MLC. The following options are possible regarding SERCOS II and SERCOS III function modules:

35 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 29/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication L40 L65 with MLC 04VRS MC CC Fig.6-10: Configuration OnBoard 1. module 2. module Function Function Function 1. module 2. module A - - MC - - B SERCOS II - MC CC - C SERCOS III - deactivated MC - D SERCOS II SERCOS II variant is not supported E SERCOS II SERCOS III variant is not supported F SERCOS III SERCOS II deactivated MC CC G SERCOS III SERCOS III deactivated MC CC A - - MC - - B SERCOS III - MC CC - C SERCOS II - deactivated MC - D SERCOS III SERCOS III variant is not supported E SERCOS III SERCOS II variant is not supported F SERCOS II SERCOS III variant is not supported G SERCOS II SERCOS II deactivated MC CC Master communication Cross communication Configuration options of SERCOS II and SERCOS III function modules. Connection of the Function Module to the MLC During startup, the control locates the SERCOS modules which can be pluged in to location 2 and 4. The order is important for the function. The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.6-11: Addressing of function modules on an IndraControl Identification of the Hardware by the Firmware Connection Displays The MLC must be disconnected from the power supply, before a function module can be attached. Upon the next switch-on, the new function module is automatically identified by the firmware. An active MLC network is indicated on SERCOS III C2C (CFL01.1-R3) by means of the LEDs L (green) or S (yellow), LINK / ACTIVITY. MLC Network, SERCOS III C2C (CFL01.1-R3), as Line or Ring First of all, the MLC network is planned and parameterized by means of Indra Works and the MLCs are switched to the operating mode. On each MLC within the parameterized MLC network, the active MLC network is indicated by means of the LEDs L or S, respectively.

36 30/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Line In case of a line,, the MLCs involved are to be interconnected. The direction can bei top-top or bottom-bottom or top-bottom... Ring Fig.6-12: Line, wiring example The line shown above can be converted into a ring, if the missing connection is added. Fig.6-13: Ring, wiring example

37 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 31/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Project Planning of MLC Network, SERCOS III (CFL01.1-R3), in the MLC Project Creation of the SERCOS III C2C Function Module (CFL01.1-R3) In order to be able to configure the participation of the MLC into the network by means of SERCOS III C2C (CFL01.1-R3), the drive control communication must be operated on the basis of SERCOS III and the "SERCOS III C2C" device must be created under the MLC. This can be done in two ways: 1. When an MLC is created, the wizard offers the connection of function modules in dialog 3, configuration. Here, the SERCOS III C2C module can be selected. Fig.6-14: Insertion of a SERCOS III 2C2 function module via the wizard 2. Drag the "SERCOS III C2C (CFL01.1-R3)" device from the "FM" group of the library onto the MLC... Fig.6-15: Dragging of the module...and "let it drop" between Profibus and SERCOS.

38 32/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-16: Insertion of the module These settings can only be made in the offline mode. The SERCOS III C2C function module is thus integrated in the MLC project. Fig.6-17: SERCOS III C2C function module prepared for configuration Configuration of the Network and the Network Participants, SERCOS III C2C (CFL01.1-R3) In the online mode, the network must be configured in the "Settings for MLC Network " dialog. The settings are, of course, made first for the network master. Afterwards, you have to access the project of the corresponding slave MLC. Here, you can - provided that the controls are connected via Ethernet - accept the basic settings (ring structure and cycle time) of the network master. You can, of course, also make separate settings for the individual slave MLCs. The same can be done for further network participants.

39 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 33/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-18: Settings for the MLC network in IndraWorks 1. Modifications to the "Network Settings" activate the "Save Settings" button. The user must validate this, after the settings were made. 2. The settings for a slave within the network can be read off by the master, if the button "Determine Online" is activated. For this, the master has to be in the operating mode (BB) and the slave has to be in the parameterization mode (P2). Save settings! 3. Settings that were modified are only accepted, if the respective control switches from the parameterization mode (P2) into the operating mode (BB). Participation in the MLC Network Identifier of the Network Control Address In the "Participate in the MLC Network" box, a check mark must be set. This activates the content of the dialog. The identifier of the network is a purely informative value used to meaningfully describe the network in order to be able to distinguish it from others. Every network participant is assigned a controller address. The address set is read in once, every time the MLC is run up to the operating mode. It must be unique within the network and defines the positions of the produced master axis positions within the network MDT. The control address must be within the range of Fragmentary addressing is permitted.

40 34/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Function Regarding its functionality for the cross-communication, the MLC control acts as a network master (data producer and consumer, telegram monitoring and administration) network slave (data producer and consumer), stand-alone Participant (no participation in the network). Network master The network master controls the cross-communication. It defines the clock pulse (cycle time) in the network, in the drive rings of all MLCs which participate in the network. The network master cyclically collects and distributes the master axis positions of all slaves within the network. Network slave A network slave establishes an interface connection to the ring / line of the MLC network. It synchronizes the telegram processing of its drive ring with the crosscommunication. Stand-alone participant The participants that are integrated in the ring / line of the MLC network, but are not parameterized for the MLC network, only make sure that the network telegrams are forwarded. This means that they only pass on the signal arriving at their input to their output (repeater function); they do not participate in the cross-communication process. The MLC network is a SERCOS ring in which exactly one participant must be configured as master. Only this master monitors and administrates the whole telegram communication. This leads to a considerably higher computing load compared to a network slave. Ring Structure The SERCOS III C2C (CFL01.1-R3) supports both the line as well as the ring structure. Line In case of the line structure, the SERCOS III C2C (CFL01.1-R3) modules of all controls are simply connected to each other. Ring In case of the ring structure, the SERCOS III C2C (CFL01.1-R3) modules of all controls are simply connected to each other. Furthermore, the gap between the first and the last control ist closed. The setting of the ring/line must be identical on all participating controls. Ring Cycle Time In the MLC network, 2 ms, 4 ms or 8 ms are supported as cycle time. The adjusted cycle time also determines the maximum number of the supported network slaves, the admissible network addresses and the cycle time in the drive ring. The setting of the ring cycle time must be identical on all participating controls. Admissible control addresses and number of network slaves The values are given in the following table:

41 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 35/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Ring cycle time Admissible control addresses Maximum number of network slaves 2 ms ms ms Fig.6-19: Admissible control addresses for an MLC network with SERCOS III C2C (CFL01.1-R3) Since all network participants synchronize their telegram processing with the network master, all drives in these drive rings operate synchronously. This also applies to the control algorithms in the drives. If the ring cycle time of the network is changed and if, therefore, the cycle time of the local drive does not tally with it anymore, a message is output which indicates the difference and offers to automatically adjust the cycle time of the drive ring: Fig.6-20: The cycle times do not tally - adjust automatically? In addition to this, it is possible to adapt the cycle time of the drive ring via the button This button is only active, if the cycle times of both rings differ. Moreover, any existing difference is indicated by the red error icon in the line of the ring cycle time. In the mouse tool tip, further information is indicated. Configuration of the Link Axes, SERCOS III (CFL01.1-R3) Configuration of the Link Axes, SERCOS III C2C (CFL01.1-R3) - Overview In order to be able to use the master axes in the entire MLC network, two basic settings are required: the "producer" must "publish" one axis as a master axis and provide the master axis positions in the MLC network, the "consumer" can use the master axis from the MLC network locally as master axes.

42 36/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication An MLC in the network can be both a producer and a consumer, i.e. it can provide its own local axes as master axes in the network (produce) and at the same time use any master axes from the network as a local link axis (consume). Link Axes in the MLC Network Settings on the Part of the Producer, SERCOS III C2C (CFL01.1-R3) In the dialog Settings for the MLC network in IndraWorks, page 33,, of the SERCOS III C2C function module, every network participant can mark up to two of its local axes as link axis. This link axis' actual position is then provided as the master axis position for other axes within the MLC network. The terms "Link axis A" and "Link axis B" are used. Fig.6-21: Selection of MLC's axes as master axes for different controls Local axes provided by the producer as link axis are not visible on the consumer's side. The consumer can only access "Link Axis A" or "Link Axis B", respectively. Dead Time Compensation Since the consumers receive the position values of the producer only after two cycle times of the MLC network - i.e. delayed, one speaks of "Dead Time". Without dead time compensation, the consumer's axis would follow the master axis with a phase offset. In order to minimize this phase offset, an automatic dead time compensation is supported for every link axis. This means that the position values provided in the network are extrapolated, i.e. precalculated position values are provided to supply the slave axes with position values as identical as possible. Very good precalculations are made for the consumer to promote the continuous changing of the position values (constant velocity), i.e. the phase offset can almost be reduced to '0'. For non-continuous changes (velocity changes), the phase offset cannot be reduced to '0'. In extreme cases, overshooting may occur on the consumer's side. The same effect appears, if master axis positions are cascaded in the network. For such cases, the dead time compensation should be set to values smaller than 100 %, i.e. the precalculation is realized in a "reduced" way. This, however, leads to the fact that the consumer follows the master axis with a phase offset. Concerning the dead time compensation, the following dependences and rules are applicable: A value of 100 % brings about the best possible concordance of the position values of producer and consumer (minimum phase offset). The smaller the network cycle time, the better a precalculation works and the smaller the phase offset.

43 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 37/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication With the cascading depth (consumer provides link axis again etc.) increasing, the phase offset grows. In addition to this, an overshooting of local link axes is still possible. If overshooting effects (e.g. mechanical vibration/humming of the machine or jerk- and acceleration-excess warnings in case of local link axes or their real slave axes) occur, the values of the dead time compensation can be modified according to the following table: Cascading depth Value for dead time compensation 1 50% 2 33% 3 25% Fig.6-22: Dead time compensation in dependence upon the cascading depth A cascading over more than two levels (Master Axis Local Link Axis/Master Axis Local Link Axis/Master Axis Local Link Axis) is to be avoided, if possible. A cascading of real master axes in the MLC network should be avoided. Local Link Axes on the MLC Settings on the Part of the Consumers, SERCOS III C2C (CFL01.1-R3) In order to be able to "consume" a "Link Axis A" or a "Link Axis B" provided on the producer's side as a master for one's own local axes, a representative must be defined locally that makes them visible for one's own MLC. For that purpose, a link axis is created locally in the IndraWorks node Motion Link Axes. This axis is assigned an axis number and a name, in order to become addressable, and is allocated to a master axis in the MLC network. Fig.6-23: Adding a link axis to the project

44 38/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-24: Selection of an external MLC's axis as link axis 1 Fig.6-25: Selection of an external MLC's axis as a link axis 2 All produced link axes that are maximally available are always specified, since it cannot be determined for the offline configuration which network participants are available or which link axes are provided. The user themselves is responsible for the fact that the selected axis is actually provided by the network's MLC concerned. The allocation of a local link axis to a(n) (external) master axis in the MLC network is carried out via list parameters "A , Link axis - master axis selection". In this parameter, the control address and the number of the desired master axis of this control are inserted. The following applies:

45 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 39/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Entry in A List element 1: xxxx (control selection) List element 2: yyyy (link axis selection) Example: A = 15 1 Effective master axis position Master axis position A/B of the MLC With the control address xxxx yyyy = 1: Master axis position A, yyyy = 2: Master axis position B MLC 15 Master axis position A (MLC 15 link axis A) Fig.6-26: Master Axis Allocation The allocation on the consumer's side, e.g. by the PLC, can be modified via parameter "A " (see configuration example "Rotary printing with 2 productions"). Local link axes - like any other local axis - have their own parameters and corresponding dialogs. The number of supported parameters is limited, corresponds, however, approximately to the number of an encoder axis (see parameter "A , List of all A parameters"). MLC Network - Online Acceptance of Data of the Network Master for the Network Slaves, SERCOS III C2C (CFL01.1-R3) Concerning the configuration of the MLC network, the focus lies on the consistent setting of the ring structure and ring cycle time, as well as on the function of the participants in the network. In order to support a consistent configuration as far as possible, IndraWorks does not only offer the manual setting described above in the "Settings for MLC Network " dialog, but also an online determination of the master's network settings. The settings of the master can thus be accepted directly for the slaves, provided, the network participants are connected via Ethernet. The optimum configuration procedure for a network is thus based upon the following steps: 1. Ethernet Connection All network participants are connected to each other via Ethernet. 2. Manual Configuration of Settings The network master is manually configured, as described in Configuration of the Network and the Network Participants, SERCOS III C2C (CFL01.1- R3), page 32, and Configuration of the Link Axes, SERCOS III (CFL01.1- R3), page 35,. 3. Online Determination of Slave Settings For the configuration of the network slaves, the button is used. A new dialog is opened:

46 40/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-27: Reading the master data from the slave MLC After the IP address of the master MLC was input, the determination of the online values can be launched via the "Search for Network Settings" button. If the determination was successful, the values are automatically configured in the settings dialog. In case of an address conflict, the next free address is set as "Control Address" with a safety prompt appearing. The "Function" (Master or Slave, Fig. Settings for the MLC network in IndraWorks, page 33) is always set to "Slave". All other data are accepted in the same way. 4. Adaptation of the Local Slave Settings In the end, some local network settings must still be adjusted. These comprise: link axes on the producer's side (link axes A and B) link axes on the consumer's side (local link axes) 5. Acceptance of Settings The MLC is switched from the parameterization to the operating mode. Only thus do the configured network settings become effective in the MLC Parameters for the MLC Network, SERCOS III C2C (CFL01.1-R3) Below, all configuration and diagnostic parameters relevant for the MLC network are listed. Parameter C , Function module bus configuration C , Control address

47 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 41/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Parameter C , Network ring identification number C , MC cycle time (Tcyc) - setpoint C , Time slot of the integrated PLC from the MC cycle time C , MLC network, cycle time (Tcyc) - setpoint C , MLC network, functional modes configuration C , MLC network, FOC length configuration C , MLC network, master axes configuration C , MLC network, binary inputs - setpoints C , MLC network, fine adjustment, dead time compensation C , MLC network, actual cycle time (Tcyc) value C , MLC network, MDT error counter C , MLC network network data status C , MLC network binary inputs status C , MLC network function modul status A , Link axis, master axis selection Fig.6-28: Configuration and diagnostic parameters for the MLC network Diagnostic Messages for the MLC Network, SERCOS III C2C (CFL01.1-R3) Problems of the MLC network are reported through diagnostics (errors / warnings / messages) in IndraWorks, through binary status variables in the PLC component (see MLC Network, SERCOS III C2C (CFL01.1-R3) - Binary PLC Inputs in the MLC Network / Binary States in the MLC Network, page 44) and on the plug-in module itself. Diagnostic F , Error during configuration of the network communication F , Error during configuration of the network communication F , Error during configuration of the network communication F , C2C XML file not found F , C2C XML file, syntax error F , Invalid C2C XML file format F , C2C XML file, unknown parser error F , C2C ring not closed F , C2C network configuration via the ring not consistent F , C2C error switch-over to phase 1 F , C2C error device not found F , C2C error during switch-over to phase 2 F , C2C error during switch-over to phase 3

48 42/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Diagnostic F , C2C error command S , preparation for switch-over to P3 F , C2C error during switch-over to phase 4 F , C2C error command S , preparation for switch-over to P4 F , C2C connection not found F , C2C wrong ring address F , C2C error start switch-over to phase 3 F , C2C error start switch-over to phase 4 F , C2C ring configuration ID in the network not constant F , C2C version in the network not constant F , C2C ring delay wrong F , C2C synchronization delay wrong F , C2C SERCOS cycle time not possible F , C2C offset in AT invalid F , C2C unknown producer date F , C2C producer date not possible F , C2C consumer date not possible F , C2C producer cycle time not supported F , C2C producer cycle timer shorter than SERCOS cycle time F , C2C producer cycle time is no multiple of SERCOS cycle time F , C2C connection name ambiguous F , C2C maximum number of connections exceeded F , C2C configuration information incomplete F , C2C invalid ring configuration ID F , C2C not configurable as master F , C2C not configurable as slave F , C2C consumer and producer data field do not have the same length F , C2C further master found at port 1 F , C2C further master found at port 2 F , C2C error switch-over to phase 0 F , Network ring - cycle time deviation detected F , Link axis cannot be planned, since C2C is not configured F , Master axis cannot be used (not configured) F , Internal error, old C2C connection cannot be deleted F , Error during initialization of the CrossComm module F , C2C memory allocation failed F , C2C hardware initialization error

49 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 43/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Diagnostic F , C2C parameter S-0-xxxx not writable F , C2C parameter S-0-xxxx not writable F , C2C parameter S-0-xxxx not writable F , C2C parameter S-0-xxxx not readable F , C2C parameter S-0-xxxx not readable F , C2C parameter S-0-xxxx not readable F , C2C parameter S-0-xxxx not readable F , C2C error not initialized F , C2C error check actual master tx enabled Fig.6-29: Error messages for MLC network errors Reasons for this can be, e.g. wrong parameterization of the MLC network (no MLC network, several masters too high a PLC time slot...), defective network cables, defective hardware MLC Network, SERCOS III C2C (CFL01.1-R3) - PLC Components MLC Network, SERCOS III C2C (CFL01.1-R3) - Binary PLC Outputs in the MLC Network / Binary MLC Network Inputs By analogy with the forwarding of axis data (data of the respective axis are written from PLC to the motion component), the network operation of several controls requires an additional binary information exchange between both components. The data required are summarized in a structure of the ML_Base.lib: ControlData AT #MDzz.x: ML_CONTROLDATA_SM; Identification in ControlData wlinksyncbits_q.link_sync1 wlinksyncbits_q.link_sync2 wlinksyncbits_q.link_sync3 wlinksyncbits_q.link_sync4 wlinksyncbits_q.link_rebuild_ring Function in the MLC network Set/Delete binary input "Network SYNC1" Set/Delete binary input "Network SYNC2" Set/Delete binary input "Network SYNC3" Set/Delete binary input "Network SYNC4" Reserved Synchronous Network Inputs Fig.6-30: Binary PLC outputs in the network The MLC network consists of a network master and a maximum of 63 network slaves. Each of these altogether 64 network participants (maximum) possesses the four binary inputs Network SYNC1 Network SYNC4. These can be set/ deleted by the PLC program via the data structure ControlData (see MLC Network, SERCOS III C2C (CFL01.1-R3) - Mode of Operation of Synchronous Network Inputs, page 46). Access to the binary MLC network inputs

50 44/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication ControlData MLC Network - Binary Input Setpoints The writing of the binary network inputs with the MLC network being active is basically carried out via the PLC. In exceptional cases, the parameter access is also possible. With the help of the PLC program, the user can set the MLC network inputs via the binary inputs in the ControlData structure and thus control the interplay of the MLC network's participants in real time. This access to the MLC network inputs is dominant. As long as the PLC program is not running, the binary MLC network inputs can be written through setting the bits 0 4 in the parameter "C , MLC network - binary input setpoints". Upon the launch of the PLC program, the setpoint configuration via the parameter becomes ineffective. MLC Network, SERCOS III C2C (CFL01.1-R3) - Binary PLC Inputs in the MLC Network / Binary States in the MLC Network By analogy with the forwarding of axis data (data of the respective axis are written from PLC to the motion component), the network operation of several controls requires an additional binary information exchange between both components. The data required are summarized in a structure of the ML_Base.lib: ControlData AT #MDzz.x: ML_CONTROLDATA_SM; The communication in the MLC network is monitored by all network participants. The following PLC inputs are used to report errors and system states of the PLC. Identification in ControlData wlinkstate_i.link_error Status in the MLC network Network transmission error wlinkstate_i.link_error _PRI Error Port 1 wlinkstate_i.link_error _SEC Error Port 2 wlinkstate_i.link_error _RED arlinkvalidbits_i[1].wlink_i.ilinkbit0 arlinkvalidbits_i[2].wlink_i.ilinkbit0 arlinkvalidbits_i[3].wlink_i.ilinkbit0 Network redundancy loss Network participant 1 data valid Network participant 2 data valid Network participant 3 data valid arlinkvalidbits_i[64].wlink_i.ilinkbit0 Network participant 64 data valid arlinksyncbits_i[1].wsync_i.isyncbit0 Status Network SYNC1 input, participant 1 arlinksyncbits_i[1].wsync_i.isyncbit0 Status Network SYNC2 input, participant 1 arlinksyncbits_i[1].wsync_i.isyncbit2 Status Network SYNC3 input, participant 1 arlinksyncbits_i[1].wsync_i.isyncbit3 Status Network SYNC4 input, participant 1 arlinksyncbits_i[2].wsync_i.isyncbit0 Status Network SYNC1 input, participant 2 arlinksyncbits_i[2].wsync_i.isyncbit0 Status Network SYNC2 input, participant 2 arlinksyncbits_i[2].wsync_i.isyncbit2 Status Network SYNC3 input, participant 2 arlinksyncbits_i[2].wsync_i.isyncbit3 Status Network SYNC4 input, participant 2

51 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 45/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Identification in ControlData Status in the MLC network arlinksyncbits_i[3].wsync_i.isyncbit0 Status Network SYNC1 input, participant 3 arlinksyncbits_i[3].wsync_i.isyncbit0 Status Network SYNC2 input, participant 3 arlinksyncbits_i[3].wsync_i.isyncbit2 Status Network SYNC3 input, participant 3 arlinksyncbits_i[3].wsync_i.isyncbit3 Status Network SYNC4 input, participant 3 arlinksyncbits_i[64].wsync_i.isyncbit0 Status Network SYNC1 input, participant 64 arlinksyncbits_i[64].wsync_i.isyncbit0 Status Network SYNC2 input, participant 64 arlinksyncbits_i[64].wsync_i.isyncbit2 Status Network SYNC3 input, participant 64 arlinksyncbits_i[64].wsync_i.isyncbit3 Status Network SYNC4 input, participant 64 Network Transmission Error Error Port 1 Error Port 2 Network Redundancy Loss Fig.6-31: Binary PLC inputs in the network This status is set, if one of the following errors occurs in the MLC network: The transmission of the master axis position is disturbed due to telegram failures (AT and/or MDT). Only in case of cross-communication with line: A cable break was detected in the line. This status is relevant in redundant systems only, i.e. with cross-communication via a ring. It is set, if a network participant detects a cable break at Port 1. This status is relevant in redundant systems only, i.e. with cross-communication via a ring. It is set, if a network participant detects a cable break at Port 2. This status is relevant in redundant systems only, i.e. with cross-communication via a ring. It is set, if at least 1 network participant reports an "Error Port 1" or an "Error Port 2". The three status messages "Error Port 1", "Error Port 1" and "Network Redundancy Loss" do not necessarily lead to the status "Network Transsmission Error". Network Participant n Data Valid After the cross-communication in the network ring / line was established, the status "Network Participant n Data Valid" is set, if the following three conditions are met: the participant n is part of the ring / the line, the data sent by participant n (network AT) are valid and the data received by participant n (network MDT) were identified as valid. Synchronous Network States Example: If a local link axis of the MLC with the control address '4' follows a master axis of the MLC with the control address '12', the status "Network Participant 12 Data Valid" must be evaluated in the MLC '4'. Furthermore, each network participant possesses the binary states Network SYNC1[n] Network SYNC4[n], (n = ). These are automatically set or deleted by the MLCs participating in the network in dependence upon the binary MLC inputs Network SYNC1 Network SYNC4 given above and can be evaluated by the user in the PLC via the ControlData data structure (see MLC Network, SERCOS III C2C (CFL01.1-R3) - Mode of Operation of Synchronous Network Inputs, page 46).

52 46/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication ControlData Dialog MLC Network - Status - SERCOS III C2C (CFL01.1-R3) Access to the binary states in the MLC network The evaluation (read access) of the binary states in the MLC network is possible via the PLC as well as via IndraWorks. With the help of the PLC program, the user can evaluate the binary states in the MLC network via the binary inputs in "ML_ControlData_SM" structure and thus monitor the status in the MLC network in real time. By analogy with the MLC and with all axes, a diagnostic window can be opened in IndraWorks for the MLC network, in the context menu of the CrossCom function module: Fig.6-32: Call of the diagnostic function - context menu of the SERCOS III C2C function module (CFL01.1-R3) Here, the most important network settings ("Settings", "Cycle Time") and network ring states ("Bits")), as is the list of the MLCs participating in the network ("Adr"). In addition to this, the current physical status of each MLC is displayed on the SERCOS III C2C function module ("Messages", "Hardware"): Fig.6-33: Diagnostic of the MLC network from the view of participant folder A MLC Network, SERCOS III C2C (CFL01.1-R3) - Mode of Operation of Synchronous Network Inputs The synchronous network inputs "Network SYNCn" serve - with active network participants - to simultaneously set and delete the binary status "Status Network SYNCn input, participant m" (n = 1...4, m = 1 64). For the allocation of the inputs to the states, the following is applicable:

53 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 47/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication If the network participant m (m = ) sets/deletes the "Network SYNCn" (n = 1..4) input, all network participants (including participant m) set/delete the status "Status Network SYNCn input, participant m" at the same time. Between the changing of the network input and the changing of the corresponding network statues, a dead time can be identified - as with the master axis positions - (cause: transmission of data via the network ring). If the data transmission via the network ring is disturbed, the corresponding synchronous network states are deleted. Example of time flow The table below gives an example for the time flow of the interplay of synchronous network inputs/states: PLC action Network participant 5 sets the output wlinksyncbits_q.link_sync1 Network participant 12 sets the outputs wlinksyncbits_q.link_sync1, wlinksyncbits_q.link_sync2, wlinksyncbits_q.link_sync3 Network participant 7 sets the output wlinksyncbits_q.link_sync4 Network participant 5 deletes the output wlinksyncbits_q.link_sync1 Fig.6-34: Effect (PLC diagnostic) The following input is set at the same time (after dead time) for all network participants arlinksyncbits_i[5].wsync_i.isyncbit0 The following inputs are set at the same time (after dead time) for all network participants arlinksyncbits_i[12].wsync_i.isyncbit0 arlinksyncbits_i[12].wsync_i.isyncbit1 arlinksyncbits_i[12].wsync_i.isyncbit2 The output of participant 5 (see above) remains set for all network participants. The following input is set at the same time (after dead time) for all network participants arlinksyncbits_i[7].wsync_i.isyncbit3 The outputs of participant 5 and 12 (see above) remain set for all network participants. The following input is deleted at the same time (after dead time) for all network participants arlinksyncbits_i[5].wsync_i.isyncbit0 The outputs of participant 7 and 12 (see above) remain set for all network participants. Example of the time flow for the interplay of the synchronous network inputs/states Application examples Synchronous start of motion function blocks or processes on all or several MLCs. Local monitoring of the MLC network regarding active participants on every (separate) network participant by toggling a synchronous MLC network input.

54 48/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication MLC Network, SERCOS III C2C (CFL01.1-R3) - Redundancy and Error Tolerance Contrary to the line structure, the ring offers the advantage that the master can take any position within the ring. Every participant within the network monitors the receiving channels at Port 1 and Port 2. In case of a cable break in the receiving channgel, the respective MLC reports its error via the binary output, see MLC Network, SERCOS III C2C (CFL01.1- R3) - Binary PLC Inputs in the MLC Network / Binary States in the MLC Network, page 44. The transition of the redundancy of the ring into error tolerance is currently being developed MLC Network, SERCOS III C2C (CFL01.1-R3) - Configuration Examples MLC Network, SERCOS III C2C (CFL01.1-R3) - Configuration Examples, Modular Structure Three MLC controls are combined to form one MLC network. The cross-communication takes place via a line. For the control's run-up, the following switch-on sequence is to be complied with: At first the slaves and then the master. The control having the control address '2' is configured as the network master, whereas the controls with the addresses '1' and '3' are operated as network slaves. MLC 2 must be situated either at the beginning or at the end of the line. All axes should follow the link axis A of the network master (MLC 2).

55 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 49/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Line Configuration Configuration of the Network Participants Fig.6-35: Configuration example for a modular construction After the configuration of the line via IndraWorks is completed, Bit 4 is set to '0' for all network participants in the parameter "C , MLC network functional modes configuration". After the configuration via IndraWorks, the bits for an active network participant must be set as follows in the parameter "C , MLC network functional modes configuration": Network participant MLC network functional modes configuration (C , Bit 4 = 0: line) Master Axis Allocation Network master (MLC 2) Network slave 1 (MLC 1) Network slave 2 (MLC 3) Fig.6-36: Configuration example: 3 network participants in single ring All local link axes on each MLC are assigned "MLC 2 Link Axis A" as master axis via IndraWorks. List parameter "A , Link axis - master axis selection" shows: A = 2 1 for all link axes on all network participants. MLC Network, SERCOS III C2C (CFL01.1-R3) - Configuration Examples, Rotary Printing with two Productions (Modified Web Guide Rollers) Rotatory Printing with Web Guide Roller 1 The first production is marked by the allocation of print tower 1 to folder A and of print towers 2 and 3 to folder B.

56 50/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Ring Configuration Configuration of the Network Participants Fig.6-37: Configuration example for the master axis network production 1 After the configuration of the ring via IndraWorks is completed, Bit 4 is set to '1' for all network participants in the parameter "C , MLC network functional modes configuration". After the configuration via IndraWorks, the bits for an active network participant must be set as follows in the parameter "C , MLC network functional modes configuration": Network participant MLC network functional modes configuration (C , Bit 4 = 1: ring) Network master (MLC 1) Network slave 1 (MLC 2) Network slave 2 (MLC 3) Network slave 3 (MLC 4) Network slave 4 (MLC 5) Master Axis Allocation Folder A Fig.6-38: Configuration example: 5 network participants in the ring Print tower 1 works on folder A; whereas towers 2 and 3 are assigned to folder B. Folder A and print tower 1 run synchronously; i.e. all axes involved in this process follow the same master axis: e.g. master axis B of the network master. With the network address set on CFL01.1-Q2 - in this exampe address '1' -, the master axis is specified.

57 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 51/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Folder B MLC 1 link axis B is assigned via IndraWorks to all link axes which are administered by MLC 3 (tower 1) and MLC 1 (folder A). List parameter "A , Link axis - master axis selection" shows: A = 1 2 for all link axes in print tower 1 and folder A. Print tower 2 and print tower 3 run synchronously with folder B; i.e. all axes involved in this process follow the same master axis: e.g. master axis A of the link slave. With the network address adjusted on CFL01.1-Q2 - in this example address '2' -, the master axis is specified. MLC 2 link axis A is assigned via IndraWorks to all link axes which are administered by MLC 4 (tower 2), MLC 5 (tower 3) and MLC 2 (folder B). List parameter "A , Link axis - master axis selection" shows: A = 2 1 for all link axes in print towers 1 and 2 as well as in folder B. Change-over to changed web guide rollers Now, all 3 print towers should work on folder B with the link axis B being the master axis. Configuration of the Network Participants Master Axis Allocation Fig.6-39: Configuration example for the master axis network The master/slave configuration of the MLC controls and the ring structure (C ) remains unchanged. Via IndraWorks, MLC 2, link axis B, is assigned to all link axes on all MLCs. The list parameter "A , Link axis - master axis selection" now shows: A = 2 2 for all link axes on all MLCs.

58 52/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication This change-over of the production can also be realized directly via the PLC through the writing of the parameter "A , Link axis - master axis selection". 6.4 CrossComm (CFL01.1-Q2), MLC Cross-Communication, SERCOS II CrossComm Function Module (CFL01.1-Q2) General, CrossCom (CFL01.1-Q2) In order to be able to distribute the master axis positions of different MLC controls to any local axes in different drive rings, the MLC controls are combined to form an MLC network. A cross-communication in this network allows the distribution of the configured master axes positions on selected local link axes in different controls. The interconnection of the MLC controls can also be carried out with the help of the MLC CrossComm function module (CFL01.1-Q2). All function modules are interconnected by means of an fiber optic cable ring and form thus the MLC network. The function module can be ordered under the material number: R With the exception of MLC controls with CrossComm function modules (CFL01.1-Q2), only PPC controls featuring a DAQ04 module can be used in a common cross-network. Max. 64 MLCs in a Network Max. 128 Master Axes in a Network Cycle Time that can be Selected in the Network With the help of the CrossCom function module (CFL01.1-Q2), up to 64 MLC controls can be combined to form an MLC network. For each MLC, the actual positions of up to two local axes can be published in the MLC network. In a network with a maximum of 64 network participants, a maximum of 128 different master positions are thus available. The network cycle time can be preset with three different values. The real maximum number of participants and master axes supported in the MLC network also depends on this presetting. Preset cycle time Number of participants Number of master axes 2 ms ms ms Fig.6-40: Typical network cycle time for CrossComm (CFL01.1-Q2) The actually achievable cycle time considerably depends on the fact how many drives were activated in the individual drive rings and which functionalities were enabled in the individual controls. The network cycle time must be adjusted in the same way for all controls in the MLC network. The cycle time in the network ring and in the drive ring of each network participant must be identical. FOC - Single Ring or Double Ring The MLC network can be closed either with a single or with a double fiber optic cable ring. The double ring offers

59 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 53/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication increased error tolerance, since e.g. a failure of the transmission distance between two MLCs is tolerated. increased availability, since e.g., in case of a switched-off control, the cross-communication can be held up with the remaining drive rings. Addressing of the Function Module, CrossComm (CFL01.1-Q2) Front View On the basis of the front view of the CrossCom function module, the configuration of a single ring and a double ring is indicated. Options of Configuration Fig.6-41: Front view of the CrossCom function module (CFL01.1-Q2) A maximum of 4 function modules can be connected to an MLC. The following options are possible regarding SERCOS II and SERCOS III function modules: L40 Configuration OnBoard 1. module 2. module Function Function Function 1. module 2. module A - - MC - - B SERCOS II - MC CC - C SERCOS III - deactivated MC - D SERCOS II SERCOS II variant is not supported E SERCOS II SERCOS III variant is not supported F SERCOS III SERCOS II deactivated MC CC G SERCOS III SERCOS III deactivated MC CC

60 54/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication L65 with MLC 04VRS MC CC Fig.6-42: Configuration OnBoard 1. module 2. module Function Function Function 1. module 2. module A - - MC - - B SERCOS III - MC CC - C SERCOS II - deactivated MC - D SERCOS III SERCOS III variant is not supported E SERCOS III SERCOS II variant is not supported F SERCOS II SERCOS III variant is not supported G SERCOS II SERCOS II deactivated MC CC Master communication Cross communication Configuration options of SERCOS II and SERCOS III function modules. Connection of the Function Module to the MLC During startup, the control locates the SERCOS modules which can be pluged in to location 2 and 4. The order is important for the function. The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.6-43: Addressing of function modules on an IndraControl Identification of the Hardware by the Firmware Connection Displays Distortion Displays FOC Ports The MLC must be disconnected from the power supply, before a function module can be attached. Upon the next switch-on, the new function module is automatically identified by the firmware. An active MLC network is incated on the CFL01.1-Q2 by means of the LEDs Ma (green) or SI (yellow), master/slave. By means of the distortion displays of the CFL01.1-Q2 (red LEDs Er-P or Er- S), error primary-/secondary ring, the quality of the optical signal received can be checked. The transmitters and receivers of the primary and secondary ring can be wired to X7S1 and X7S3 or to X7S2 and X7S4, respectively. MLC Network as Single and Double Ring, CrossComm (CFL01.1-Q2) First of all, the MLC network is planned and parameterized by means of Indra Works and the MLCs are switched to the operating mode. On each MLC within the parameterized MLC network, the active MLC network is indicated by means of the LEDs Ma or Sl, respectively (exactly one network master and several network slaves).

61 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 55/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Single Ring: Primary Ring Afterwards, the distortion displays Er-P or Er-S are to be checked and, if necessary, the transmitting power of the physical predecessor is to be corrected or the fiber optic cable is to be checked for damage. In case of a parameterized single ring (only primary ring), the Sl distortion displays Sl will light up. This status is correct. In case of a single ring, only the primary ring is used; the secondary ring is not connected. Primary Ring, Secondary Ring Fig.6-44: FOC ports in the single ring Normally, the primary ring is used for the communication. The secondary ring serves to transmit redundancy signals.

62 56/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-45: FOC ports in the double ring Optical Adjustment of the Ring(s), CrossComm (CFL01.1-Q2) The secondary ring must be connected in the opposite direction - as shown above. According to the length of an fiber optic cable in the network, it might be necessary to adapt the optical transmitting power.

63 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 57/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Optical Transmitting Power - Single Ring Optical Transmitting Power - Double Ring Fig.6-46: Transmitting cables of the MLC 02 The transmitting power is adjusted in the parameter "C , MLC network - FOC length configuration". The length entered in the first list element refers to the fiber optic cable 1 situated between the current and the subsequent CrossComm function module (CFL01.1-Q2) in the primary/single ring. The transmitting power is adjusted via IndraWorks in the parameter "C , MLC network - FOC length configuration". The length entered in the first list element refers - as in case of the single ring - to the fiber optic cable 1 situated between the current and the subsequent CrossComm function module (CFL01.1-Q2) in the primary ring 1. The length inserted in the second list element is relevant for the secondary ring Project Planning of the MLC Network, CrossComm (CFL01.1-Q2), in the MLC Project Creation of the Function Module, CrossComm (CFL01.1-Q2) In order to be able to configure the participation of the MLC into the networklink, the "CrossComm" device must be created under the MLC. This can be done in two ways: 1. When an MLC is created, the wizard offers the connection of function modules in dialog 3, configuration. Here, the CrossComm module can be selected.

64 58/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-47: Insertion of a CrossComm function module via the wizard 2. Drag the "CrossComm (CFL01.1-Q2)" device from the "FM" group of the library onto the MLC... Fig.6-48: Dragging of the module

65 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 59/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication...and "let it drop" between Profibus and SERCOS. Fig.6-49: Insertion of the module These settings can only be made in the offline mode. The CrossComm function module is thus integrated in the MLC project. Fig.6-50: CrossComm function module prepared for configuration Configuration of the Network and the Network Participants, CrossComm (CFL01.1-Q2) In the online mode, the network must be configured in the "Settings for MLC Network " dialog. The settings are, of course, made first for the network master. Afterwards, you have to access the project of the corresponding slave MLC. Here, you can - provided that the controls are connected via Ethernet - accept the basic settings (ring structure and cycle time) of the network master. You can, of course, also make separate settings for the individual slave MLCs. This procedure is used accordingly for further network participants.

66 60/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Participation in the MLC Network Identifier of the Network Control Address Fig.6-51: Settings for the MLC network in IndraWorks In the "Participate in the MLC Network" box, a check mark must be set. This activates the content of the dialog. The identifier of the network is a purely informative value used to meaningfully describe the network in order to be able to distinguish it from others. Every network participant is assigned a controller address. The address set is read in once, every time the MLC is run up to the operating mode. It must be unique within the network and defines the positions of the produced master positions within the network MDT. The control address must be within the range of Fragmentary addressing is permitted. Function Regarding its functionality for the cross-communication, the MLC control acts as a network master (data producer and consumer, telegram monitoring and administration) network slave (data producer and consumer), stand-alone participant (no participation in the network). Network master The network master controls the cross-communication. It defines the clock pulse (cycle time) in the network, in the drive rings of all MLCs which participate in the network. The network master cyclically collects and distributes the master axis positions of all slaves within the network. Network slave

67 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 61/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication A network slave establishes an interface connection to the fiber optic cable ring of the MLC network. It synchronizes the telegram processing of its drive ring with the cross-communication. Stand-alone participant The participants that are integrated in the FOC ring of the MLC network, but are not parameterized for the MLC network, only make sure that the network telegrams are forwarded. This means that they only pass on the signal arriving at their input to their output (repeater function); they do not participate in the cross-communication process. The MLC network is a SERCOS ring in which exactly one participant must be configured as master. Only this master monitors and administrates the whole telegram communication. This leads to a considerably higher computing load compared to a network slave. Ring Structure The CrossComm (CFL01.1-Q2) modules supports both the double ring as well as the single ring. Single Ring In case of a single ring, only the primary ring is used; the secondary ring is not connected. Double Ring In case of the double ring, both the primary ring as well as the secondary ring are used for the cross-communication. The orientation of both rings is counterdirectional. The setting of the ring structure must be identical on all participating controls. Ring Cycle Time In the MLC network, 2 ms, 4 ms or 8 ms are supported as cycle time. The adjusted cycle time also determines the maximum number of the supported network slaves, the admissible network addresses and the cycle time in the drive ring. The setting of the ring cycle time must be identical on all participating controls. Admissible control addresses and number of network slaves The values are given in the following table: Ring cycle time Admissible control addresses Maximum number of network slaves 2 ms ms ms Fig.6-52: Admissible control addresses for an MLC network with CrossComm (CFL01.1-Q2) Since all network participants synchronize their telegram processing with the network master, all drives in these drive rings operate synchronously. This also applies to the control algorithms in the drives.

68 62/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication If the ring cycle time of the network is changed and if, therefore, the cycle time of the local drive does not tally with it anymore, a message is output which indicates the difference and offers to automatically adjust the cycle time of the drive ring: Fig.6-53: The cycle times do not tally - adjust automatically? In addition to this, it is possible to adapt the cycle time of the drive ring via the button This button is only active, if the cycle times of both rings differ. Moreover, any existing difference is indicated by the red error icon in the line of the ring cycle time. In the mouse tool tip, further information is indicated. Configuration of the Link Axes, CrossComm (CFL01.1-Q2) Configuration of the Link Axes, CrossComm (CFL01.1-Q2) - Overview In order to be able to use the master axes in the entire MLC network, two basic settings are required: the "producer" must "publish" one axis as a master axis and provide the master axis positions in the MLC network, the "consumer" can use the master axis from the MLC network locally as master axes. An MLC in the network can be both a producer and a consumer, i.e. it can provide its own local axes as master axes in the network (produce) and at the same time use any master axes from the network as a local link axis (consume). Settings on the Part of the Producer, CrossComm (CFL01.1-Q2) Link Axes in the MLC Network In the Settings for the MLC network in IndraWorks dialog, page 60,, of the CrossComm function module, every network participant can mark up to two of its local axes as link axis. This link axis' actual position is then provided as the master axis position for other axes within the MLC network. The terms "Link axis A" and "Link axis B" are used.

69 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 63/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-54: Selection of MLC's axes as master axes for different controls Local axes provided by the producer as link axis are not visible on the consumer's side. The consumer can only access "Link Axis A" or "Link Axis B", respectively. Dead Time Compensation Since the consumers receive the position values of the producer only after two cycle times of the MLC network - i.e. delayed, one speaks of "Dead Time". Without dead time compensation, the consumer's axis would follow the master axis with a phase offset. In order to minimize this phase offset, an automatic dead time compensation is supported for every link axis. This means that the position values provided in the network are extrapolated, i.e. precalculated position values are provided to supply the slave axes with position values as identical as possible. Very good precalculations are made for the consumer to promote the continuous changing of the position values (constant velocity), i.e. the phase offset can almost be reduced to '0'. For non-continuous changes (velocity changes), the phase offset cannot be reduced to '0'. In extreme cases, overshooting may occur on the consumer's side. The same effect appears, if master axis positions are cascaded in the network. For such cases, the dead time compensation should be set to values smaller than 100 %, i.e. the precalculation is realized in a "reduced" way. This, however, leads to the fact that the consumer follows the master axis with a phase offset. Concerning the dead time compensation, the following dependences and rules are applicable: A value of 100 % brings about the best possible concordance of the position values of producer and consumer (minimum phase offset). The smaller the network cycle time, the better a precalculation works and the smaller the phase offset. With the cascading depth (consumer provides link axis again etc.) increasing, the phase offset grows. In addition to this, an overshooting of local link axes is still possible. If overshooting effects (e.g. mechanical vibration/humming of the machine or jerk- and acceleration-excess warnings in case of local link axes or their real slave axes) occur, the values of the dead time compensation can be modified according to the following table: Cascading depth Value for dead time compensation 1 50% 2 33% 3 25% Fig.6-55: Dead time compensation in dependence upon the cascading depth

70 64/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication A cascading over more than two levels (Master Axis Local Link Axis/Master Axis Local Link Axis/Master Axis Local Link Axis) is to be avoided, if possible. A cascading of real master axes in the MLC network should be avoided. Local Link Axes on the MLC Settings on the Part of the Consumer, CrossComm (CFL01.1-Q2) In order to be able to "consume" a "Link Axis A" or a "Link Axis B" provided on the producer's side as a master for one's own local axes, a representative must be defined locally that makes them visible for one's own MLC. For that purpose, a link axis is created locally in the IndraWorks node Motion Link Axes. This axis is assigned an axis number and a name, in order to become addressable, and is allocated to a master axis in the MLC network. Fig.6-56: Adding a link axis to the project

71 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 65/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-57: Selection of an external MLC's axis as link axis 1 Fig.6-58: Selection of an external MLC's axis as a link axis 2

72 66/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication All produced link axes that are maximally available are always specified, since it cannot be determined for the offline configuration which network participants are available or which link axes are provided. The user themselves is responsible for the fact that the selected axis is actually provided by the network's MLC concerned. The allocation of a local link axis to a(n) (external) master axis in the MLC network is carried out via list parameters "A , Link axis - master axis selection". In this parameter, the control address and the number of the desired master axis of this control are inserted. The following applies: Entry in A List element 1: xxxx (control selection) List element 2: yyyy (link axis selection) Example: A = 15 1 Effective master axis position Master axis position A/B of the MLC With the control address xxxx yyyy = 1: Master axis position A, yyyy = 2: Master axis position B MLC 15 Master axis position A (MLC 15 link axis A) Fig.6-59: Master axis allocation The allocation on the consumer's side, e.g. by the PLC, can be modified via parameter "A " (see configuration example "Rotary printing with 2 productions"). Local link axes - like any other local axis - have their own parameters and corresponding dialogs. The number of supported parameters is limited, corresponds, however, approximately to the number of an encoder axis (see parameter "A , List of all A parameters"). MLC Network - Online Acceptance of Data of the Network Master for the Network Slaves, CrossComm (CFL01.1-Q2) Concerning the configuration of the MLC network, the focus lies on the consistent setting of the ring structure and ring cycle time, as well as on the function of the participants in the network. In order to support a consistent configuration as far as possible, IndraWorks does not only offer the manual setting described above in the "Settings for MLC Network " dialog, but also an online determination of the master's network settings. The settings of the master can thus be accepted directly for the slaves, provided, the network participants are connected via Ethernet. The optimum configuration procedure for a network is thus based upon the following steps: 1. Ethernet Connection All network participants are connected to each other via Ethernet.

73 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 67/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication 2. Manual Configuration of Settings The network master is manually configured, as described in Configuration of the Network and the Network Participants, CrossComm (CFL01.1-Q2), page 59, and Configuration of the Link Axes, CrossComm (CFL01.1-Q2), page 62,. 3. Online Determination of Slave Settings For the configuration of the network slaves, the button is used. A new dialog is opened: Fig.6-60: Reading the master data from the slave MLC After the IP address of the master MLC was input, the determination of the online values can be launched via the "Search for Network Settings" button. If the determination was successful, the values are automatically configured in the settings dialog. In case of an address conflict, the next free address is set as "Control Address" with a safety prompt appearing. The "Function" (Master or Slave, Fig. Settings for the MLC network in IndraWorks, page 60) is always set to "Slave". All other data are accepted in the same way. 4. Adaptation of the Local Slave Settings In the end, some local network settings must still be adjusted. These comprise: FOC lengths at the transmitter output link axes on the producer's side (link axes A and B)

74 68/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication link axes on the consumer's side (local link axes) 5. Acceptance of Settings The MLC is switched from the parameterization to the operating mode. Only thus do the configured network settings become effective in the MLC Parameters for the MLC Network, CrossComm (CFL01.1-Q2) Below, all configuration and diagnostic parameters relevant for the MLC network are listed. Parameter C , Function module bus configuration C , Control address C , Network ring identification number C , MC cycle time (Tcyc) - setpoint C , Time slot of the integrated PLC from the MC cycle time C , MLC network, cycle time (Tcyc) - setpoint C , MLC network, functional modes configuration C , MLC network, FOC length configuration C , MLC network, master axes configuration C , MLC network, binary inputs - setpoints C , MLC network, fine adjustment, dead time compensation C , MLC network, actual cycle time (Tcyc) value C , MLC network, MDT error counter C , MLC network network data status C , MLC network binary inputs status C , MLC network function modul status A , Link axis, master axis selection Fig.6-61: Configuration and diagnostic parameters for the MLC network Diagnostic Messages for the MLC Network, CrossComm (CFL01.1-Q2) Problems of the MLC network are reported through diagnostics (errors / warnings / messages) in IndraWorks, through binary status variables in the PLC component (see MLC Network, CrossComm (CFL01.1-Q2) - Binary PLC Inputs in the MLC Network / Binary MLC Network Status, page 70) and on the plugin module itself. Diagnostic F , Error during configuration of the network communication F , Error during configuration of the network communication F , Error during configuration of the network communication F , Network ring - transmission distance defective

75 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 69/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Diagnostic F , Network ring - master axis position incorrect MDT F , Network ring - master axis position incorrect AT Fig.6-62: Error messages for MLC network errors In these cases, it is possible to search for causes with the help of the indications Ma, Sl, Er-P, and Er- S on the CrossComm function module (see Fig. Front view of the CrossCom function module (CFL01.1-Q2), page 53). Reasons for this can be, e.g. wrong parameterization of the MLC network (single ring, double ring, no MLC network, several master, too high a PLC time slot), wrongly adjusted transmitting power of primary or secondary ring, defective fiber optic cables, defective hardware MLC Network, CrossComm (CFL01.1-Q2) - PLC Components MLC Network, CrossComm (CFL01.1-Q2) - Binary PLC Outputs in the MLC Network / Binary MLC Network Inputs By analogy with the forwarding of axis data (data of the respective axis are written from PLC to the motion component), the network operation of several controls requires an additional binary information exchange between both components. The data required are summarized in a structure of the ML_Base.lib: ControlData AT #MDzz.x: ML_CONTROLDATA_SM; Identification in ControlData wlinksyncbits_q.link_sync1 wlinksyncbits_q.link_sync2 wlinksyncbits_q.link_sync3 wlinksyncbits_q.link_sync4 wlinksyncbits_q.link_rebuild_ring Function in the MLC network Set/Delete binary input "Network SYNC1" Set/Delete binary input "Network SYNC2" Set/Delete binary input "Network SYNC3" Set/Delete binary input "Network SYNC4" Restore double ring in the MLC network Restore Double Ring in the MLC Network Synchronous Network Inputs Fig.6-63: Binary PLC outputs in the network This input of the MLC network allows the restitution of the double ring structure during operation, after all ring breaks are repaired again in the automatically reconfigured ring. The MLC network consists of a network master and a maximum of 63 network slaves. Each of these altogether 64 network participants (maximum) possesses the four binary inputs Network SYNC1 Network SYNC4. These can be set/ deleted by the PLC program via the data structure ControlData (see MLC Network, CrossComm (CFL01.1-Q2) - Mode of Operation of Synchronous Network Inputs, page 73). Access to the binary MLC network inputs The writing of the binary network inputs with the MLC network being active is basically carried out via the PLC. In exceptional cases, the parameter access is also possible.

76 70/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication ControlData MLC Network - Binary Input Setpoints With the help of the PLC program, the user can set the MLC network inputs via the binary inputs in the ControlData structure and thus control the interplay of the MLC network's participants in real time. This access to the MLC network inputs is dominant. As long as the PLC program is not running, the binary MLC network inputs can be written through setting the bits 0 4 in the parameter "C , MLC network - binary input setpoints". Upon the launch of the PLC program, the setpoint configuration via the parameter becomes ineffective. MLC Network, CrossComm (CFL01.1-Q2) - Binary PLC Inputs in the MLC Network / Binary MLC Network Status By analogy with the forwarding of axis data (data of the respective axis are written from PLC to the motion component), the network operation of several controls requires an additional binary information exchange between both components. The data required are summarized in a structure of the ML_Base.lib: ControlData AT #MDzz.x: ML_CONTROLDATA_SM; The communication via the MLC-Link optic fiber cable ring is monitored by all link participants. The following PLC inputs are used to report errors and system states of the PLC. Identification in ControlData wlinkstate_i.link_error wlinkstate_i.link_error _PRI wlinkstate_i.link_error _SEC wlinkstate_i.link_error _RED arlinkvalidbits_i[1].wlink_i.ilinkbit0 arlinkvalidbits_i[2].wlink_i.ilinkbit0 arlinkvalidbits_i[3].wlink_i.ilinkbit0 Status in the MLC network Network transmission error Error primary ring Error secondary ring Network redundancy loss Network participant 1 data valid Network participant 2 data valid Network participant 3 data valid arlinkvalidbits_i[64].wlink_i.ilinkbit0 Network participant 64 data valid arlinksyncbits_i[1].wsync_i.isyncbit0 Status Network SYNC1 input, participant 1 arlinksyncbits_i[1].wsync_i.isyncbit0 Status Network SYNC2 input, participant 1 arlinksyncbits_i[1].wsync_i.isyncbit2 Status Network SYNC3 input, participant 1 arlinksyncbits_i[1].wsync_i.isyncbit3 Status Network SYNC4 input, participant 1 arlinksyncbits_i[2].wsync_i.isyncbit0 Status Network SYNC1 input, participant 2 arlinksyncbits_i[2].wsync_i.isyncbit0 Status Network SYNC2 input, participant 2 arlinksyncbits_i[2].wsync_i.isyncbit2 Status Network SYNC3 input, participant 2 arlinksyncbits_i[2].wsync_i.isyncbit3 Status Network SYNC4 input, participant 2 arlinksyncbits_i[3].wsync_i.isyncbit0 Status Network SYNC1 input, participant 3 arlinksyncbits_i[3].wsync_i.isyncbit0 Status Network SYNC2 input, participant 3

77 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 71/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Identification in ControlData Status in the MLC network arlinksyncbits_i[3].wsync_i.isyncbit2 Status Network SYNC3 input, participant 3 arlinksyncbits_i[3].wsync_i.isyncbit3 Status Network SYNC4 input, participant 3 arlinksyncbits_i[64].wsync_i.isyncbit0 Status Network SYNC1 input, participant 64 arlinksyncbits_i[64].wsync_i.isyncbit0 Status Network SYNC2 input, participant 64 arlinksyncbits_i[64].wsync_i.isyncbit2 Status Network SYNC3 input, participant 64 arlinksyncbits_i[64].wsync_i.isyncbit3 Status Network SYNC4 input, participant 64 Network Transmission Error Error Primary Ring Error Secondary Ring Network Redundancy Loss Fig.6-64: Binary PLC inputs in the network This status is set, if one of the following errors occurs in the MLC network: The transmission of the master axis position is disturbed due to telegram failures (AT and/or MDT). Only with cross communication with single ring: In the network ring, an optic fiber cable break was detected. This status is relevant in redundant systems only, i.e. with cross-communication via a double ring. It is set, if a network participant detects an fiber optic cable break in the primary ring. This status is relevant in redundant systems only, i.e. with cross-communication via a double ring. It is set, if a network participant detects an fiber optic cable break in the secondary ring. This status is relevant in redundant systems only, i.e. with cross-communication via a double ring. It is set by all network participants, if at least 1 participant reports an "Error Primary Ring" or an "Error Secondary Ring". The three status messages "Error Primary Ring", "Error Secondary Ring" and "Network Redundancy Loss" do not necessarily lead to the status "Network Transmission Error". Network Participant n Data Valid After the cross-communication in the network ring was established, the states "Network Participant n Data Valid" are set, if the following three conditions are met: the participant n is part of the ring, the data sent by participant n (network AT) are valid and the data received by participant n (network MDT) were identified as valid. Synchronous Network States Example: If a local link axis of the MLC with the control address '4' follows a master axis of the MLC with the control address '12', the status "Network Participant 12 Data Valid" must be evaluated in the MLC '4'. Furthermore, each network participant possesses the binary states Network SYNC1[n] Network SYNC4[n], (n = ). These are automatically set or deleted by the MLCs participating in the network in dependence upon the binary MLC inputs Network SYNC1 Network SYNC4 given above and can be evaluated by the user in the PLC via the ControlData data structure (see MLC Network, CrossComm (CFL01.1-Q2) - Mode of Operation of Synchronous Network Inputs, page 73).

78 72/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication ControlData Dialog MLC Network - Status - CrossComm Access to the binary states in the MLC network The evaluation (read access) of the binary states in the MLC network is possible via the PLC as well as via IndraWorks. With the help of the PLC program, the user can evaluate the binary states in the MLC network via the binary inputs in "ML_ControlData_SM" structure and thus monitor the status in the MLC network in real time. By analogy with the MLC and with all axes, a diagnostic window can be opened in IndraWorks for the MLC network, in the context menu of the CrossCom function module: Fig.6-65: Call of the diagnostic function - context menu of the CrossCom function module (CFL01.1-Q2) Here, the most important network settings ("Settings", "Cycle time") and network ring states ("Bits")), as is the list of the MLCs participating in the network ("Adr"). In addition to this, the current physical status of each MLC is displayed on the CrossComm function module ("Messages", "Hardware"):

79 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 73/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-66: Diagnostic of the MLC network from the view of participant folder A MLC Network, CrossComm (CFL01.1-Q2) - Mode of Operation of Synchronous Network Inputs The synchronous network inputs "Network SYNCn" serve - with active network participants - to simultaneously set and delete the binary status "Status Network SYNCn input, participant m" (n = 1...4, m = 1 64). For the allocation of the inputs to the states, the following is applicable: If the network participant m (m = ) sets/deletes the "Network SYNCn" (n = 1..4) input, all network participants (including participant m) set/delete the status "Status Network SYNCn input, participant m" at the same time. Between the changing of the network input and the changing of the corresponding network statues, a dead time can be identified - as with the master axis positions - (cause: transmission of data via the network ring). If the data transmission via the network ring is disturbed, the corresponding synchronous network states are deleted. Example of time flow The table below gives an example for the time flow of the interplay of synchronous network inputs/states:

80 74/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication PLC action Network participant 5 sets the output wlinksyncbits_q.link_sync1 Network participant 12 sets the outputs wlinksyncbits_q.link_sync1, wlinksyncbits_q.link_sync2, wlinksyncbits_q.link_sync3 Network participant 7 sets the output wlinksyncbits_q.link_sync4 Network participant 5 deletes the output wlinksyncbits_q.link_sync1 Fig.6-67: Effect (PLC diagnostic) The following input is set at the same time (after dead time) for all network participants arlinksyncbits_i[5].wsync_i.isyncbit0 The following inputs are set at the same time (after dead time) for all network participants arlinksyncbits_i[12].wsync_i.isyncbit0 arlinksyncbits_i[12].wsync_i.isyncbit1 arlinksyncbits_i[12].wsync_i.isyncbit2 The output of participant 5 (see above) remains set for all network participants. The following input is set at the same time (after dead time) for all network participants arlinksyncbits_i[7].wsync_i.isyncbit3 The outputs of participant 5 and 12 (see above) remain set for all network participants. The following input is deleted at the same time (after dead time) for all network participants arlinksyncbits_i[5].wsync_i.isyncbit0 The outputs of participant 7 and 12 (see above) remain set for all network participants. Example of the time flow for the interplay of the synchronous network inputs/states Application examples Synchronous start of motion function blocks or processes on all or several MLCs. Local monitoring of the MLC network regarding active participants on every (separate) network participant by toggling a synchronous MLC network input MLC Network, CrossComm (CFL01.1-Q2) - Redundancy and Error Tolerance MLC Network, CrossComm (CFL01.1-Q2), Double Ring, Error-Free Error-Free Case Contrary to the single ring, the double ring offers error tolerance concerning a series of errors. The first error occurring is tolerated (single error security). Every participant within the network monitors the receiving channels in the primary and secondary ring. A FOC break in the receiving channel is reported via a binary output by the MLC concerned. After the first error that occurred, a reconfiguration of the network ring is automatically executed without the running operation being impaired. This is done through redirection of the data to intact FOC connections. The following illustration shows a simplified MLC network with 5 participants. In the error-free case, the communication is realized on the primary ring, whereas the secondary ring is (only) used to send redundancy signals.

81 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 75/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Fig.6-68: FOC rings in an error-free case The following errors are distinguished: MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Primary Ring (Single Error), page 75, MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Secondary Ring (Single Error), page 76, MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Primary and Secondary Ring Between Two Neighbored Network Participants (Double Error), page 77, With the help of the binary outputs of the MLCs, the error type and and error place can be uniquely identified, after the first error occurred. These outputs can be accessed with the PLC via the "ControlData.wLinkState_i" status bar or with IndraWorks via the "Diagnostic for MLC Network" dialog. If a network participant reports the status "Error Primary Ring" (Bit LINK_ERROR_PRI), the fiber optic cable connection to the receiver is faulty in the primary ring of this participant. If a network participant reports the status "Error Secondary Ring" (Bit LINK_ERROR_SEC), the fiber optic cable connection to the receiver is faulty in the secondary ring of this participant. If a double FOC break appears between 2 network participants, one of those participants reports the status "Error Primary Ring" (Bit LINK_ERROR_PRI), the other "Error Secondary Ring" (Bit LINK_ERROR_SEC). In case of an error, all network participants report the status "Network Redundancy Loss" (Bit LINK_ERROR_RED). MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Primary Ring (Single Error) Here, as an example, a single error is shown between the network slaves 3 and 4:

82 76/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Reconfiguration Diagnostic Fig.6-69: Reconfiguration in case of single FOC break in the primary ring with CrossComm (CFL01.1-Q2) Network slave 4 detects that, at its input in the primary ring, the data signal is missing. Therefore, it switches its receiving channel to the input in the secondary ring. The switch-over is detected by the neighburing participants (network slave 3 and network master) and leads to an automatic redirection of the data to the secondary ring. The FOC break is detected as an error in the receiving channel of CrossComm 5 (slave 4). The MLC 5 sets the binary output "Error Primary Ring" (Bit LINK_ERROR_PRI) = 1. The LED Er-P on the CrossComm 5 reports "Error Primary Ring". All network participants report "Network Redundancy Loss" (Bit LINK_ERROR_RED) = 1. MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Secondary Ring (Single Error) Here, as an example, a single error is shown between the network slaves 3 and 4: Reconfiguration Fig.6-70: Reconfiguration in case of a single FOC break in the secondary ring with CrossComm (CFL01.1-Q2) Network slave 3 detects that, at its input in the secondary ring, the data signal is missing. Therefore, it switches its receiving channel to the input in the primary ring. The secondary ring is disconnected and is omitted as a redundant system. The data are continued to be transferred via the primary ring.

83 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 77/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Diagnostic The FOC break is detected as an error in the receiving channel of CrossComm 4 (slave 3). The MLC 4 sets the binary output "Error Secondary Ring" (Bit LINK_ERROR_SEC) = 1. The LED Er-S on the CrossComm 4 reports "Error Secondary Ring". All network participants report "Network Redundancy Loss" (Bit LINK_ERROR_RED) = 1. MLC Network, CrossComm (CFL01.1-Q2), FOC Break in Primary and Secondary Ring Between Two Neighbored Network Participants (Double Error) Here, as an example, a double error is shown between network slave 4 and the network master. Reconfiguration Diagnostic Fig.6-71: Reconfiguration in case of a double FOC break with CrossComm (CFL01.1-Q2) The network master and master slave 4 detect the FOC break in the respective receiving channel. Both participants switch their input so as to make sure that the communication via the secondary ring is maintained. The OWG break in the primary ring is detected as an error in the receceiving channel of the CrossComm 1 (Master). The break in the secondary ring leads to an error in the receiving channel of CrossComm 5 (network slave). The MLC 1 sets the binary output "Error Primary Ring" (Bit LINK_ERROR_PRI) = 1. The LED Er-P on the CrossComm 1 reports "Error Primary Ring". The MLC 5 sets the binary output "Error Secondary Ring" (Bit LINK_ERROR_SEC) = 1. The LED Er-S on the CrossComm 5 reports "Error Secondary Ring". All network participants report "Network Redundancy Loss" (Bit LINK_ERROR_RED) = 1. MLC Network, CrossComm (CFL01.1-Q2), Restitution of the Double Ring, Error-Free After an error was repaired in the network, the reconfiguration on the ring structure can be executed in the error-free case. This can be done though stopping the system and newly initializing it via phase 0 or dynamic reconfiguration in the operating mode. The dynamic reconfiguration is released via the PLC through setting the binary input in the bit string ControlData.wLinkSyncBits_q (bit LINK_REBUILD_RING).

84 78/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication If the reconfiguration was successful, the binary error messages (LINK_ERROR_PRI, LINK_ERROR_SEC, LINK_ERROR_RED) will be deleted. An external signal for dynamic reconfiguration must have an effect on all inputs of all network participants at the same time. As long as the PLC program is not running, the dynamic reconfiguration can also be triggered through setting Bit 4 (0x0010) in the parameter "C , MLC network - binary input setpoints". Upon the launch of the PLC program, the setpoint configuration via the parameter becomes ineffective MLC Network, CrossComm (CFL01.1-Q2) - Configuration Examples MLC Network, CrossComm (CFL01.1-Q2) - Configuration Examples, Modular Structure Three MLC controls are combined to form one MLC network. The cross-communication takes place via a single ring. The control having the control address '2' is configured as the network master, whereas the controls with the addresses '1' and '3' are operated as network slaves. All axes should follow the link axis A of the network master (MLC 2). Single Ring Configuration Configuration of the Network Participants Fig.6-72: Configuration example for a modular construction After the configuration of the single ring via IndraWorks is completed, Bit 4 is set to '0' for all network participants in the parameter "C , MLC network functional modes configuration ". After the configuration via IndraWorks, the bits for an active network participant must be set as follows in the parameter "C , MLC network functional modes configuration":

85 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 79/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Network participant MLC network functional modes configuration (C , Bit 4 = 0: single ring) Master Axis Allocation Network master (MLC 2) Network slave 1 (MLC 1) Network slave 2 (MLC 3) Fig.6-73: Configuration example: 3 network participants in single ring All local link axes on each MLC are assigned "MLC 2 Link Axis A" as master axis via IndraWorks. List parameter "A , Link axis - master axis selection" shows: A = 2 1 for all link axes on all network participants. MLC Network, CrossComm (CFL01.1-Q2) - Configuration Examples, Rotatory Printing with Two Productions (Changed Web Guide Roller) Rotatory Printing with Web Guide Roller 1 The first production is marked by the allocation of print tower 1 to folder A and of print towers 2 and 3 to folder B. Double Ring Configuration Configuration of the Network Participants Fig.6-74: Configuration example for the master axis network production 1 After the configuration of the double ring via IndraWorks, Bit 4 is set to '1' for all network participants in the parameter "C , MLC network functional modes configuration". After the configuration via IndraWorks, the bits for an active network participant must be set as follows in the parameter "C , MLC network functional modes configuration":

86 80/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Network participant MLC network functional modes configuration (C , Bit 4 = 1: double ring) Network master (MLC 1) Network slave 1 (MLC 2) Network slave 2 (MLC 3) Network slave 3 (MLC 4) Network slave 4 (MLC 5) Master Axis Allocation Folder A Folder B Fig.6-75: Configuration example: 5 network participants in the double ring Print tower 1 works on folder A; whereas towers 2 and 3 are assigned to folder B. Folder A and print tower 1 run synchronously; i.e. all axes involved in this process follow the same master axis: e.g. master axis B of the network master. With the network address set on CFL01.1-Q2 - in this exampe address '1' -, the master axis is specified. MLC 1 link axis B is assigned via IndraWorks to all link axes which are administered by MLC 3 (tower 1) and MLC 1 (folder A). List parameter "A , Link axis - master axis selection" shows: A = 1 2 for all link axes in print tower 1 and folder A. Print tower 2 and print tower 3 run synchronously with folder B; i.e. all axes involved in this process follow the same master axis: e.g. master axis A of the link slave. With the network address adjusted on CFL01.1-Q2 - in this example address '2' -, the master axis is specified. MLC 2 link axis A is assigned via IndraWorks to all link axes which are administered by MLC 4 (tower 2), MLC 5 (tower 3) and MLC 2 (folder B). List parameter "A , Link axis - master axis selection" shows: A = 2 1 for all link axes in print towers 1 and 2 as well as in folder B. Change-over to changed web guide rollers Now, all 3 print towers should work on folder B with the link axis B being the master axis.

87 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 81/156 SERCOS III C2C (CFL01.1-R3) and CrossComm (CFL01.1-Q2), MLC Cross-Communication Configuration of the Network Participants Master Axis Allocation Fig.6-76: Configuration example for the master axis network The master/slave configuration of the MLC controls and the ring structure (C ) remains unchanged. Via IndraWorks, MLC 2, link axis B, is assigned to all link axes on all MLCs. The list parameter "A , Link axis - master axis selection" now shows: A = 2 2 for all link axes on all MLCs. This change-over of the production can also be realized directly via the PLC through the writing of the parameter "A , Link axis - master axis selection".

88 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description

89 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 83/156 SRAM Module (CFL01.1-Y1) - Memory Expansion for the MLC L40 7 SRAM Module (CFL01.1-Y1) - Memory Expansion for the MLC L General The 8 MByte SRAM function module serves with the MLC control for filing of kinematics programs. It is orderable under the material number R Addressing of Function Module SRAM (CFL01.1-Y1)Addressing of Function Module SRAM (CFL01.1-Y Front View Connection of the Function Module with the MLC Addressing of the Function Module Fig.7-1: Front view of the SRAM function module (CFL01.1-Y1) At the function module bus of the MLC (connection on the left side) a SRAM function module (CFL01.1-Y1) can be stuck on. Besides, is to be paid attention to the correct module address (DIP switch S1 at the module). It is essential: 1. Module (the next to the MLC): Address 1; 2. Module: Address 2 etc. At a MLC 4 function modules can be connected maximally whereas it is indifferent in which slot the module is stucked in.

90 84/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SRAM Module (CFL01.1-Y1) - Memory Expansion for the MLC L40 Fig.7-2: Addressing of function modules on an IndraControl 7.3 Creating the Function Module SRAM (CFL01.1-Y1) Creating the 8 MByte SRAM function module can take place in two different ways: 1. When creating a MLC from 03VRS the Wizard offers in dialog 3, Configuration, the connection of function modules. Here the module SRAM can be selected. Fig.7-3: Insertion of a SRAM-Function module via the wizard 2. Drag the device "SRAM (CFL01.1-Y1)" from group "FM" of the library on the MLC...

91 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 85/156 SRAM Module (CFL01.1-Y1) - Memory Expansion for the MLC L40 Fig.7-4: Drag the module...and "drop" it between Profibus and SERCOS or on the MLC self. Fig.7-5: Insertion of the module These settings are only possible in Offline mode. With it the SRAM-Function module is integrated in the MLC-Project. PopUp menu of the function module Identification of the Hardware by the Firmware Fig.7-6: SRAM function module ready for configuration Delete: SRAM and all its subnotes will be deleted permanently. With the next switch-on the new function module is automatically identified by the firmware. 7.4 Battery Battery Buffering The keeping of the data takes place via a CR2450 3V Lithium Battery (Sony CR2450, is UL Approved (Material No.: ). The capacity of the battery reaches with typical buffer currents for 4.2 years.

92 86/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description SRAM Module (CFL01.1-Y1) - Memory Expansion for the MLC L Battery Monitoring Battery Exchange In operation the battery is loaded one-time every 24 hours and the battery voltage is tested. From experience a buffering of at least one month is still guaranteed after remaining of the limit value. The limit value undershooting is inserted in the diagnostics- and error memory of IndraWorks engineering and is indicated in the MLC L40 display. The battery case is on the front side of the SRAM module, under the black cap with the label "Battery". To avoid data loss with the exchange of the battery, the device must be switched on.

93 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 87/156 PLS (CFL01.1-N1) - Camshaft Gear 8 PLS (CFL01.1-N1) - Camshaft Gear 8.1 PLS (CFL01.1-N1) Function Module - General For the completion of the already existing gamshaft gear module "MC_Digital CamSwitch" of the "ML_TechCommon.lib" library, a hardware-based camshaft gear function module was developed for the versions as of MLC 03VRS (PLS = Programmable Limit Switch). It can be ordered under the material number R Fig.8-1: Comparison of hardware- and software-based camshaft gear The essential differences in comparison to the software-based gears result from the cycle time of 125 µs, irrespective of the respective SERCOS cycle time of ms and the parameterization via dialogs instead of a FB as programming interface.

94 88/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description PLS (CFL01.1-N1) - Camshaft Gear Fig.8-2: 125 µs, hardware-based 1 ms, SERCOS cycle time, software-based 2 ms, SERCOS cycle time, software-based 4 ms, SERCOS cycle time, software-based Resolution in dependency upon the revolutions and cycle time As regards details, differences can occur between the softwarebased and the hardware-based version! Altogether 4 camshaft gears can be connected to one MLC. 8.2 Operating Principle of the Hardware-Based PLS Axis // Cam Disk // Output The hardware-based PLS works according to the following operating principle: A (reference) axis is allocated to a cam disk. The cam disk follows this axis' mouvements. Every cam disk controls one output. A maximum of eight (reference) axes can be used within one PLS to control the 16 cam disks, i.e. at least one (reference) axis controls all 16 cam disks and a maximum of eight (reference) axes can share the control of the 16 cam disks in any way whatsoever. Every cam disk can be allocated the technologically required number of directional cams. Altogether 64 cams are available. The directionality is the common property of all cams of the cam disk. Scaling of the Axis and Direction of Movement rotatory, constant direction of rotation One axis revolution corresponds to a full circle of the cam disk; the directionally effective cams commutate once per axis revolution. rotatory, alternate direction of rotation One axis revolution corresponds to the entire circle of the cam disk. The directionally effective cams commutate either in the clockwise or anticlockwise direction or are effective in both directions of rotation. translatory, alternating directions of movement

95 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 89/156 PLS (CFL01.1-N1) - Camshaft Gear Cam Disk's Operating Modes The full circle of the cam disk is theoretically cut open and unrolled over the distance to cover. The directionally effective cams commutate either in the clockwise or anticlockwise direction or are effective in both directions. In addition to their directional effectiveness, cams can be operated in two different cam disk's modes: Position-related mode In consideration of correction time and correction distances, the rising and / or falling edge of the active cam determines the status of the cam disk. Time-related mode On the basis of the active cam's rising edge (and any corrections), the cam stays active for a time to be defined (increments of 125 µm to 1 s). If a subsequent cam becomes active in this period of time, the effect of the first cam is prolonged by the same amount of time. Example: Application of adhesive; the cam's edge determines the beginning of the adhesive's flow, the duration, the adhesive quantity. For the compensation of internal processing times and the delay in the connected devices, separate hold times can be defined for each cam disk for the switch-on and switch-off process (dead time compensation). Every cam has its own switch-on and switch-off position (switch-on and switchoff angle). Fig.8-3: PLS operating modes The hysteresis used to avoid the flickering of an output, when the switch-on and switch-off position is achieved, can be defined for each direction (positive or negative hysteresis value).

96 90/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description PLS (CFL01.1-N1) - Camshaft Gear Positive Hysteresis: In the positive direction, the switch-on and switch-off positions define the switch-on and switch-off of the cam disk (of the output register allocated to it). In the negative direction, the switch-on and switch-off positions define the switch-on and switch-off of the cam disk - less the hysteresis value - (of the output register allocated to it). Negative Hysteresis: In the positive direction, the switch-on and switch-off positions plus the hysteresis values define the switch-on and switch-off of the cam disk (of the output register allocated to it). In the negative direction, the switch-on and switch-off positions define the switch-on and switch-off of the cam disk (of the output register allocated to it). PLC Finishing The result (active or inactive) derived from the axis movement, the cam disk properties and the cam positions or cam position, respectively, and the duty time, is transferred to one bit each of the camshaft gear register and (16 cam make a 2*8 bit "register". The values included in the "Register" can be processed with the PLC support. Register Force Source Output Fig.8-4: Data of camshaft gear Data of PLC Decision bit "Register" or "Force" Output data after the manipulation Basic commutation of the post-processing Subject to the "Source" bit, either the "Register" bit or the "Force" bit are used as "Output" bit. Example: Until now, for the "Application of the Adhesive", the cam disk working in the time-related mode was taken into consideration. Now, a PLC-controlled cleaning run is to take place irrespective of the camshaft gear: The PLC released the cleaning fluid and, via the "Output" bit, the PLC releases the adhesive nozzle valve. 8.3 Addressing of the PLS Function Module (CFL01.1-N1) Front View In the following, the front view of the function module is shown.

97 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 91/156 PLS (CFL01.1-N1) - Camshaft Gear Connection of the Function Module to the MLC PLS Addressing of the Function Modules Fig.8-5: Front view of the PLS function module (CFL01.1-N1) A maximum of four PLS function modules can be connected to the function module bus of the MLC (connection on the left side). It must be made sure that the correct module address be used (DIP switch S1 on the module slot adress). The following applies: 1. module (nearest to the MLC): address 0; 2nd module: address 1 etc. Up to 4 function modules can be connected and to one MLS; it does not matter, which slot the PLS module is plugged in. The assignment of PLS adresses begins with the modules being situated nearest to the control. Modules of other types are ignored for PLS addresses. Type Function module address PLS address PLS (CFL01.1-N1) 00 PLS1 SRAM (CFL01.1-Y1) 01 - PLS (CFL01.1-N1) 10 PLS2 PLS (CFL01.1-N1) 11 PLS3 Fig.8-6: Example for address assignment

98 92/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description PLS (CFL01.1-N1) - Camshaft Gear Fig.8-7: Addressing of function modules on an IndraControl The MLC must be disconnected from the power supply, before a function module can be attached. Identification of the Hardware by the Firmware External Power Supply Upon the next switch-on, the new function module is automatically identified by the firmware, provided it was configured. Every PLS function module must also be supplied via its X1S connector. 8.4 Project Planning of the PLS Function Module (CFL01.1-N1) Project Planning of a PLS Function Module (CFL01.1-N1) First and foremost, the project planning of the function module is based upon the "creation of a PLS function module (CFL01.1-N1)" in IndraWorks. Two dialogs support the configuration as such: Configuration of a Camshaft Gear (Overall Overview Dialog), page 94, (properties of the cam disks including the axis assignment for all cam disks), Configuration of a Camshaft Gear (Detail View Dialog), page 96, (properties of every single cam disk). Essential context menu items are: enabling / disabling of the function module Configuration of a Camshaft Gear (Reference Axis Context Menu), page 96 overview of reference axes, cannot be edited, entry of the position offset cam disk / (reference) axis, Modulo value, can only be changed here, if the scaling type for position data is "absolute", Configuration of a Camshaft Gear (Error Reaction Context Menu), page 97, presetting for the behaviour in case of an error, diagnostics that are output by the PLS, as well as the possibility to reset the PLS parameters = deleletion and updating of dialogs Creation and Deletion of the PLS Function Module (CFL01.1-N1) The creation of the PLS function module can be realized in two different ways:

99 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 93/156 PLS (CFL01.1-N1) - Camshaft Gear 1. When an MLC is created, the wizard offers - as of 03VRS - the connection of function modules in dialog 3, configuration. Here, the PLS module (CFL01.1-N1) can be selected. Fig.8-8: Insertion of a PLS function module via the wizard 2. Drag the "PLS (CFL01.1-N1)" device from the "FM" group of the library onto the MLC... Fig.8-9: Dragging of the module...and "let it drop" between Profibus and SERCOS or on the MLC itself. Fig.8-10: Insertion of the module These settings can only be made in the offline mode. The PLS function module (CFL01.1-N1) is thus integrated in the MLC project.

100 94/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description PLS (CFL01.1-N1) - Camshaft Gear Deletion of a PLS Module Fig.8-11: PLS (CFL01.1-N1) function module ready for configuration Only the PLS module with the highest index can be deleted, since, upon every removal of the card, the remaining elements "move up" and are thus displaced Configuration of a Camshaft Gear (Overall Overview Dialog) Fig.8-12: Overall overview of the PLS camshaft gear Each of the 16 cam disks 1 (= outputs) can be allocated to an axis 2 (maximum of eight (reference) axes per function module); however, all 16 cam disks could also follow one and the same axis. The status "S" 8 of the output is visible in the overall overview ("Output", not "Register"). A green lamp shows an active and a grey lamp an inactive output. For the positioning mode 6, the hold times "ON" and "OFF" that can be entered in column 3 are valid. For the time mode 6, the hold time "ON" and the duty time 4 that can be entered in column 3 play an important role. The hold time "OFF" is invalid. The cam disks work directionally 7, i.e. in case of a movement in the positive or negative or in both directions, they are switched off. The hysteresis 5 completes the data record connected with the cam disk.

101 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 95/156 PLS (CFL01.1-N1) - Camshaft Gear On the right side in the dialog, cams are indicated that were allocated to the respectively selected cam disk. Every cam has its own switch-on and switchoff position (switch-on and switch-off angle). Since only the cams of the preselected cam disk are visible, but not those that are provided on the other disks, the other cams available are listed at the right bottom of the dialog. Cam disk 1: three cams; still available: 60 cams, i.e. for the remaining disks - here cam disk 2 - one cam is available.. Differences During Disabling: Parameters Used The disabling of an output via the reference axis selection is only possible in phase P2; the disabling via the output direction, however, is also possible in BB. In the latter case, the output is nevertheless calculated. The table given below shows an overview of C parameters created for the PLS camshaft gears (CFL01.1-N1). Parameter PLS01 PLS02 PLS03 PLS04 Control word C C C C Signal selection C C C C Control signal C C C C Outputs C C C C Internal register C C C C Reference axis configuration C C C C Additive reference axis position C C C C Reference axis definition C C C C Hysteresis C C C C Hold time during switch-on C C C C Hold time during switch-off C C C C Cam disk number C C C C Cam switch-on position C C C C Cam switch-off position C C C C Command: initialize cam disks C C C C Command: enable cam disks C C C C Output mode C C C C Duty time C C C C Fig.8-13: PLS parameters

102 96/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description PLS (CFL01.1-N1) - Camshaft Gear Configuration of a Camshaft Gear (Detail View Dialog) Parameters Used Fig.8-14: Detail view of a PLS cam disk 1 The detail view is subdivided into three sections: Left Side The data of the cam disk given in the head (output x) of the overall overview are repeated. Centre In addition to that, the current position of the axis and the position offset between the (reference) axis and cam disk that can be entered in the context menu point "Reference axis..." are displayed. The overview of cams of the cam disk from the overall view is repeated. Right Side For the cam disk indicated at the left side (output x), the current states of its four bits "Register", "Force", "Source" and "Output" are indicated. The table PLS parameters on page 95, given below shows an overview of C parameters created for the PLS camshaft gears (CFL01.1-N1) Configuration of a Camshaft Gear (Reference Axis Context Menu) Fig.8-15: Overview of (reference) axes For each reference axis, the position offset, the modulo value, the scaling type for the position data and the unit are indicated.

103 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 97/156 PLS (CFL01.1-N1) - Camshaft Gear The position offset is always added to the current axis position. It can be entered directly into the table. It is thus identical for all cam disks that are controlled by this very axis. The modification can be made in the MLC status "BB" (P4). The cam disk /cam disks of the axis "jump" irrespective of the hysteresis. The modulo value can only be changed, if the scaling type for position data is "absolute". If the scaling type for position date is "modulo", the "Scaling/Measuring Units" dialog is provided under the respective axis for the setting of the modulo value. All other values cannot be changed in this dialog Configuration of a Camshaft Gear (Error Reaction Context Menu) Parameters Used Fig.8-16: Presetting of the error reaction Via this dialog, the user can set the error reaction of the complete camshaft gear according to their necessities. Short-Circuit on the Output error reaction "F , Overtemperature", optimum standstill procedure for all axes. error reaction "F , Overtemperature" no error reaction. No Voltage on the Output error reaction "F , Voltage supply failure", optimum standstill procedure for all axes. error reaction"f , Voltage supply failure" no error reaction. The table given below shows an overview of C parameters created for the PLS camshaft gears (CFL01.1-N1). Parameter PLS01 PLS02 PLS03 PLS04 Control word C C C C Going Online Set/Actual Comparison During booting and going online, a set/actual comparison of the hardware is carried out.

104 98/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description PLS (CFL01.1-N1) - Camshaft Gear Enabling / Disabling Parameterization Parameter Handling Parameterization in the Operating and Parameterization Mode If a configured or non-enabled camshaft gear is not physically connected to the MLC, going online in IndraWorks is interrupted with a corresponding error message. The PLS module must be manually disabled, before it is possible to go online. During the booting of the MLC, the case mentioned above leads to an F5 error. The MLC goes up to phase P2 and stays in the stop state, since - otherwisestill more errors would occur. After the booting process, it is possible to go online in order to read out the error. The camshaft gear can be disabled. This means that the parameters are maintained, but the PLS module must not exist. If the function module is physically existing, it is not addressed by the firmware. However, even with the function module being disabled, it is possible to change settings. Camshaft gears that are not configured in the project, but are physically connected to the MLC, are disabled. A PLS module can be disabled in two different ways. Either with a click on the device's icon in the project tree or via the context menu of the device. The parameters used for the configuration are C parameters and are stored in the MLC - just as the PLS firmware -, since the function module only has a RAM. This means that the parameterization is not lost, when the camshaft gear is removed. There is one set of parameters each for every camshaft gear. During the parameter back up, these parameters are stored together with those of the MLC. The camshaft gear can be parameterized online or in the "Offline Parameterization"mode. With the exception of the parameters required to set the the output mode/direction and the cams, all parameters can only be changed in the parameterization mode. During the switch-over to the operating mode, all modifications made to the PLS module parameterization are automatically accepted. Modifications made in the operating made are only accepted, after the command "Update" was executed. This can be done via the corresponding buttons in the dialogs "Overall Overview" and "Detail View" or in the context menu of the PLS module. 8.5 SPS Post-Processing of the Camshaft Gear Data Brief Description The current version of the IndraMotion MLC supports four camshaft gear modules, the data of which are stored - on the PLC side - as ARRAY of the ML_PLSDATA_SM type in the "Shared Memory": Program: VAR_GLOBAL PlsData AT %MB8520: ARRAY[1..4] OF ML_PLSDATA_SM; (* data of all PLS - function modules *) END_VAR Program: TYPE ML_PLSDATA_SM : STRUCT (* --- PLS control --- *) (* --- PLS control bytes for direct output control --- *) Source_0_q : BYTE; (* source control register (0/1 = force register/pls register) *) Source_1_q : BYTE; (* source control register (0/1 = force register/pls register) *) Force_0_q : BYTE; (* force register for output 'X201' *) Force_1_q : BYTE; (* force register for output 'X202' *) (* --- PLS monitor --- *) (* --- PLS monitor bytes for diagnostics --- *)

105 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 99/156 PLS (CFL01.1-N1) - Camshaft Gear Output_0_i : BYTE; (* physical output 'X201' *) Output_1_i : BYTE; (* physical output 'X202' *) Register_0_i : BYTE; (* internal PLS state register *) Register_1_i : BYTE; (* internal PLS state register *) END_STRUCT END_TYPE Functional Description Every camshaft gear has four variables of 2*8 =16 bits, i.e. for each output (cam disk) 1 bit each with the following function: Register (C , C , C , C ), The bits are supplied directly from the internal state of the camshaft gear for every cam disk. Force (C , C , C , C ), The bits are provided as information by the PLC and can alternatively be given to the Register to Output (default: FALSE). The Source bit decides, whether the Register bit or the Force bit are given to Output. Source (C , C , C , C ), These bits are predefined by the PLC and serve to control the signal source selection (Register or Force). The decision can be made separately for every single bit (default: Force). Output (C , C , C , C ), These bits contain the result: Register bit or Force bit controlled by the Source bit. The four C parameters indicated are allocated to the four possible camshaft gears, i.e. camshaft gear 1 uses C / C / C / C etc.).

106 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description

107 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives 9 Fast I/O Function Module CFL01.1-E2 9.1 Hardware Description Connection of the Function Module to the MLC Bosch Rexroth AG 101/156 Fast I/O Function Module CFL01.1-E2 The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.9-1: Addressing of function modules on an IndraControl The MLC must be disconnected from the power supply, before a function module can be attached.

108 102/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Fast I/O Function Module CFL01.1-E2 Properties A B C D E F G Fig.9-2: S1, Switch for slot number Stat, Function module status indication X2I1, Digital inputs X2D1, Digital inputs/outputs X2O1, Digital outputs X1S, Voltage supply and FE Mounting rail locking Fast I/O function module Every Fast I/O function module is equipped as follows: 8 inputs 8 inputs/outputs (can be chosen bit-wise) 8 outputs 3 MICRO COMBICON spring force terminals with 8 outputs or inputs each (X2I1, X2D1 and X2O1)

109 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 103/156 Fast I/O Function Module CFL01.1-E2 Interfaces 1 MICRO COMBICON spring force terminal with voltage supply and functional earthing LED status lamp Powerfail and Overload Current per output: 500 ma in case of 24 V mains voltage Delay times of the input drivers 0 1 typ. 40 µs, 1 0 typ. 45 µs Delay times of the output drivers 0 1 typ. 70 µs, 1 0 typ. 70 µs Input plug X2I1 port Input / Output plug X2D1 port Output plug X2O1 port Input 0 Input/Output 0 Output 0 Input 1 Input/Output 1 Output 1 Input 2 Input/Output 2 Output 2 Input 3 Input/Output 3 Output 3 Input 4 Input/Output 4 Output 4 Input 5 Input/Output 5 Output 5 Input 6 Input/Output 6 Output 6 Input 7 Input/Output 7 Output 7 Fig.9-3: Input and output plugs X2I1, X2D2 and X2O1 Feed plug X1S port 24 V (+) S (sensor supply) GND ( ) FE Fig.9-4: Feed plug X1S Displays The function module must be grounded with two 0.5 mm 2 conductors on the FE plug-in connections. These conductors must not exceed a length of 0.5 m. The functional earthing (FE) serves to deviate disturbances. It does not serve as shock protection for persons The status LED show three different states: Wiring the Assembly Status LED Green Red Off Fig.9-5: Meaning Supply voltage exists. Assembly is operational. Supply voltage is missing. Short-circuit or overload at one or several outputs. PCI interface defective (assembly defective). Watchdog error (assembly is not addressed by the system). Supply voltage of the control is missing. States of the status LED

110 104/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Fast I/O Function Module CFL01.1-E2 Fig.9-6: Wiring the assembly

111 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 105/156 Fast I/O Function Module CFL01.1-E2 WARNING Digital Inputs X2I1, X2D1 Destruction of the assembly due to improper connection! Avoid the reverse polarity with simultaneous short-circuit of the output lines. Avoid the reverse polarity with simultaneous connection of external polarized protective diodes. Do not apply an external voltage exceeding the supply voltage. Do not connect any sensor to an external voltage. Sensors must be fed from the sensor voltage (X1S). Number of inputs 16 (of which 8 can be selected bit-wise as input or output) Connection technique Single conductor Type of inputs Type 1 acc. to EN Digital Outputs X2O1, X2D1 Potential separation for the supply of the logics Reverse polarity protection Input voltage: Nominal value at "0" Nominal value at "1" Input current: Nominal value at "0" Nominal value at "1" Delay time: at "0" to "1" at "1" to "0" Length of line (unshielded) Sensor supply (port "S") Output supply, nominal value Nominal current (sum) Short-circuit, overcurrent protection Fig.9-7: Number of outputs Connection technique Data of digital inputs Yes Yes -3 V +5 V 11 V 30 V < 2.5 ma 2.8 ma 6 ma typ. 40 µs, 50 µs at most typ. 45 µs, 55 µs at most < 100 m 24 V 0.2 A typ. 1.2 A 16 (of which 8 can be selected bitwise as input or output) Single conductor Type of outputs semi-conductor outputs, not saving protected, with automatic restart current-supplying Potential separation for the supply of the logics Output supply, nominal value Yes 24 V

112 106/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Fast I/O Function Module CFL01.1-E2 Output's rating current: Nominal value Maximum value acc. to EN signal 0 signal (leakage current) UL rating: - General Purpose - Tungsten Parallel connection of outputs Maximum sum current of outputs 0.5 A 0.6 A 2 ma A 0.5 ma 0.5 A 5 W Yes, but only within the half-byte (0-3; 4-7 etc.) 4 A Output's delay time (ohmic load) at "0" to "1" at "1" to "0" typ. 70 µs, 95 µs at most typ. 70 µs, 75 µs at most Contactor size (at 1 Hz) (inductive load) SG1 (6.2 W) Lamp load (at 8 Hz) 5 W Overload protection: - typical current level leading to switch-off - minimum current level leading to switch-off - automatic restart at reduced load Overload indication Limitation of inductive switch-off voltage at nominal operation to Reverse polarity protection Supply voltage acc. to EN Power consumption at idle from 24 C Length of line (unshielded) 1.2 A 0.6 A After about 10 ms Red status LED for all 16 outputs Electronically to (Vext 50 V) Typ. 26 V Guaranteed without load connection 24 V DC Typ. 20 ma < 100 m Fig.9-8: Data of digital outputs Connection of inductive loads Noise levels can lead to a malfunctioning of the installation. Very high noise levels are triggered by cable breaks, by the removal of a plug to the inductive load (e.g. solenoid valves, contactors) or by the intentional switch-off through a mechanical contact. These noise levels can spread through galvanic, inductive or capacitive coupling in the system and might release the malfunctioning of the installation or different installations. In order to reduce noise levels, a corresponding suppressor (suppressor diodes, varistors, RC elements) must be connected directly to the inductive load. The suppressor activation must not be dispensed with, particularly, if a switch is connected in series to the inductive load, e.g. for safety locks. Any commercial suppressors can be used. GND break resistance If the GND line leading to the function module breaks, a leakage current of up to 25 ma per output can occur. If outputs are connected in parallel, the current is multiplied accordingly.

113 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 107/156 Fast I/O Function Module CFL01.1-E2 Peripheral Voltage X1S The GND break resistance is thus not guaranteed. For the peripheral voltage, the following values apply acc. to DIN EN : Nominal value Tolerance 24 VDC -15 % / +20 % (without residual ripple) Residual ripple +/-5 % Umax Umin Power consumption 30 V 19.2 V 4 A at most Fig.9-9: Peripheral voltage acc. to DIN EN External power unit The power unit must be equipped with a safe isolation acc. to DIN EN 50178, section Transformers with a safe isolation must be built acc. to DIN EN The 24 V voltage supply is then considered as small voltage with a safe isolation according to DIN EN 50178, section The execution can either be a safety low voltage (Safety Extra Low Voltage = SELV) without grounding of the reference conductor or as protective low voltage (Protective Extra Low Voltage = PELV) with grounding of the reference conductor. A 3-phase power unit with simple full bridge rectifier suffices. The superimposed AC proportion must not exceed 5 %. All lines of the 24 V voltage supply must be laid separately of lines of higher voltages or be isolated specifically, the isolation being designed so as to at least resist the highest voltage possible, see EN : 1997, section All peripheral devices, such as e.g. digital sensors/actuators, that are connected with the function module interfaces must also comply with the criteria of the safe isolation of current circuits. 9.2 Project Planning of the Fast I/O (CFL01.1-E2) in the MLC Project Creation of Fast I/O (FM1) Object in the Project The Fast IO module serves to quickly read in up to 16 inputs or to read out up to 16 outputs. A maximum of 4 Fast IO modules can be used at the same time. In order to be able to use the function module, the "Fast I/O (FM1)" module must be created under MLC. This can be done in two ways: 1. When an MLC is created, the wizard offers the connection of function modules in dialog 3, configuration. Here, the Fast I/O (CFL01.1-E2) module can be selected.

114 108/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Fast I/O Function Module CFL01.1-E2 Fig.9-10: Insertion of a Fast I/O function module via the wizard 2. Drag the "Fast I/O (CFL01.1-Q2)" device from the "FM" group of the library onto the MLC (Mlc1)...

115 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 109/156 Fast I/O Function Module CFL01.1-E2 Fig.9-11: Dragging of the module...and "let it drop" on the MLC.

116 110/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Fast I/O Function Module CFL01.1-E2 Fig.9-12: Insertion of a Fast I/O module The Fast I/O function module is thus integrated in the MLC project. Fig.9-13: Fast I/O function module integrated in the MLC project Configuration of Fast IO These settings can only be made in the offline mode. The inputs/outputs can be used byte- or bit-wise. A special position concerning the use is taken by the 2nd byte (plug X2D1). This byte provides both inputs as well as outputs. The marking of this byte in the Project Explorer and a push on the right mouse button shows a selecton of 9 possible I/O combinations.

117 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 111/156 Fast I/O Function Module CFL01.1-E2 Fig.9-14: Possible combinations are R-FASTIO_I8, 8 inputs Selection I/O allocation 2nd byte R-FASTIO_I7O1, 7 inputs 1 output R-FASTIO_I6O2, 6 inputs 2 outputs R-FASTIO_I5O3, 5 inputs 3 outputs R-FASTIO_I4O4, 4 inputs 4 outputs R-FASTIO_I3O5, 3 inputs 5 outputs R-FASTIO_I2O6, 2 inputs 6 outputs R-FASTIO_I1O7, 1 input 7 outputs R-FASTIO_O8, 8 outputs The addressing of the 3 I/O bytes is effected by analogy with the adressing of MLC Onboard I/O or Inline I/O.

118 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description

119 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives 10 DeviceNet Master Function Module CFL01.1-V Hardware Description Connection of the Function Module to the MLC Bosch Rexroth AG 113/156 DeviceNet Master Function Module CFL01.1-V1 The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.10-1: Addressing of function modules on an IndraControl The MLC must be disconnected from the power supply, before a function module can be attached.

120 114/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description DeviceNet Master Function Module CFL01.1-V1 X7D DeviceNet Interface A B C D E Fig.10-2: Pin S1, Switch for slot number Stat, Function module status indication MNS, Module/Network status X7D, DeviceNet plug Mounting rail locking DeviceNet master module Meaning 1 V 2 CAN_L

121 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 115/156 DeviceNet Master Function Module CFL01.1-V1 Pin Meaning 3 Shield 4 CAN_H 5 V + Fig.10-3: Pin assignment of the X7D plug Cable fixation required for the installation! Display Elements Further descriptions are given in the respective system-specific manual. The meaning of the display elements (two LEDs) is given in the following table: LED Color Status Blinking frequency Description Stat. red blinking slow, 1 Hz The device is in the boot loader mode and waits for a firmware download. blinking quick, 5 Hz The firmware is loaded. acyclic blinking green cyclic blinking acyclic blinking 3 times quick, at 5 Hz 8 times slow, 0.5 Hz to 1 Hz quick, 5 Hz 3 times quick, at 5 Hz 8 times slow, 0.5 Hz to 1 Hz Hardware error identified. The device must be replaced; please contact Bosch Rexroth. No configuration error; the device is online and ready for the field bus communication; it was tried to establish a connection, but no field bus participant was found yet. During switch-on: no configuration found; the device must be configured. During operation: critical firmware, such as e.g. time-out. constantly ON - The device has established at least one configured connection. OFF - - The device has no voltage supply. MNS green constantly ON - Device is online, connections are established. The device is connected to a different master. The device established a connection to a slave. blinking slow, 1 Hz Device is online, no connections established. No configuration found. The device completed the address verification, but did not establish a connection to another device. red Device has no access to the bus, due to a bus error. Double addressing identified. OFF - - Device is not online; the address verification is not terminated. The device has no supply voltage. Fig.10-4: Meaning of light-emitting diodes on the DeviceNet master function module

122 116/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description DeviceNet Master Function Module CFL01.1-V Project Planning of the DeviceNet Master CFL01.1-V1 in the MLC Project Creation of DeviceNet/M Object (CFL01.1-V1) in the Project The DeviceNet master function module makes it possible to connect DeviceNet slaves and to access the standardized DeviceNet protocol (EN 50325). In order to be able to use the function module, a "DeviceNet/M (CFL01.1-V1)" object must be created under MLC. This can be done in two ways: 1. When an MLC is created, the wizard offers the connection of function modules in dialog 3, configuration. Here, the DeviceNet/M (CFL01.1-V1) module can be selected. Fig.10-5: Insertion of a DeviceNet master function module via the wizard 2. Drag the "DeviceN/M (CFL01.1-V1)" module from the "FM" group of the library onto the MLC (Mlc1)...

123 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 117/156 DeviceNet Master Function Module CFL01.1-V1 Fig.10-6: Dragging of the module...and "let it drop" on the MLC.

124 118/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description DeviceNet Master Function Module CFL01.1-V1 Fig.10-7: Insertion of DeviceNet master module The DeviceNet master function module is thus integrated in the MLC project. Fig.10-8: DeviceNet master function module integrated in the MLC project Configuration of Master-Specific Settings These settings can only be made in the offline mode. Double click on the "DeviceNet/M" object in the Project Explorer. Thus, a window opens in the working area.

125 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 119/156 DeviceNet Master Function Module CFL01.1-V1 CAUTION Master Settings "Parameter" Register Fig.10-9: "DeviceNet/M" window Name: internal device name of the DeviceNet master Bus address: bus address of the DeviceNet master. The address "0" is inserted automatically. Please enter a different address, if necessary. Comment: here, you can enter any comments as to the detailed description of the DeviceNet master. Based upon: the EDS file (EDS: Electronic Data Sheet) contains the module's setting possibilies and is provided by the device manufacturer. SW version: software version acc. to EDS file. HW version: hardware version acc. to EDS file. Contains the parameters required for the operation of the DeviceNet master. Any modification to the parameters may lead to unpredictable behavior of the installation! For this reason, parameters must only be modified by trained DeviceNet experts who are aware of the effects of such a modification! Baud rate: set data transfer rate of the DeviceNet network in Baud. All slaves connected must support the indicated value. Possible settings: , ,

126 120/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description DeviceNet Master Function Module CFL01.1-V Insertion of DeviceNet Slaves Auto Clear: Activate this option in order for the master to set all remaining slaves to a safe state after a communication error. All DeviceNet slaves available for the MLC are given in the "Periphery" library under "DeviceNet". Drag the required slaves from the library into the "Device Net/M" object. New slaves can also be inserted between existing slaves in the Project Explorer. Alternatively, you can use the function Add slave in the context menu of the "DeviceNet/M" object, see fig "Insertion of the DeviceNet slave via the context menu of the "DeviceNet/M" object" on page 120. Here, the new slave is inserted as last slave under "DeviceNet/M". If a required slave is not listed by default in the library, it can be integrated by means of import of its EDS file via the function Import EDS files... provided in the context menu of the "DeviceNet/M" object in the library. Fig.10-10: Insertion of the DeviceNet slave via the context menu of the "DeviceNet/ M" object The maximum number of slaves is 63. In the master, altogether 3.5 kbytes are available for IN and OUT.

127 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 121/156 DeviceNet Master Function Module CFL01.1-V Configuration of DeviceNet Slaves General 1 2 Fig.10-11: DeviceNet slave current bus address DeviceNet slave (example) For the configuration of a DeviceNet slave, you have to double click on the corresponding slave entry in the project explorer. Thus, a window opens in the working area.

128 122/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description DeviceNet Master Function Module CFL01.1-V1 "Slave Settings" Fig.10-12: Window of a DeviceNet slave (example) Name: device name acc. to EDS file. The EDS file contains the slave's setting possibilies and is provided by the device manufacturer. Bus address: bus address of the slave. Here, IndraWorks automatically enters the next free bus address. Please enter a different address, if necessary. Alternatively, you can open the "DeviceNet Bus Addresses" dialog by means of the "..." button. Here, the complete address assignment of all DeviceNet participants is indicated. With a double click on a free field of the "Status" table column, the related bus address for the currently selected slave is accepted. The bus address of the slave also appears in the Project Explorer, see fig "DeviceNet slave (example)" on page 121. Active: enable the option in order for the slave to be commissioned after the next program download on the DeviceNet master. Disable this option, if the slave is configured and archived, but is not to be commissioned on the DeviceNet. The setting (enabled/disabled) can also be recognized or carried out in the Project Explorer. When the mouse pointer is positioned on the slave, the setting can be changed by a click on the left button, see the following figure (2).

129 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 123/156 DeviceNet Master Function Module CFL01.1-V1 "I/O Settings" Register "Parameter" Register 1 2 Fig.10-13: Display of settings "disabled" (first line) and "enabled" (second line). Display of settings, when the mouse pointer is positioned on the slave. Setting "enabled"/"disabled" in the project explorer Based upon: file name of the underlying EDS file. Version: hardware version acc. to EDS file. Button "EDS Info": shows the content of the EDS file. Button "Extended": UCMM (Unconnected Message Manager for multiple connections): enable this option in order to realize the establishment of the connection via UCMM. If the slave does not understand UCMM, the establishment of the connection delays by about 2 seconds. Possible classification: Group1 to Group5. Standard setting: enabled, Group3. Start: definition of checks that are to be carried out upon the Start of the network for the DeviceNet slave. In the framework of such a check, the system compares the corresponding data of the module with the values given in the EDS file. Comment: here, you can enter any comments as to the detailed description of the slave. Start here the automatic allocation of I/O addresses. As of Output / As of Input: desired start address for the automatic numbering of inputs and outputs of the DeviceNet slaves. Numbers all inputs/outputs of the subordinate modules of the DeviceNet slave in ascending order starting with the start addresses indicated (see "As of Output / As of Input"). Note that any address gaps that might exist are closed during this procedure! If the automatic numbering leads to collisions with address areas already allocated, IndraWorks indicates the reason for the collision and automatically determines the next free address area. The automatic numbering of subordinate modules can also be carried out in the module configuration. Display and processing of module-specific parameters of the DeviceNet slave. The parameters are defined in the EDS file.

130 124/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description DeviceNet Master Function Module CFL01.1-V1 Fig.10-14: Parameter table of the DeviceNet slave (example) The tool tip gives further information in the columns "ID", "Type" "Parameter" and "Value": In the "ID" column: the Connection Path. In the "Type" column: the object address as class/instance/attribute. In the "Parameter Name" column: short information on the parameters. In the "Value" column: the standard values of a parameter from the EDS file. For this, the mouse pointer must be stopped in the desired field. In order to change a parameter's value, double click on the "Value" field in the corresponding table line. Subject to the type of parameter, the value can be entered directly within the admissible limits ("Min" and "Max" field) and selected via a drop-down list from a predefined number of possibilities. As soon as you change a value, this is indicated in the second table column, see fig "Parameter table of the DeviceNet slave (example)" on page 124. Any modification only becomes active upon the next program download! Before, the settings must be transferred to IndraLogic. For this, use the context menu function "Transfer Modified Parameters or Parameters Marked with Default Values to IndraLogic" in the "Value" column. Marking (empty) Meaning No modification of the value Write protection: It is not possible to change the value.

131 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 125/156 DeviceNet Master Function Module CFL01.1-V1 Marking Meaning The value was changed in comparison with the default value: The changed value is transferred to the control upon the next download. Transferring default value to the control: This means that the default value is written into the device, whenever a connection is established to the device. Thus, a defective device can be replaced by a non-configured device. This functionality is also called "Automatic Device Replacement" (ADR). This setting should be limited to relevant individual parameters in order to avoid memory space problems in the control! Fig.10-15: Status of the parameter value: marking in table column 2 The context menu of the "Value" column can be used to influence parameter value states. In case of write-protected parameters, no context menu is indicated. The following settings are possible: Context menu function Select parameters with default value for transfer to IndraLogic Effect The current parameter is set to the status. Select all parameters with default values for transfer to IndraLogic All parameters are set to the state. If parameters are changed ( ), the respective default value is, however, not used for these. Annul selection of parameters with default values The selection of the current parameter is reset. Annul selection of all parameters with default values The selections of all parameters are reset. Reset parameter to default Reset all parameter to default The changed parameter ( EDS file. The changed parameters ( the EDS file. ) is reset to the default value given in the ) are reset to the default values given in Transfer changed parameters or selected parameters with default values to IndraLogic Transfer parameter value into the slave All marked and changed parameters are entered in a configuration file within the IndraLogic software, meaning that the changed data are loaded into the control upon the next download. The value of the currently selected parameter is transferred directly into the slave. Fig.10-16: Context menu of the "Value" column The Online functions are available, if a connection exists between IndraWorks and the control and if a connection exists between the control and the slave via DeviceNet (essential condition for a connection is the fact that the "Active" check box is marked with a check mark). In the Parameter register, the online values are indicated, see fig "Parameter table of the DeviceNet slave in the online mode (example)" on page 126.

132 126/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description DeviceNet Master Function Module CFL01.1-V Fig.10-17: switch online the display for the reading out of values read out values from the slave last online values read out planned values. Parameter table of the DeviceNet slave in the online mode (example) Put a check mark behind "Online" (see 1 in Fig ) and then select "Read Values" (see 2 in Fig ). The online values are given in the "Online Values" table, see 3 in Fig These values are highlighted in blue as soon as they differ from the planned values from the "Values" column (see 4 in Fig ). A modification of the parameter values is only possible via the context menu of the "Value" column (see 4 in Fig ). Changed values are transferred with the menu item "Transfer Parameter Values into the Slave". Errors that are reported during the transfer into the slave are indicated in a window. The errors reported by the slave are defined in the DeviceNet specification of ODVA (CIP Specification Edition 3.0, Volume 1, Appendix B Status Codes.) Configuration of the I/O Connection of a DeviceNet Slave For the configuration of an I/O connection of a DeviceNet slave, open the next level of the DeviceNet slave: I/O Connection Types 1 Fig.10-18: I/O connection type I/O connection of the DeviceNet slave used Poll: the data of the slave are queried cyclically from the master (masterslave procedure).

133 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 127/156 DeviceNet Master Function Module CFL01.1-V1 Bit Strobe: the DeviceNet master sends a broadcast telegram to all slaves requesting them to send their current data. The slaves repond in the ascending order of their bus addresses. The data that can be sent back by any device after the Bit Strobe command are limited to a length of 8 bytes. Cos (Change of State): the slave automatically sends data after its input was changed. Cyclic: the slave automatically sends data after the expiration of a cycle time ("Heartbeat" function). If the I/O connection type indicated is not suited, delete the I/O connection type via the context menu item "Delete": Fig.10-19: Deletion of an I/O connection type of a DeviceNet slave Then select the desired I/O connection type of the slave from the library, drag it to the slave and let it drop there. You can only select I/O connection types that are admissible for the current slave: Fig.10-20: Setting of an I/O connection type of a DeviceNet slave Double click on the I/O connection type object in order to configure the I/O connection of the DeviceNet slave. Thus, a window opens in the working area.

134 128/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description DeviceNet Master Function Module CFL01.1-V1 General Data "I/O Addresses" Register Fig.10-21: I/O Connection Types dialog, "I/O Addresses" register Module name: name of the I/O connection type. I/O connection: I/O connection type of the DeviceNet slave. Slave name: bus address and name of the DeviceNet slave. here, allocate the I/O areas of the modules to the physical addresses of the control (I/O addresses of the PLC). Identifier: this column gives the input and output structure. By means of the plus and minus symbol, respectively, one can switch between byte and bit representation. For every absolute address, the allocation to a symbolic address is possible (double click on the respective field). After the entry, a symbolic address is automatically created in the PLC project as a global variable. The symbolic address of a node also appears in the Project Explorer. Address: I/O address. Enter the desired I/O address as byte address (e.g. % IB10). Italic entries are only used for display purposes and cannot be edited. An automatic readdressing can be carried out in the "I/O Settings " register. "I/O Settings" Register Data type: byte addresses are characterized by means of "BYTE", bit addresses by means of "BOOL". Comment: enter here any comment to an address you might like. Status: physical status of the input/output. The status is only displayed in the diagnostic mode in case of communication between IndraWorks and MLC. Start here the automatic allocation of I/O addresses. As of Output / As of Input: current or desired start addresses of the inputs or outputs. According to the module functionality used (module with inputs, module with outputs), only relevant entry fields are indicated. If e.g. you parameterize a module only having inputs, the entry field "As of output" is missing.

135 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 129/156 DeviceNet Master Function Module CFL01.1-V1 "I/O Connection Configuration" Register "Accept": numbers all inputs/outputs of the module in ascending order starting with the start addresses indicated (see "As of Output / As of Input"). Note that any address gaps that might exist are closed during this procedure! If the automatic numbering leads to collisions with address areas already allocated, IndraWorks indicates the reason for the collision and automatically determines the next free address area. define the I/O field size here. According to the I/O connection type, further data can be edited here, see fig ""I/O Connection Configuration" register for the I/O connection type "Poll"" on page 129 to fig ""I/O Connection Configuration" register for the I/O connection type "Bit Strobe"" on page 131. The length of the I/O assignment must be entered subjec to the the actual module equipment. In "I/O Assignment", click on the "Length" field in order to change the setting. If several connections are indicated per data direction, you can select a maximum of one connection. The tool tip shows the possible values for the "Length" column. For this, the mouse pointer must be stopped in the "Length" field. Fig.10-22: "I/O Connection Configuration" register for the I/O connection type "Poll"

136 130/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description DeviceNet Master Function Module CFL01.1-V1 Fig.10-23: "I/O Connection Configuration" register for the I/O connection type "Change of State" Fig.10-24: "I/O Connection Configuration" register for the I/O connection type "Cyclic"

137 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 131/156 DeviceNet Master Function Module CFL01.1-V1 Fig.10-25: "I/O Connection Configuration" register for the I/O connection type "Bit Strobe"

138 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description

139 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives 11 Profibus-DP Master Function Module CFL01.1-P Hardware Description Connection of the Function Module to the MLC Bosch Rexroth AG 133/156 Profibus-DP Master Function Module CFL01.1-P1 The following applies: 1. module (nearest to the MLC): address 1; 2nd module: address 2 etc. (DIP switch S1 on the module). Fig.11-1: Addressing of function modules on an IndraControl The MLC must be disconnected from the power supply, before a function module can be attached.

140 134/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Profibus-DP Master Function Module CFL01.1-P1 Fig.11-2: A S1, Switch for slot number B State, function module status indication C Bus, DP status D X7P, Profibus-DP plug E mounting rail locking Profibus-DP master function module Cable fixation required for the installation! Further descriptions are given in the respective system-specific manual.

141 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 135/156 Profibus-DP Master Function Module CFL01.1-P1 X7D PROFIBUS Interface DSub Female Connector, 9-pin Pin 1 n. c. Meaning 2 n. c. 3 RxD / TxD P 4 CNTR P 5 DGND 6 VP 7 n. c. 8 RxD / TxD N 9 n. c. Display Elements Fig.11-3: Pin assignment of the X7D plug The meaning of the display elements (two LEDs) is given in the following table: LED Color Status Blinking frequency Description Stat. red blinking slow, 1 Hz The device is in the boot loader mode and waits for a firmware download. blinking quick, 5 Hz The firmware is loaded. acyclic blinking green cyclic blinking acyclic blinking 3 times quick, at 5 Hz 8 times slow, 0.5 Hz to 1 Hz quick, 5 Hz 3 times quick, at 5 Hz 8 times slow, 0.5 Hz to 1 Hz Hardware error identified. The device must be replaced; please contact Bosch Rexroth. No configuration error; the device is online and ready for the field bus communication; it was tried to establish a connection, but no field bus participant was found yet. During switch-on: no configuration found; the device must be configured. During operation: critical firmware, such as e.g. time-out. constantly ON - The device has established at least one configured connection. OFF - - The device has no voltage supply. Bus green constantly ON - Device is online, connections are established. The device is connected to a different master. The device established a connection to a slave. blinking slow, 1 Hz Device is online, no connections established. No configuration found. The device completed the address verification, but did not establish a connection to another device. red Device has no access to the bus, due to a bus error. Double addressing identified. OFF - - Device is not online; the address verification is not terminated. The device has no supply voltage. Fig.11-4: Meaning of light-emitting diodes on the DP-Master function module

142 136/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Profibus-DP Master Function Module CFL01.1-P Planning of the Profibus-DP Master CFL01.1-V1 in the MLC Project The Profibus-DP master module is a complement for the local interface that can - in addition to the FM - also work as a Profibus slave, if the function module is used. The use of the Profibus-DP master module is based upon the fact that the Onboard Profibus interface of the MLC is not configured as master. The configuration of the interface as slave is admissible. This has to be taken into account during the creation of the MLC. If the local interface is configured as a master (default) and if you try to create a Profibus master via the library, a corresponding error message is displayed. Fig.11-5: Error message, if a Profibus master module is created from the library, although the onboard interface was configured as master (default) 11.3 Creation of Profibus/M Object (COM-DPM) in the Project In order to be able to use the function module, the "ProfibusM (COM-DPM)" module must be created under MLC. This can be done in two ways: 1. When an MLC is created, the wizard offers the connection of function modules in dialog 3, configuration. Here, the Profibus-DP master (CFL01.1-P1) can be selected. Please make sure that the local Profibus interface is not configured as master (see marking). This is particularly important, as this setting cannot be corrected later.

143 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 137/156 Profibus-DP Master Function Module CFL01.1-P1 Fig.11-6: Insertion of a Profibus/M function module via the wizard 2. Drag the "Profibus/M (COM-DPM))" module from the "FM" group of the library onto the MLC (Mlc1)...

144 138/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Profibus-DP Master Function Module CFL01.1-P1 Fig.11-7: Dragging of the module...and "let it drop" on the MLC.

145 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 139/156 Profibus-DP Master Function Module CFL01.1-P1 Fig.11-8: Insertion of a Profibus/M module The Profibus/M function module is thus integrated in the MLC project. Fig.11-9: Profibus/M function module integrated in the MLC project These settings can only be made in the offline mode Configuration of Master-Specific Settings Double click on the "Profibus/M" object in the Project Explorer. Thus, a window opens in the working area.

146 140/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Profibus-DP Master Function Module CFL01.1-P1 Master Settings Fig.11-10: "Profibus/M" window Name: internal device name of the bus master Bus address: bus address of the bus master (FDL address: Fieldbus Data Link). The address "1" is inserted automatically. Please enter a different address, if necessary. The address "0" is reserved for project planning devices and cannot be used. Always use the smallest address values possible for masters. High address values aggravate the bus performance! "Bus Parameter" Register CAUTION Comment: here, you can enter any comments as to the detailed description of the bus master. Based upon: file name of the underlying ID no. according to GSD file. The GSD file contains the device's setting possibilies and is provided by the device manufacturer. SW version: software version acc. to GDS file. HW version: hardware version acc. to GDS file. Contains the bus parameter required for the operation of the Profibus DP. If the option "Set to Default" is enabled, only the fields "Baud rate" and "Max. Retry Limit" can be edited. All other parameters are adapted to the currently indicated Baud rate and suitable for the majority of applications. In order to change any values, disable the option "Set to Default" and set the option "Optimization" to "Permitted". In order to block the entry fields, you can reset the "Optimization" to "Blocked". As soon as the option "Set to Default" is enabled, the values set before are overwritten with adapted values. Any modification to the bus parameters may lead to an unpredictable behavior of the installation! For this reason, bus parameters must only be modified by trained Profibus DP experts who are aware of the effects of such a modification!

147 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 141/156 Profibus-DP Master Function Module CFL01.1-P1 "Groups" Register Baud rate (transfer rate): choose here the data transfer rate of the entire bus system. All slaves connected must support the indicated value. The maximum Baud rate corresponds to the highest Baud rate possible of the "worst" slave. Max. Retry Limit: maximun number of repetitions of the call telegram through the initiator, if no answer is sent from the responder (addressee). Possible settings: 1 to 15. Target Rotation Time (Ttr): set token rotation time for the multi-master operation. Possible settings: 256 to 6,647 TBit (bit time units). Quiet Time (Tqui): modulator die-away time or repeater converter time. During this period of time, one waits until the "Bus is Quiet". Telegrams are neither sent nor received. Possible settings: 0 to 255 TBit. Setup Time (Tset): Trigger time. maximum period of time that elapses from the occuring of the event until the execution of the required reaction. Possible settings: 1 to 255 TBit. Slot Time (Tsl): "Waiting for Reception" time. Maximum period of time in which the initiator waits for the immediate acknowledgment or answer after a call telegram was sent (news cycle). Due to the direct influence of Tid2, it is possible to choose a setting between Tid and 16,383 TBit. Poll Timeout: time monitoring for an acyclic service (DPV1). Maximum period of time in which the initiator waits for the acknowledgment of an answer, after an acyclic request was sent. The setting can be selected in steps of 10 ms in the range of 10 to 655,350 ms. Data_Control_Time:slave-related monitoring time in the bus master, in the course of which at least one user data transfer must be realized with the slave concerned. Possible settings: 1 to 65,535 ms GAP Update Factor: factor with which one can control, after how many bus cycles new masters are recognized. Possible settings: 1 to 10 Min. Tsdr: the period of time which a responder requires at least in order to answer to a call telegram. Possible settings: 11 to 255 TBit. Max. Tsdr: the period of time which a responder requires at most in order to answer to a call telegram. Possible settings: 35 to 1,023 TBit. Min_Slave_Intervall: this is the minimum time interval which has to elapse between two accesses of the bus master to one and the same slave. Possible settings: 1 to 65,535 (Factor: 100 µs) The group allocation refers to the Sync and Freeze commands of the "Global Control" services of Profibus DP. In the column "Sync" or "Freeze", enable the group(s) to which the master shall send the Freeze or Sync commands. Example: With the group allocation illustrated in the following figure, the bus master is allowed to send Sync commandes to slaves of groups 3 and 4 as well as Freeze commandes to slaves of the groups 1 and 3.

148 142/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Profibus-DP Master Function Module CFL01.1-P1 Fig.11-11: "Profibus/M" window, "Groups" register In order to allocate slaves to a certain group, see "Group Allocation Register" on page 148. Control commands of the "Sync" and "Freeze" modes can be generated with the help of the DP_SYCFR function block. If, for this, slaves of a "blocked" group are indicated as addressees, the master blocks the transfer of commands to the relevant slaves. "Parameter" Register Display and processing of any available, manufacturer-specific bus master parameters Insertion of Profibus DP Slaves All Profibus DP slaves available for the MLC are given in the "Periphery" library under "ProfibusDP". Drag the required slaves from the library into the "Profibus/ M (COM-DPM)" object. New slaves can also be inserted between existing slaves in the Project Explorer. Alternatively, you can use the function Add slave in the context menu of the "Profibus/M (COM-DPM)" object. Here, the new slave is inserted as last slave under "Profibus/M (COM-DPM)". If a required slave is not listed by default in the library, it can be integrated by means of import of its GDS file via the function Import GDS files... provided in the context menu of the "Profibus/M (COM- DPM)" object in the library.

149 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 143/156 Profibus-DP Master Function Module CFL01.1-P1 Fig.11-12: Inserting a Profibus DP slave via the context menu of the "Profibus/M (COM-DPM)" object 11.6 Configuration of Profibus DP Slaves Profibus DP distinguishes between two types of slaves: Compact: In case of a compact slave, the modular structure is firmly defined. After the slave was inserted into the Project Explorer, modules of the compact type are already completely listed under the slave's object node. Modular: The modular structure of the slave is variable. The modules can be arranged individually however, in accordance with the equipment instructions applicable to the device. Directly after the slave was inserted into the Project Explorer, no subordinate (I/O) device leves of the slaves are listed yet. In case of a modular slave, the modules must be allocated manually. For the insertion of modules, seechapter 11.7 "Insertion of Modules in Profibus DP Slave " on page 149.

150 144/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Profibus-DP Master Function Module CFL01.1-P Fig.11-13: modular Profibus DP slave; still without subordinate modules compact Profibus DP slave current bus addresses of the Profibus DP slaves Profibus DP slaves (example) In order to change the bus address of a slave, open the "DP Bus Addresses" dialog via the context menu item Bus Address. Here, the complete address assignment of all Profibus DP participants is indicated. With a double click on a free field of the "Status" table column, the related bus address for the currently selected slave is accepted. Always use the smallest address values possible for masters. High address values aggravate the bus performance! For the configuration of a Profibus DP slave, you have to double click on the corresponding slave entry in the Project Explorer. Thus, a window opens in the working area (see figure):

151 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 145/156 Profibus-DP Master Function Module CFL01.1-P1 "Slave Settings" Fig.11-14: Window of a Profibus DP slave (example) Name: device name acc. to GDS file. Bus address: bus address of the slave (FDL address). Here, IndraWorks automatically enters the next free bus address. Please enter a different address, if necessary. Alternatively, you can open the "DP Bus Addresses" dialog by means of the "..." button. Here, the complete address assignment of all Profibus DP participants is indicated. With a double click on a free field of the "Status" table column, the related bus address for the currently selected slave is accepted. Please take into account the following limitations for the address selection: Address "0": reserved for project planning devices Address "1": reserved for the Profibus DP master The bus address of the slave also appears in the Project Explorer (see the following figure). Active: enable the option in order for the slave to be commissioned after the next program download on the Profibus. Disable this option, if the slave is configured and archived, but is not to be commissioned on the Profibus. The setting (enabled/disabled) can also be recognized or carried out in the Project Explorer. When the mouse pointer is positioned on the slave, the setting can be changed by a click on the left button, see 2 the following figure (2).

152 146/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Profibus-DP Master Function Module CFL01.1-P1 "I/O Settings" Register 1 2 Fig.11-15: Display of settings "disabled" (first line) and "enabled" (second line). Display of settings, when the mouse pointer is positioned on the slave. Setting "enabled"/"disabled" in the project explorer Based upon: file name of the underlying ID no. according to GSD file. SW version: software version acc. to GDS file. HW version: hardware version acc. to GDS file. Comment: here, you can enter any comments as to the detailed description of the slave. Start here the automatic allocation of I/O addresses. As of Output / As of Input: desired start address for the automatic numbering of inputs and outputs of all subordinate modules of the Profibus DP slaves. Accept: numbers all inputs/outputs of the subordinate modules of the Profibus DP slave in ascending order starting with the start addresses indicated (see "As of Output / As of Input"). Note that any address gaps that might exist are closed during this procedure! If the automatic numbering leads to collisions with address areas already allocated, IndraWorks indicates the reason for the collision and automatically determines the next free address area. The automatic numbering of subordinate modules can also be carried out in the module configuration. For this, see fig "Profibus DP slaves (example)" on page 144. "Manufacturer-Specific Data" Register Display and processing of any available, manufacturer-specific slave parameters. If, in the GSD file, "Manufacturer-specific Data" exist for the slave, these are indicated. In order to change a parameter's value, double click on the "Parameter Value" or "Value" field, respectively,in the corresponding table line. The confirmation of Default triggers the overwriting of all initial values from the GSD file with modified values. According to the type of the GSD file, the data can be indicated in two different ways: Display with address, parameter name and value:

153 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 147/156 Profibus-DP Master Function Module CFL01.1-P1 1 2 Fig.11-16: list with parameter name and value parameter data in byte illustration Manufacturer-specific data with address, parameter name and value In this display, a parameter value is indicated and edited on the basis of its file type 1, e.g. "Enabled" and "Disabled" for Boolean values. All resulting parameter data are also indicated in the byte illustration 2. Display of the address and the value:

154 148/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Profibus-DP Master Function Module CFL01.1-P1 "Group Allocation " Register Fig.11-17: Manufacturer-specific data with address and value In this illustration, the values are subdivided in bytes. For the display of the byte value, the Number Base can be set. The group allocation refers to the Sync and Freeze commands of the "Global Control" services of Profibus DP. In order to assign the slave to one or several groups, enable the desired group with the "Member of" column. The columns Sync Mode and Freeze Mode indicate to which groups the masters actually sends the Sync or Freeze commands. These allocations are set in the "Groups" register in the "Master Settings", see fig ""Profibus/M" window, "Groups" register" on page 142. Example: With the group allocation illustrated in the following figure, the master is allowed to send Sync commandes to slaves of groups 3 and 4 as well as Freeze commandes to slaves of the groups 1 and 3. The outputs of the slave are frozen (synchronized) to the current value, as soon as the master sends the Sync command to group 3. The states of the inputs are frozen to the current value, as soon as the master sends the Freez command to Group 1 or to Group 3.

155 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 149/156 Profibus-DP Master Function Module CFL01.1-P1 Fig.11-18: Group allocation of a Profibus DP slave (example) 11.7 Insertion of Modules in Profibus DP Slave Modules can only be inserted in case of modularly structured Profibus DP slaves, see chapter 11.6 "Configuration of Profibus DP Slaves " on page 143. The modules suited for the respective Profibus DP slave are given in the "Periphery" library, "ProfibusDP" below the respective Profibus DP slave. Drag the required modules from the library into the slave object. New modules can also be inserted between existing modules in the Project Explorer. Alternatively, you can use the function "Add module" n the context menu of the slave object, see fig "Adding a module" on page 150. Here, the new module is inserted as last module below the slave.

156 150/156 Bosch Rexroth AG Electric Drives Rexroth IndraMotion MLC03VRS Functional Description Profibus-DP Master Function Module CFL01.1-P1 Fig.11-19: Adding a module 11.8 Configuration of Modules of a Profibus DP Slave Fig.11-20: Modules of a Profibus DP slave (example) For the configuration of a module, you have to double click on the corresponding module entry in the Project Explorer. Thus, a window opens in the working area.

157 Functional Description Rexroth IndraMotion MLC03VRS Electric Drives Bosch Rexroth AG 151/156 Profibus-DP Master Function Module CFL01.1-P1 "Module Information" "I/O Addresses" Register Fig.11-21: Window of a module (example) Name: module name (left field) and the internal module identifier acc. to GSD field (right field). here, allocate the I/O areas of the modules to the physical addresses of the control (I/O addresses of the PLC). Identifier: this column gives the input and output structure. By means of the plus and minus symbol, respectively, one can switch between byte and bit representation. For every absolute address, the allocation to a symbolic address is possible (double click on the respective field). After the entry, a symbolic address is automatically created in the PLC project as a global variable. The symbolic address of a node also appears in the Project Explorer. Address: I/O address. Enter the desired I/O address as byte address (e.g. % IB17). Italic entries are only used for display purposes and cannot be edited. An automatic readdressing can be carried out in the "I/O Settings " register. Data type: byte addresses are characterized by means of "BYTE", bit addresses by means of "BOOL". Comment: enter here any comment to an address you might like.